Zckry's '98 GSX Budget Build

[zckry]

Well, I think it's time to for me to quit wining and start my GSX rebuild.
As man of you know, my GSX recently spun a rod bearing:

http://www.youtube.com/watch?v=b2Mv5bXgK5w

http://www.youtube.com/watch?v=YkYIWcYxFTE

It came completely unexpected as I didn't have a crazy setup or and never ran my GSX hard and it really got me down (when has a DSM not gotten us down from time to time).
Anyway, I've since parted most of it out and am starting my rebuild.
This build will take at least one year so updates will not happen every week with fancy new parts :rolleyes:

Because of my lower income (college student), I will not be able to go with an ultimate setup but it will still be very nice and done right.
My ultimate goal is to have an ~450whp/tq lightweight GSX so I can make some quick times at the tracks and have a fun weekend car that is somewhat reliable.

What I've already gotten started on is eliminating all HVAC (A/C, Heater) components, spoiler, rear windshield washer, power steering, and plan on converting to Non-ABS brakes.
From the past I've already had many little weight loss things here and there around my GSX.

As of right now, I completely re-wiring my engine harness; eliminating any unneeded wires, sensors, etc.
I plan on doing a full wire tuck and have already coated my engine bay in Herculiner for a unique look.

I will post up some photos when I get everything eliminated on it and start my build from there.

[Red1991TSI]

Need some pics in here...

[Loner]

Sounds like you have the right mind set.

[g9s5r]

I watched the first video and noticed you dont have bolts on your valve cover.. Did you have it apart to check lifters?

[zckry]

Need some pics in here...

Working on it Red, I was just waiting for someone to submit the thread.
I got my nice camera back so I should have photos shortly.

I watched the first video and noticed you dont have bolts on your valve cover.. Did you have it apart to check lifters?

Yeah, it was just temporary because I just checked out the head.

[zckry]

How she sits right now, very messy, very stripped:

http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6092.jpg
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6093.jpg
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6095.jpg
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6098.jpg

I have a lot of cleaning up to do but right now I'm not worried about it because I'm still trying to lighten her up.

Right now my main project is hitting up the wiring harness.
Got the help from Turbosax2 over on Tuners.
I am currently eliminating the following from the main harness:
The following connectors and their wiring will be eliminated:
1. Manifold Differential Pressure (MDP) sensor
11. Auto-Cruise Control Vacuum Pump (Cruise Control Actuator)
13. Fuel Pressure Solenoid (FPS) Valve
14. Exhaust Gas Recirculation (EGR) Control Solenoid
16. Brake Fluid Level Switch
18. Hood Switch
19. Dual Pressure Switch (AC)
27. Evaporative Purge Solenoid
28. Theft Alarm Horn (Anthony knows!)
30. Turbocharger Waste Gate Solenoid Valve [Boost Control Solenoid (BCS)]
35. EVAP Emission Purge Control Solenoid Valve
36. Air Conditioning (A/C) Compressor
43. Left Fog Light
44. Right Fog Light
52. Fuel Pump Check Connector
Rear o2 sensor
ABS module connector
I know this with throw a million CEL's when I get her back up and running but I plan on using DSMlink v3 so that doesn't bother me.

Here is the mess right now:

http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6087.jpg
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6089.jpg
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6090.jpg
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6088.jpg

[ferriolom]

Your a brave soul monkeying with the harness. I'm a fan of the herculiner.
Good luck with your build. A year goes by quickly.

[zckry]

It's actually not too bad because someone (snowboarder on here) took photos and documented EVERY engine bay connector on our 2G's, so it's basically a follow-along.

The herculiner turned out well but it's already looks super dirty from grass and such getting caught on it, oh well, nothing a simple wash can't take care of.
I'll take better photos when I start cleaning it up and adding fun stuff to the bay.
I also don't like how dark it looks right no but from what I've read the color is supposed to lighten up a bit as time goes on.

[123abc]

I'm more of a fan of nice clean paint instead of bed liner for the engine bay. But if you like it that's all that matters.


Looks like you have some ambitious plans. Good luck with them.

[Gamble]

What is a herculiner?

