Winter 05/06 Plans for the DSM. Pics!

[project_tsi]

Just a small update. Yesterday I ordered A new Clutch disk, new TOB, new pivot ball, new flywheel bolts, 3 bottles of BG Syncroshift, a SBR tranny LSD, and a Magnus Intake Heat Barrier Gasket, hopefully it performs as well as they are saying it does.

And the UPS man stopped in this morning and brough the Tial WG combo I bought off a local memer. It came with a black Tial WG, 4 springs, and a custom dump tube already fabbed around a SBR manifold and Bullseye turbine housing, so its going to work perfectly for me.

 

[ITSME4G63]

JESUS CHRIST, YOU JUST GET A TAX REFUND OR WHAT! thats good shit right there though, I like that wastegate setup, it just goes around the o2 housign right?

 

[99gst_racer]

The gate looks good Dan.

 

[project_tsi]

JESUS CHRIST, YOU JUST GET A TAX REFUND OR WHAT! thats good shit right there though, I like that wastegate setup, it just goes around the o2 housign right?

Tax money hasn't come in yet, still waiting for it.

This is what it will look like installed. This was a pic from the guy I bought it from. Its nice becouse I have the exact same setup of manifold and turbine housing, so it will fit perfect. Also it leaved plenty of room to the alt and stuff over there.

 

[project_tsi]

Now this setup just plain kicks ass.

 

[99gst_racer]

Lookin good. Don't forget to weld the flapper on the turbine housing.

 

[project_tsi]

Yeah thanks Paul, I may have forgotten that part!!! Not.

 

[99gst_racer]

Yeah thanks Paul, I may have forgotten that part!!! Not.

Wouldnt surprise me.

:: "Paul, I'm spooling, but I'm not building boost, and my external WG isn't opening. What could it be"::



So when are we putting the engine back together and back in the car?

 

[project_tsi]

I have to give my engine guy a call today to see if everything is ready for assembly. I've got to have the big end of the rods checked for size per Mitch's instructions and also double check my PTW clearances.

 

[Absinthminded]

Its lookin real kick ass Dano...I want the first ride.

 

[project_tsi]

I was able to assemble the bottom end today, and it tuned out real nicely.

First off, Mitch, I told the machine shop to check to rods like you had stated, and I also made them re-check them today when I was there. Please don't ask me any technical mumbo jumbo, but the rods checked out fine. They were not too large and they were right in-round of where they should be. Maybe since you have stopped using Eagles, they have stepped up there quality control a bit? Maybe you got a bad batch when you had them?

Ok, durring assembly, every precaution was taken as it should have been. All rods and mains were plastigaged. Crank end play was checked and was fit to spec. ARP moly lube was liberally used on all threads/washed/nuts. Assembly lube was used liberally as well. Piston rings were file fitted to spec. Main studs were torqued to 65 ft. lbs. Rod bolts were installed using the bolt stretch method for more precise readings. All new 35mm core/ freeze plugs were installed with sealer. Balance Shaft BlockOff bearings were installed.

Also this week the head was resurfaced to ensure a great seal.

The only problem with assembly was that the #3 rod durring rotation was slightly rubbing/catching on the block casting lip inside. A few min with the die grinder took care of the problem, as a small notch was cut into the casting. But hey thats what you get when building a stroker. Other than that, there were no problems. I will post a pic and cirle where I had to cut the notch.

As soon as I order my timing parts I will begin more assembly.

I will be primering and painting the block this week.

Let me know what you think.

 

[Baron4406]

Very interesting thread-keep up with the updates. For me working on my car is about as fun as driving it. I just checked the compression on the AWD I just got and its 145 to 130, not bad since it has 135k on it, however for the last 10k miles its had a Walbro 255 and no AFPR. I think the mega rich condition has really hurt the motor. So like you, I'm probably gonna build another motor soon. I just love seeing other people's buildups!

 

[99gst_racer]

Perdy.

