DSM_BOY’s 800hp Goal/ AWD Conversion Build

[DSM_BOY]

Well after a Year 1/2 of constant beating on my stock 7 bolt, she finally blew and am now ready to move on to some real power

Here’s the damage from the 7 Bolt
Threw the #2 Rod out the block
I guess those toothpick rods don’t like 30psi for very long
(Unfortunately I didn’t get to take a pic of the block but there were 2 holes on the front and 1 hole in the back of the block)





Here’s a list of the Main important NEW parts:
(please feel free to comment opinions/advice)
I change my mind a lot so this setup is just what I have planned as of right now...

Block:
Wiseco 1400 HD .20 Over Pistons
Manley “I” Beam Rods
L19 ARP Headstuds
ARP Main Studs
Felpro MLS Headgasket
ACL Race Bearings
Kiggly Girdle

(Entire bottom end will be balanced and cryotreated)

Head:
JMS Port/Polished
FP3 Cams
Kiggly Beehive Springs & Retainers
Kiggly HLA Pressure Regulator
SS 1mm Over Valves
(Ceramic Coated/Cryotreated)
Turbo:
Forced Performance HTA T4Z .82 Hotside
Punishment Racing T3 Manifold
JM Fab Drag SMIM
Boomba Racing 75mm TB
Zex Turbo Application Wet Shot 35-75hp (for spool up/dyno)

Drivetrain
Shep Stage 4 (will run stock tranny during break in so i can save some money for the rebuild)
QuarterMaster Twin Disc 7.25" V-Drive Clutch w/Flywheel

Suspension
D2 Racing Full Coilovers
Prothane Total Suspension Kit
CNC Aluminum Rear Differential Bushings
CNC Aluminum Driveshaft Bushings
15’ Volk TE37
M/T Drag Radials

[DSM_BOY]

This is what my car looked like from the last build thread i did..





12/01/2008
I managed to snatch up the rear end w/driveshaft for $400
Just need the tranny/Transfercase/axles



My New Turbo
Forced Performance T4Z .82 Hotside


Hotside was ceramic coated by Tirado Custom Coatings


1/07/2009
So last night I picked up the pistons from Carlos at Tirado Custom Coatings who's now offering Piston Top Coatings! You guys def gotta hit him up because they came out great!
Wiseco 1400HD .20 Pistons (Sending to get ceramic coated)



Also got some CNC Machined Rear Differential and Driveshaft Bushings from an ebay member who makes these… I def recommend him because not only is his price unbeatable! But they came out perfect and with quick shipping..

Heres a link to one of his ads..
eBay Motors: 95-99 DSM REAR DIFFERENTIAL BUSHINGS Eclipse Talon Diff (item 260336884223 end time Jan-22-09 11:49:21 PST)

His ebay name is hx2600

[DSM_BOY]

1/10/09
Some goodies that came in

ARP L19 Head Studs


Kiggly 6 Bolt Main Girdle


ARP Main Studs


Satin Black Chassis Paint for the Front/Rear Subframe/Control Arms


1/20/09
Haven’t had too much going on right now, took a few side jobs on some local DSMs that have been taking up my weekends but i did manage to get some goodies

My FP3 Cams


Few things i got back from the chrome shop




I got almost every bolt/nut in the engine bay chromed

[DSM_BOY]

1/21/09
TCC Started on the welding:



Grinding down the welds to make everything nice and smooth:


Used paint on the areas I grinded down to prevent corrosion until we decide on paint color:






2/13/09
Haven’t had any real good updates lately
Currently waiting on the block to be finished by the machine shop...
Just bought the paint for the engine bay to be sprayed...

A local upcoming shop/team here named JMS Racing did a port/polish on my head and i think they did a real good job. They have some pretty sick Evos including (1) that i hope to see into the "9s on pump" with the Buschur Setup...
(Dont mind the Valve Guides, those arent the ones im going with)




Cleaned up my 3g Lifters by soaking them in Brake Cleaner for (2) days and bleeding them


I went to a local exhaust shop and got all the stock rubber bushings torched out so that i can press in the new Prothane Full Suspension kit


I also got a chance to press in the New Aluminum CNC Bushings from Orlando @ HX2600 Performance..
Fit great!!