[Gamble]

Umm, why are you taking off the rear o2 wires? I put my AEM uego and wired it to those wires, so it is nice and easy to put there.
Also the mdp wires is where you want to tap to your your pigtail for the MAP sensor if you decide to get one.
I don't know, you wouldn't catch me removing half of this crap.

[zckry]

Well for the rear o2 I'm not removing the pin from the connector and I'm leaving about a foot of wire from the ECU pin for that exact reason (to tap into it for datalogging).

Same goes for the MDP wires, I can always extend them further if need be, I plan on using the same deutsch connectors (from laddinc.com) as 16g95gsx (on here) and turbosax2 (on tuners) so adding wires back in will be very very simple and easy, gives me plenty of room to expand if need be.
I simply do not need any of those wires listed up there.
I don't plan on going all out like 16g95gsx but my main goal for eliminating those wires is to make my wire tuck that much easier.

Here is a photo of what I plan on using (taken from turbosax's build thread, not mine):

http://www.dsmtuners.com/forums/attachments/hangout/96003d1244596935-my-fuse-box-relocation-project-log-img_8376.jpg
http://www.dsmtuners.com/forums/attachments/hangout/95995d1244596877-my-fuse-box-relocation-project-log-img_8335.jpg
http://www.dsmtuners.com/forums/attachments/hangout/95997d1244596877-my-fuse-box-relocation-project-log-img_8340.jpg

[zckry]

I'm more of a fan of nice clean paint instead of bed liner for the engine bay. But if you like it that's all that matters.


Looks like you have some ambitious plans. Good luck with them.

I too would like a nicely painted engine bay more but I lined it with truck bed liner for many reasons:

*Don't have to move my GSX shell to a paint shop (garage is way to full to paint in there, plus I don't have a nice gun)
*Much easier to apply, prep, etc. for than paint
*Cheaper than nice paint job
*Gives a unique look that I think will look great with a nicely tucked bay
*Much much more durable than paint, I'll never have to touch the engine bay again expect to do minor touch-ups (which is super easy to do BTW)

[Loner]

I think it is a good idea, and different.

[kstallard34]

Damn that thing is knocking like a jehovah's witness. Good luck! You know guys don't care about text, its all about pictures man. lol

[swade]

http://www.dsmtuners.com/forums/attachments/hangout/95997d1244596877-my-fuse-box-relocation-project-log-img_8340.jpg

Where did you get this?

swade

[zckry]

Where did you get this?

swade

?

[zckry]

Small update:
I got my Non-ABS parts in from Harry Harry today so I thought I'd bolt em up.
From my gut feeling, the ABS parts weighted about 10-15lbs with everything, the new prop. valve and non-abs lines weighed probably less than 4lbs.
Decent weight loss and a less cluttered engine bay :D

Possibly the last full non-ABS 2G parts left evAr! (Many thanks to Harry):
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6116.jpg

Old ABS parts removed:
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6133.jpg

Non-ABS parts installed:
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6134.jpg
http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_6135.jpg

My GSX as a whole is still so messy.
My next update will be removal off the sound deadening material from the interior, then I can start putting my dash back on and cleaning up :)

[b00sted_spyder]

Is that engine bay painted already? Sorry to say but it looks dirty.

[zckry]

Haha it's Herculined, kinda like Rhino Lining, and yes it's very dirty.
The Herculiner traps grass and dirt pretty easily and we've been mowing around it so it gets in there easily right now without a front bumper.
It will be easy to clean up, just a nice power wash.

[burkgonzo]

Coming along man...can't wait to see it done

[DSM4LIFE-AWD]

You should have painted this non/abs proportionnal valve ...

Sorry but I don't like this herculined paint, it looks like too much undercoating from the picture ...

Good luck with your build ;)

[i need a dsm]

LOoks like you a good path, just don't give up hope! Was the car originally red?

What the engine build consits of?

[zckry]

You should have painted this non/abs proportionnal valve ...

Sorry but I don't like this herculined paint, it looks like too much undercoating from the picture ...

Good luck with your build ;)


Why should I have painted it?

Not a problem, sometimes I don't like it but it's really not bad at all in person and when it's cleaned up, in the photos it's super dirty.