Dan - What did you file the rings to? (just curious)

 

[project_tsi]

I got some more parts today. A new FMIC Core as my old was beaten up a bit, sold old one and with the money, this one cost me $100. Also a SBR Tranny LSD Insert, 3 bottles of BG Synchroshift, new clutch pivot pall, new OEM TOB (throw out bearing), a Magnus Intake Heat Barrier Gasket, 6 New Flywheel bolts, and a set of Crower Titanium Springs and Retainers. Also, SBR threw in some freebie can coolies. Wow. The clutch disk I ordered is on backorder so I am still waiting on that.

More updates to come as I am painting the block this week/weekend.

 

[tibby_boy]

Looks good! Dan your project is coming along really nicely. I want to see the painted block. Post some pics as soon as you finish. You should do a write up on the step by step process, as im sure some one might want to do this in the future. Just a thought.

 

[1GenDSM]

Looks good! Dan your project is coming along really nicely. I want to see the painted block. Post some pics as soon as you finish. You should do a write up on the step by step process, as im sure some one might want to do this in the future. Just a thought.

kiss ass

 

[project_tsi]

Ok, this weeked I did a little bit of work to parts and painted the block finally.

The block turned out very nice. It was professionally painted by a good friend of mine, and he did a great job. It looks even better in person.

Other than that, I cut off my 02 housing dump tube and welded a plate over the hole and also I welded shut the wg flapper on the turbine housing.

Also, the Crower Ti Springs and Retainers were installed this week.

Also not shown, but I drilled a hole for the EGT probe in the JMF heat shield.

I am most likely going to start assembly of the engine tommorow.

 

[Suparata]

You should have installed the rear main seal housing before you put it on the stand.
Also don't forget to install the oill galley plug but make sure it is nothing else than the correct one.
I still can't believe you only resurfaced the head and did nothing else to it, including thoroughly clean it. Why is that?

 

[project_tsi]

Mitch, thanks for the advice.

I'm going to install the rear main seal today before I throw the engine on the stand for final assembly. I know its easier this way, I had a hell of a time getting the plate on, on Pauls car.

No worries on the oil galley plug, its in there, you just barely can't see it in the pics.

As for the head, the shop I took it to is a relatively small, local shop, and old friend of mine, and he said he doesn't have an aluminum safe hot tank. With the work I did on it myself it looks 10x better than what it started at. I'm still not fully done cleaning it out but it is alot better. I really didn't have the money to fully build the head which is why nothing else mod wise was done to it. Thats why is has no beautiful port and polish job, or 1mm OS Ferrea valves, etc. The head is something I can build up at a later date.

 

[project_tsi]

I started assembling the engine today.

I started by installing the rear main seal and gasket.

Then I installed the ARP head studs, and set on the SCE Titan ICS Head Gasket. Then the head went on and was torqued down to 90 ft. lbs, in 3 stages, 30-60-90.

Then I installed the no-tick lifters and rockers, lubed up the cam journals, and installed the cams and torqued to 18 ft. lbs.

Then I set the Magnus Heat Barrier Gasket in place, and Also put on a Mitsu 4 layer exhaust manifold gasket. Then I proceeded to install the SBR ex. mani w/ TRE EGT Probe.

Thats about all I got done today, more to come soon!

 

[Black94DSM]

You should have painted your exhaust manifold. Even though you will have a Heat Shield on there, youll be able to see the manifold. It will rust as it already is. I painted mine with VHT High Temp Exhaust Paint.

 

[project_tsi]

Well it was mid 40's the other day and very humid and thats what happened to it. I think I may sandblast it. I have seen a few that have been sandblasted, they look great and haven't rusted yet.

 

[ITSME4G63]

nice, I waiting on the same intake manifold gasket to arrive to my doorstep. THat exhasut manifold looks sick, sbr did their homework.

 

[Suparata]

There are two gaskets that would have been my choice over anything else out there especially a Copper one: Mitsu MLS and FelPro MLS with the second one probably being the first choice. But that’s me.

 

[turboTSi1320]

You should have painted your exhaust manifold. Even though you will have a Heat Shield on there, youll be able to see the manifold. It will rust as it already is. I painted mine with VHT High Temp Exhaust Paint.

Will that last for a long time?