[DSM_BOY]

Also got in the DVD/T Fab FMIC This thing is SICK!!



Picked up some of the :Bling: from the chrome shop..




5/04/09
Its been a long time since the last update and finally got some stuff going

New 1g Timing Tensioner, STD Clevite Main Bearings/ACL Rod Bearings


Manley "I" Beams.. Decided to go with them after seeing so much success out of them with most of Buschur's builds not to mention iv'e seen some DD EVO's making some pretty sick power out of these...


QuarterMaster 7.25'' Twin Disk


Also, my block finally got finished!!
For some reason my 1st machine shop had my Block/Crank/Parts/Deposit Money for 5 Months and didn’t even touch it… so I finally had enough and got my stuff and went to a new machine shop which did a great job and took 2 weeks tops!



Once everything comes back from being Cryotreated, Ceramic Coated and Fully Balanced... we'll get to bulding the block...

Next I decided to run the infamous “Saturn Alternator” to solve the DSM Alternator woes under high boost/RPM pressures. I used a lot of info of the DSMLink forums with this thread:
ECMTuning User Support Forums

I went to a local junk yard to pull the Alternator plug off 1.9L 94 Saturn (ill show hot to hardwire it later into the thread)



1st thing I had to do was grind down the alternator case inorder for it to bolt up to the 4g63 Block, I used a Mini Dremel and Grinder to shave it down

[DSM_BOY]

Next I had to grind down the block along with it… The frontcase cover has to be done as well but im going to wait until its bolted on


I also got the final parts for the AWD Swap...
Going to give the Tranny and Transfercase a good cleaning/new seals before i thow everything in...




Also Carlos @ TCC got the subframe finished up with the Suspension Paint… looks sick!


And now.. The Beginning of the “AWD Swap”


What the undercarrage looks like now…

[DSM_BOY]

Until next time… she’s tucked away for Part II





7/13/09
I was hoping to get further into this build by now but… I gotta admit ive been slacking…

I recently turned 21 a couple of months ago and have been focusing more time Downtown than anything!

Although I’m really hoping to really get things moving soon…

I finished the rear end of the AWD Swap a while back but never got around to posting it so here it goes…

1st started off by finding the rear bolt that needs to be moved to the front


I cut around this square that was hiding the bolt



I bought some replacement bolts/washers that I had welded together and then to the frame..



Here’s an under shot of what needs to be cut/moved


Next was to find the front hole and throw/weld the bolt in there


Now that was left is to remove the FWD Gas tank hangers that are in the way for the AWD Rear end
A regular drill will be able to drill through the spot welds and just hammer it off..


Done! AWD Rear Subframe bolted and mocked up!

[DSM_BOY]

As far as the longblock goes…

The head is currently at the Machine shop getting the 1mm Over valves seated then going to head to TCC to get ceramic coated…




Big Thanks! To Bill & Patrick over at Mountain High Performance
Home Page
I sent Bill my Crank/Rods/Bearings/Valves to get Cryotreated and he was able to send me some pics to show just how cold these parts get
I highly recommend them, they’re no stranger to DSMs, Patrick is a fellow DSMer and even on the DSMLink forums
Not only are they EXCELLENT in turnaround time but great in customer service!





After that,
Parts were sent directly over to TCC for his Dry Film Lubricating coating...
TCC Powder and Ceramic Coating
Definitely did an excellent job in the coating and masking off the journals!



I’m dropping the bottom end parts to get fully balanced and hoping to start putting together the bottom end this week!