Thanks.

[burkgonzo]

Who cares if the valve is painted? His car was red, then black. But only time will tell what color he is going to use.

[zckry]

LOoks like you a good path, just don't give up hope! Was the car originally red?

What the engine build consits of?

Trying not too, it's hard when you have a beautiful GSX sitting there that your still making payments on :(

Yeah, it was originally red and was painted pearl jet black on the exterior.

Not sure yet, I'm either going with the Evo 9 pistons/ 1G rod, 1G rod/2G pistons, or forged internals.
The head will be pretty basic, just a port and polish, beefy cams, springs, etc.

[zckry]

Well, now that school is finally starting to dwindle down I've had little more time to work on my build.

I've ditched the harness re-wiring because after I got the final quotes on everything it would turn out to be $600!
I'd rather spend that money on a turbo.
I decided to start with a clean harness since mine was hacked beyond my patience to repair.
I've already purchased one from a member on here, just waiting on it to arrive so I can get back to wiring everything back up.

Anyway, I've made a little more direction with my build by compiling a rough budget list of what I'm wanting out of this build.
I'm currently leaning towards a build similar to Cory Bower's TSi and plan on making great times like he did with a fairly stock block.
It is as the follows (everything starred if was I currently have):

Engine:
*7-Bolt Block (.020 over, milled)
*1G Big Rods (7-Bolt and 22mm conversion at DSMGraveyard)
2G or Evo 9 Pistons (.020 over)
OEM Oil Pump & Waterpump
*OEM crank
272 camshafts
*3G lifters
Cometic MLS HG
ARP headstuds
ARP rods/flywheel/etc. hardware
OEM timing set
Drivetrain/Suspension:
Shep Stage 4 build (w/ 4-Spider diff)
PTT Twin Disc Clutch/Flywheel
Shifter Bushings
*Eibach Pro-kit
*2G GST 16in. wheels
Drilled/Slotted Rotors
SS brake lines
Prothane mounts
Cooling:
CXRacing radiator/fans
Samco radiator hoses
VR-Speed intercooler
DEI Titanium turbo shield/blanket
Evo 3 Intake Manifold w/ NT throttle body
Fuel:
2G Full-Blown Dual 255lph Walbro Fuel Pumps
-8AN fuel lines (from tank to rail)
1000+cc injectors
AFPR w/ -8AN return line
Water injection kit
Electronics:
DSMlink v3
Prosport gauges
Innovative wideband
Turbo/Exhaust:
Holset HX35 w/ divided T3 v-band exhaust housing
Divided T3 manifold (haven't decided on one yet)
3in. v-band o2 housing
*3in v-band TBE (no cat)
Extra:
*Non-ABS brakes conversion
*Emissions delete
2G Miata-style steering rack conversion
*DSM extreme weight-loss
BS Elimination
Hawker PC680 Battery



As I said earlier, all things starred I already have so I'm back off to a decent start.
I got a great deal from a local for his machined (still needs to be decked) block so I switched directions a little.
I'll also be doing a bit more purchasing here soon (thank you Christmas) so you'll see my list being checked off a little quicker.

What has been done since my last update beside what's mentioned above is all the sound deadening material is finally gone (still needs to be cleaned up) thanks to a cheapo heat gun I borrowed (worked much better than dry ice people!). I also got the dash back in, had the spoiler/rear windshield holes welded up and shaved, and stripped the car down a ton. All free stuff while I've been strapped for money in this awesome economy situation and college.

Photos coming soon!

[4g64fiero]

May I suggest skipping the cometic and going with a mitsu MLS?

[zckry]

You may :cool:
Me and Aaron (dsmgonzo) were disscusing head gaskets the other day and I wasn't sure what to go with on my build and planned boost around 25psi.
I'm still fairly new to rebuilding these engines so I take any advice from DSMer's (esp. ones who have gone through a wrong rebuild, ahem, thrust bearing, ahem).

[4g64fiero]

Ouch.

What year 7 bolt are you going with? Are you going to rebuild it yourself?

[frankozz]

Nice list you got going on man. ;)

[93_GSX]

+1 on the Mitsu MLS gasket. It holds up to quite a bit of punishment.

