david-b's 95 Eagle Talon ESi-T Motor Build

[david-b]

They took some persuasion. Did a little oil on the O-Rings, and had to take off the top part of the IM so I had more leverage, but they went in and they're snug in there. Not going anywhere anytime soon.

I'm off to get some work done. More pics tonight. I'm taking tomorrow off of work also to try to finish it up

[ned032002]

When I put in my 650s I had a hard time getting them to go straight in. A buddy of mine was putting 550s in his TSi and he actually bent the fuel rail because one of the injectors weren't seated properly. Guess he didn't pay much attention when putting them in.

[SilvrEclipse]

RC injectors seem to be a tight fit on these cars. Some thinner o rings would be a good idea to help them go in. Motor looks awesome man cant wait till that thing runs

[vanilla gorilla]

Originally Posted by Blackcrow64

I thought it had already been painted once?

He got into a slight front end collision, and got a new front bumper and had that painted. IIRC

[david-b]

Originally Posted by vanilla gorilla

He got into a slight front end collision, and got a new front bumper and had that painted. IIRC

That's right, I had the front bumper painted, but that was all. That thing still looks brand new.

Big progress made today. I got there nice and early today after not being able to sleep last night and was excited rolling in. I finished mounting up the tranny to the block and getting the rest of the mounts in. I start hooking up the slave cylinder to the fork and adding in fluid. The slave and the fork look a little 'off'. Something about it didn't look right, and there was no play at all on the fork. I called Jason (my hero for the week BTW) and told me there should be play. I pulled the little rubber cover off and see the fork wedged between the pressure plate and the little pivot ball in not in place. I was pissed thinking I would have to pull the motor again. I seperated the tranny from the block as much as I could without releasing the whole thing, and after ~25 minutes of trying, got the fork on the pivot ball and on the TOB properly. You could just tell that it was in the right place then. Best pic I could get of it...



Once this was all fixed, I filled up and bled the clutch. My god this thing is stiff and feels like a clutch. The last 2 I had always had a soft touch, where you couldn't feel where it was being disengaged. This one it's obvious. Feels great. Have to workout my legs a little more though. City driving will be hard with it.


Once that was in, I had to reinstalled the alternator and the crank pulley (pulled off yesterday) and did the belts, rechecked timing, got the PS all up and hosed, and attached all the wiring. Those saying that it would take forever to find where each harness goes... I think I've done this too many times... took 2 minutes to hook them all up (I timed myself )

I then made my mounts for the FMIC and redid some of the piping. Drilled out the broken stud from yesterday and welding in a new stud. Did some painting. Basically got everything in the car. Made HUGE progress today.



So tomorrow, I'm taking the day off of work and finishing her up and take the hoist back. I have to pick up some extra fuel line since some SS I ordered is still on backorder, reattached the lower cross member, fully installed the manifold, turbo, WG, and make a custom DP, and it's ready to fire up. MSns is not fully wired, so will use stock ECU for all control to begin with at idle here. I don't plan on it leaving the garage. Hopefully I have no leaks and it's perfect straight out the box. Wish me luck for tomorrow.


Pic at about 6pm tonight.

[SilvrEclipse]

Wow dave that looks amazing. I hope you aren't using the stock ECU to control those 750s? There is no way in hell you will be able to run that much injector with the stock ECU. Other than that everything looks good. Do you happen to know what lb pressure plate you got? Im betting you are getting a stiff pedal from warn out hydrolics. Even thought they aren't leaking, them being warn is causing your pedal to be stiffer. My looked to be in perfect shape but I went ahead and changed them my last clutch change and wow what a difference. I would recommend this for anyones car thats 10+ years old.

Also can you get a few more pics of the manifold wastegate and downpipe area. Im just trying to get an idea of mine.

[vanilla gorilla]

Looks awesome bud, good job. And about the stiff clutch, I actually prefer a hard beefy clutch any day out the week. Even in the city.

[david-b]

Got some more work done today. Let me start off by saying, I hate this manifold. So many things about it suck. I broke the T-Stat housing trying to bend that out since the one tube is dead against the hose then and wont fit right. Plus, my turbo is so big that it's a PITA to get it all fitted properly with that damn WG flange right in the way. WTF were they thinking. I had so many problems with it, I nearly pulled it off and put the log-style back on. I hope to god that this thing does not cause any problems once it's altogether. I recommend not buying it, or putting it on. My .02.
</rant>

Because of that, I didn't get to finish her up today. I worked ~12 hours on her and she's so close, but not quite yet. Let's see what I did..

-Installed crossmember and finished back of block wiring
-Fully mounted manifold
-Mounted turbo
-Made WG pipe and mounted that. Need to make dump tube now
-Ran ~95% of vaccuum lines (no turbo)
-Redid melted wiring harness by timing belt
-Did some wire tucking
-Finished all fuel lines
-Started on new DP. This is actually what slowed me down then. If you look at my tutorial I have in the tech section, I made a little 4" sectional to connect the DP to the flex pipe. Well I had enough pipe to get rid of that. I started cutting and welding, and called it quits tonight on that... too tired.

I'm betting the stiffer clutch pedal is from it being a heavier clutch. I don't remember the rating, but it was a ~375lb torque capable plate or something like that. It feels perfect. When I was in Dustys car last year, it felt just about the same. Feels perfect to me now.

So what's left is to finish the DP and finish MSnS. I don't know when the next time I will be there will be though.

[ned032002]

I'm lovin all the super sexy pictures keep 'em comin'. I like what you did with the wastegate btw.

[david-b]

Originally Posted by ned032002

I'm lovin all the super sexy pictures keep 'em comin'. I like what you did with the wastegate btw.

The WG has to get a brace so it doesn't break off. Plus have to make a dump tube for it. Need to get some pipe for that still.

Looks like I won't be out to the garage until Saturday morning and then Sunday. Hoping to get the DP finished up on Saturday and if all that goes smooth, then the wiring. Also want to mod the manifold a little so it will fit better. I'm not liking the way to sit on the t-stat housing.

Startup is for sure on Sunday though. Of course followed with pics and video.

[david-b]

Since I'm throwin a HUGE Halloween party tomorrow, I decided to work on the car this cold, rainy Friday night. I finished the DP (Started out good, but that last piece of fab to match up always sucks for me), ran SS fuel line on the return, and finished the IC piping. Also bunch of random other crap too.

Pics...

Downpipe with V-Clamp at turbo. Connects to my modified GST flexpipe then.


Pic of it installed along with the IC piping leading to the FMIC and oil return. Tight fit. I may wrap the DP by the IC piping to protect against heat.

[vanilla gorilla]

Still looking great man. Should be a beast.

[SilvrEclipse]

Ye aman it looks awesome. We need to go over MS sometime tmrw to make sure everything is ready to go.

[cantgo2fast]

Wow thats a tight fit in there but it looks great, I would definitely recommend trying your hardest to keep those hot parts from effecting those parts you want cold, That will kill your power.

[ned032002]

Lookin great. Is sunday still 1st start up?