If you build it.......

[X.Krunkt]

So for the last year i've been building up my FWD 92 Talon. Here is some background on the car. I bought it in October of 2006. It had a swapped 6-bolt 4g63 N/T motor in it, with a basic stock turbo system. I ran it at 10-12 psi for about a year and I loved it. After tons of research and gathering parts, the inevitable happened. I have spent the last 6 months building my previously N/T Talon into a "stockish" GS-T.

Here are some pics of what it looked like the day I got her home.

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_423_0747.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=423_0747.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_423_0751.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=423_0751.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_423_0748.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=423_0748.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_423_0732.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=423_0732.jpg)
http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_423_0757.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=423_0757.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_423_0743.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=423_0743.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_423_0737.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=423_0737.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_423_0736.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=423_0736.jpg)

This is what she looked like 6 months ago. After going through 2 N/T transmissions, I decided to upgrade to the turbo tranny. I then also decided to pull the motor and rebuild, turning the N/T 4g63 into a 4g63T. And no thats not me, that my fiancee helping me out :D

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000131.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000131.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000132.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000132.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000144.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000144.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000146.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000146.jpg)
http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000161.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000161.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000162.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000162.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000163.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000163.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000164.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000164.jpg)
http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000167.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000167.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000169.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000169.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/th_P1000160.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/rebuild/?action=view&current=P1000160.jpg)

After 3 months of fighting with the machine shop to find time to do my block I finally got it back home and started putting everything back together. It almost seemed like I was doing something wrong 'cause everything went real smooth, maybe too smooth.

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000243.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000243.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000244.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000244.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000245.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000245.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000248.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000248.jpg)
http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000251.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000251.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000252.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000252.jpg)

So last week I finally get everything put together and started the car for the first time. After a couple of cranks it fired right up. I let it idle for about 10 minutes, turn 'er off, checked for leaks, all good.

So after its all said and done the car is now a full 4g63T. This is how she looks today.

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000266.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000266.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000267.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000267.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000268.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000268.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_P1000269.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=P1000269.jpg)
http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_425_1874.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=425_1874.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_425_1877.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=425_1877.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/1G/th_425_1876.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/1G/?action=view&current=425_1876.jpg)

Here's the mod list:

-ENGINE-
-Stock 4g63T Block Bored .20 over
-2G Pistons on 1G Rods
-Ported 16G
-Ported 2G Manifold
-Ported 2G o2 housing
-FMIC
-1G BOV
-N/T Throttle Body
-2.5" Cat-less exhaust w/ Magnaflow Muffler
-MBC
-ACL Race Bearings
-ARP Hardware
-MLS Head Gasket
-OEM Gasket Set
-New OEM Timing Components (Belt, pulleys, tensioner, etc.)
-New OEM Water Pump
-New OEM Oil Pump


-FUEL/ELECTRONICS-
-FIC 550cc's
-SAFC
-2G MAF
-Autometer Boost Gauge
-Autometer Water Temp Gauge
-Autometer Oil Pressure Gauge

-DRIVETRAIN-
-1990 FWD Turbo Transmission w/ LSD
-Short Throw Shifter
-Symbroski Shift Kit
-XTD Stage 4 Clutch Kit

There might have been some things I left out, but this is pretty much the basics.

[Johnnie929]

She's looking good!
Looks like you are missing an exhaust bolt and may need to tuck those wires.

[swade]

No more type-s?

swade

[X.Krunkt]

No more type-s?

swade

Defenately not. :D That thing was a POS.

[Bradikus7]

Wow man nice transformation. Now is the time to turn up the boost:D! Get link or atleast log that shit so you don't screw anything up. Keep us posted.

[X.Krunkt]

Actually I do have a logger. One of the things I forgot to mention. I have already logged my first run. I'll post that up as soon as I upload it.

The boost is set too factory settings until I break in the new engine. 36 miles down, 464 more to go.

[X.Krunkt]

The worst possible thing happened last night. Four miles from my house the timing belt shredded. After towing her home I found it was the timing belt tensioner bolts had backed themselves out shredding my timing belt in a matter of seconds.

The good part is that I didn't originally do the timing belt. Why good do you ask? That was the only part of the car that my mechanic had done for me since I was scrapped for time. I called him up, and he accepted full responsability for all damages. He had told me that he had a hard time getting those bolts tight.

So a new head for me.

[aworldsdeath]

Good thing your mechanic is honest and taking responsibility for it! You going to get port and polish while your at it?

[93_GSX]

Holy lucky you, batman!!! Free head, I wish I had that kind of luck....

Nice build. Now fix that driver's side dent ASAP!!

[X.Krunkt]

My mechanic is an awesome guy. He's very honest.

And yes, you better believe that its getting ported and polished. That would be the only money out of my pocket.

[Red1991TSI]

Frankly this belongs in the build forum unless you have a specific tech or tuning question.

Let me know if you want it moved.

[X.Krunkt]

Go ahead and move it please.

I was going to put it in the build forum but I thought that it was more for big fancy setups, not my stockish build. I will be updating this regularly so it would be good to move it.

Thanks Red!

[X.Krunkt]

Snapped some picks of my t-belt. :shakes head in disbelief:

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000272.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000272.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000273.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000273.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000271.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000271.jpg)

[Red1991TSI]

It's hard to believe but I do watch out for our members.

Nice write up and build.

EDIT: The above pics are why I prefer to do my own work. Nice that you have an honest mechanic who's willing to stand behind his work. :tree: for his word.

[X.Krunkt]

The best thing about it is that before he even saw the car, he knew that it was an interference engine, and that valves WERE bent. The head hasn't even come off the car yet.