[zckry]

Ouch.

What year 7 bolt are you going with? Are you going to rebuild it yourself?

Yur booty hert more? :P
I'm kidding though, that would be very disappointing man.

'95, the guy I got it from (know him very well, trustworthy guy) was getting it machined to be a badass block (all forged internals) but then he got his hands on a 6-bolt and swapped it in his 2G.
No crankwalk on this sucker :D

I will be re-building it by *myself* with the help of local guys (including the one who sold me the block) who have rebuilt these motors.

[4g64fiero]

Mine is a 95. They had the lowest occurrence of crankwalk statistically of any year 7 bolt. And dont worry about CW, as long as you make sure endplay is around .001" when you first put it together you shouldnt have an issue. Also, you have to make sure the main girdle is aligned by apply lateral pressure to the crank in the direction the clutch would when you tighten the mains down. Its a pain in the ass, some people dont torque their mains down until they install the motor and can put clutch pressure on it!

I am parting everything out except for my built motor, I am confident in it despite my mistake.

[rhinop21]

You aint cool unless you do a six bolt swap.

[zckry]

Mine is a 95. They had the lowest occurrence of crankwalk statistically of any year 7 bolt. And dont worry about CW, as long as you make sure endplay is around .001" when you first put it together you shouldnt have an issue. Also, you have to make sure the main girdle is aligned by apply lateral pressure to the crank in the direction the clutch would when you tighten the mains down. Its a pain in the ass, some people dont torque their mains down until they install the motor and can put clutch pressure on it!

I am parting everything out except for my built motor, I am confident in it despite my mistake.

Well actually my '95 GST (first DSM) crankwalked but I didn't know what to look for at the time.
Anyway, I'm confident in the block/crank because it's not from a stranger or a sketchy person.

Thanks for the tips, I'll keep this in mine when I start putting her together this winter!

Good luck on you're build man, are you still going RWD?

[zckry]

You aint cool unless you do a six bolt swap.

Ain't it the truth :cool:

[4g64fiero]

I am parting everything out until I finish my degree. Its not going to get finished until then anyways so I cant reason having two shells taking up space all the time.

I'm keeping my damn built motor though hahaha. I'm not out, just need to spend the money on my house and the time on school.

[zckry]

Understandable, I had to decide on a similar situation when my GSX spun a rod bearing.

Here's the motor:

http://i394.photobucket.com/albums/pp24/zacawesome/IMG_0145.jpg
http://i394.photobucket.com/albums/pp24/zacawesome/IMG_0144.jpg
http://i394.photobucket.com/albums/pp24/zacawesome/IMG_0146.jpg


Shaved spoiler holes, I still need to work on the bondo and then paint.
These were (will be) done the correct way: welded closed, grinded down, bondo, then paint.
I had to primer them as soon as the job was done because my GSX stays outside for the most part and it was going to rain that night.
I don't like rust.


http://i394.photobucket.com/albums/pp24/zacawesome/IMG_0147.jpg
http://i394.photobucket.com/albums/pp24/zacawesome/IMG_0148.jpg

Dash back in, I need to wire everything back up, I'm waiting on a member from here to ship my harness:


http://i394.photobucket.com/albums/pp24/zacawesome/IMG_0149.jpg

I also need to take some time to clean up what's left over from the sound deadening.
I got every last bit of it off (minus behind the rear speakers, will get to them soon), everything under the dash floor pans, hatch area, rear seat area, etc.
It weighed around 30 lbs altogether, not bad.


http://i394.photobucket.com/albums/pp24/zacawesome/IMG_0150.jpg
http://i394.photobucket.com/albums/pp24/zacawesome/IMG_0151.jpg

[burkgonzo]

Better send Santa your wish list! :)

[zckry]

Got my virgin harness in today, thanks twenty5Psi:

http://i491.photobucket.com/albums/rr279/zackaryb/GSX%20Project/IMG_0166-1.jpg

[99gsx99]

Swade already asked this, but where did you get your "harness plug" looks like something off a BMW.

If youre doing what I think youre doing, its an awesome idea and I havent seen it done on a DSM yet.

Good work.