I prepped the block a while back by painting and installing oil Squirters/BSEK bearings

[DSM_BOY]

8/23/09
TCC continues on the engine bay, about 20% completed.
There is still alot of work left to make this bay showcar quality :thumb:

BEFORE


AFTER


JMS Racing Port/Poished
Kiggly Beehive Springs/Retainers
English Racing 1mm over SS Valves (Cryotreated)
FP3 Cams
3g Lifters

And TCC Ceramic Coating on the Valves, Combustion Chambers, Exhaust Ports

[DSM_BOY]

9/03/2009

Building the Bottom End

I had the block

*Bored .020 w/torque plate
*Decked
*Line Honed
*Hot Tanked
*Bottom End Fully Balanced
*Cryotreated - Crank/Rods/Bearings
*Ceramic Coated - Pistons/Rods/Crank




Parts
*OEM Crank (Cryotreated/Ceramic Coated Counterweights)
*Wiseco 1400 HD .020 Pistons (Ceramic Coated Tops)
*Manley “I” Beam Rods (Cryotreated/Ceramic Coated)
*Clevite Main Bearings STD (Cryotreated)
*ACL Rod Bearings STD (Cryotreated)
*Kiggly Main Girdle

Piston Ring Filing
1st thing I like to do is file the rings. Wiseco calls for .018 TOP and .020 Second but since I’m planning on running around 40-45psi with a shot on top of that I decided to go with a .020 TOP .023 Bottom.

Tools I used

Piston Ring Filer, Ring Compressor, Feeler Gauge

Magnet, Dial Indicator

Lubriplate Assembly Lube, ARP Moly Lube

Plastigage


Here's what comes ina set, Top, 2nd and Oil Rings


I like to fill up a cup with oil to make sure the walls are always lubed up and ill re-lube everytime I take out the ring…



The best way to set the ring in the center of the bore is by using a piston w/ring. This will insure that you get the most accurate reading with the feeler gauge…



Check the starting end gap with a feeler gauge…

[DSM_BOY]

When using the Piston Ring Filer, I always file down (1) side only and use the other as a reference..


Next is the Bottom Ring, same method applies except when filing this ring, be careful as it will be a lot easier to file than the TOP ring…


Piston / Connecting Rod

Once I’ve filed all my rings ill start installing the Pistons into the Connecting Rods…




To make things easy when inserting the C-Clips, i use the grove in the piston to press in the clip.



Use plenty of assembly lube on the wrist pin and slide it through the Piston-Connecting Rod

[DSM_BOY]

2nd C-Clip to lock the wrist pin into place



Done




The Piston Rings

I start with the Oil rings, I sandwich all (3) together and Install as a single ring





The Rings endgaps will go accordingly

[DSM_BOY]

Crank Install
Starting with the Main Bearings to the block, with plenty of assembly lube





Carefully set the crank onto the bearings and give it a few spins around just to make sure it spins freely..


At this point I like to check the clearances using Plastigage's



Rest of the Main Bearings on to the Main Caps and lube up the top…

Installed along with the Kiggly Girdle




I also like checking the Crank Endplay by using a Magnet and Dial Indicator.
Using a lever to push the Crank, The endplay was right at .0025 (Perfect)



Finally I removed the Main caps and checked the plastigage's, right at .003 (Perfect)

[DSM_BOY]

Piston/Rods Install

Using the Piston Ring Compressor, I wrapped it around the piston and tightened it down.


Used a towel and Hammer to press down the Piston into the bore


Lined up the Rod to the crank journal and torqued down the ARP bolts to 40ft lbs w/Moly Lube


Finished Product, giving it a few spins to make sure nothing hits and spins freely

[DSM_BOY]

11/18/2009

Teaser






800awhp coming to a dyno near you...

[dd_man]

Nice looking build. Do you plan on bringing the car to the shootout? It would be fun to run our cars against each other.

[stevolution]

Maybe you could run some buschur parts in there too...Just a thought...

[95TSIAWD$]

I've been following this build for a long time and can't wait to see some more updates!

[DSM_BOY]

Nice looking build. Do you plan on bringing the car to the shootout? It would be fun to run our cars against each other.

Id like to, its a 24hour drive and im hoping i can find someone with a truck to trailer it

Maybe you could run some buschur parts in there too...Just a thought...

Might run a bushcur COP after break in

I've been following this build for a long time and can't wait to see some more updates!

wow, very nice job done there. Congratulations on your built!

Thnx!

[TiradoCustomCoatings]

Once this build is completed, it's going to be one of the craziest and nicest 2g's around for sure.
The attention to detail Richard is taking is amazing, I just wish he would post more pics already! lol.