I'm not even sure what to expect. I was going about 45 when the car kind of bogged a bit. I thought to myself "wtf!?" So I was completely off the gas. I then noticed oil pressure rising, and rising, and rising and pop! Car turned off. I immediately pulled over, popped the hood and saw what looked like black spiderwebs all over the driver side of the engine bay. I looked down, and saw what you see in the pictures just sitting there off of both cams.

I know for sure that at least half, if not all, of the valves are bent. I just hope my brand new pistons are ok. I'll keep yous posted.

I just hope he doesn't sing a different tune once the head if off :rolleyes:

By the way Red. I know you're looking out. It's greatly appreciated. And i'm pretty sure a few people would concur.

[X.Krunkt]

So before removing the head we checked the compression. It was about 90-100 on all cylinders. Just for shits and giggles we threw a new timing belt on and tested again with the same results. Took the head off......just as expected, all 8 intake valves were bent. No piston damage though.

It just sucks having to wait again to drive the car.

[shadow_FIX]

I had a shop have to take full responsibility for a timing belt failure on my 2.0 N/T. The transformation looks like it went well though!

[X.Krunkt]

Jackass decided to not honor his work and now im stuck with having to get a head on my own. I knew he was gonna change his mind once the $$$ got involved. Doesn't matter anyway, since no one will ever touch my car again. Thats why I do ALL my own work. Frustrating as hell.

Anyone selling a complete turbo head keep a look out for my WTB thread in the classifieds.

[shadow_FIX]

I hate it when people don't accept the responsibility for their work. :mad:

[X.Krunkt]

If I get a head by next Saturday, I should be up and running that same day.

By the way my mechanic had the balls to throw out a $600+ labor fee, after his computer told him that it was a 9 1/2 hour job.

9 1/2 f@$%ing hours. And he's a "professional." Disgusting.

[X.Krunkt]

So I finally had time to start putting everything together and she should be up and running by this weekend with pics to come.

Now I have a question. I had put on 157 "break-in" miles on the engine before the belt snapped. Once the new head goes on, should I continue to break in the engine for a couple of hundred more miles, or should I go for broke and give it boost righ off the bat?

[1badgvr4]

I say wait for the 500 to come.Do all kinds of driving at different rpms and loads.Use engine braking as well.

[hawaiifiveoh]

I wouldn't suggest it to anyone, but I've kinda wanted to try the whole rev the hell out of it for a few seconds, change the oil + filter, and repeat four times, I can't remember where I saw it, but I do believe that if done correctly, there have been people that have had success with it before.

[sherloc123]

A local shop around us breaks all their engines in on the dyno while tuning the car. Not one of them has blown up and a bunch have over 10k miles and 500whp. They are honda's but it should be a similar concept

[X.Krunkt]

I want to do it on the dyno, I just don't wanna be that guy whos car breaks on the dyno and causes a huge mess. I will most likely do a hard break-in. I 've been doing alot of reading and I don't really see a problem with doing it that way as long as I do it correctly.

[X.Krunkt]

Here are some pics of the damage after the timing belt broke.

This is what it looked like when I took the head off. I found 4 rockers just laying in the head. Another four of them were loose and fell off when I just touched them. :eek:

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000306.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000306.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000307.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000307.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000308.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000308.jpg)

These were the pistons. Not any real bad damage. Just a few knicks on each of the pistons. Those have been all ground down and fixed.

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000312.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000312.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000313.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000313.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000314.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000314.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000315.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000315.jpg)

Then I flipped the head around and there they were. All my bent valves. They slapped the hell out of the pistons. But not with enough force to crack of break the pistons in any way.

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000318.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000318.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000320.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000320.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000321.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000321.jpg)

I have also purchased the rest of my fuel mods. That should be coming in the mail any day now. Man I love tax return time. I will be doing a Walbro 255, Aeromotive AFPR, all new SS braided lines throughout, then hitting the dyno to get it tuned.

[lazylaser]

Walbro 255, Aeromotive AFPR, all new SS braided lines throughout
Good call.

Sorry to hear about the d-bag mechanic...But From now on I'm sure you'll be doing ALL you own work, (maybe not alignments) Good luck. Nice build thread.

[X.Krunkt]

I got a few people that are telling me that I shouldn't have reused these pistons. I haven't fired her up yet since i'm waiting for the rest of my fuel system but from what i've read and from what I know, there shouldn't be any problems with the way I did it. I just used a little sandpaper and got rid of the sharp edges. Just kinda smoothed it out.

If that's not the case i'm gonna be pissed! lol

Will there be any problems with this?

[xuberantz]

You'll be fine reusing them, nice thread! :P

[drifte]

Machinist was happy to reuse my contacted pistons. said great for clearancing! Meaning valves made themselves a little space. smooth them off and you'll be fine. That is assuming no cracks.

[X.Krunkt]

A few more pics I found.

This is my oil pump sprocket. Snapped off and ate a perfectly round hole in my lower timing cover.

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000352.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000352.jpg)

And then just some random pics of my new head and such.

http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000324.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000324.jpg) http://i22.photobucket.com/albums/b312/themonkeygoesmoo/misc/th_P1000323.jpg (http://s22.photobucket.com/albums/b312/themonkeygoesmoo/misc/?action=view&current=P1000323.jpg)

I have a few bugs I still need to work out but so far so good. Can't wait to be done.

[firebirdvert305]

Pretty cool to see someone else in Davenport build there own DSM. Trying to break 650whp this year on my current fwd. Got a blue laser running around here, made 578whp previously. You should stop on by sometime.