Thor's Car Progress Thread: '90 TSI AWD project, parts cars, and the Cavy. 56k death!

[Thor06]

EDITED 3/15/08:

This is the project thread for my baby, the Purple People Eater. The plans are to make it a stock appearing "sleeper" sort of car. I got it in March of 2006 and have collectively put 1150 miles on it. I've spent a gross amount of time working on it, I estimated that I've put in around 20 minutes of work (either on this car or one of the parts cars for it) for every mile I've driven in it. The car was not taken care of before I got it, as made evident by the fact that I've been over every single part under the hood of the car and many everywhere else. I wont stop until this car is perfect, which will be a loooong time.

My baby is going to be transformed into a stock appearing street car bent on nothing but total street domination . Only kidding, its going to be a fun car for me to work on at night and cruise in on the weekends. I'll probably take it to the tracks once in a while, but its largely going to be a fun weekend car.

Current Mods
Engine and Bolt-Ons
K&N air filter
Extrude honed intake manifold
Evo III exhaust manifold, gasket matched
Big 16g, ported hotside
Ported 1g o2 housing
3" Megan downpipe, test pipe, and catback
JoeP MBC

Drivetrain, Brakes, Suspension, and Misc.
Modified stock 91 shifter
95 AWD 2 piston calipers
Hawk pads
Second gen 300zx wheels, 16x8, painted gunmetal
Yokohama tires
Removed rear seat and some interior, spare tire, AC, bypassed heatercore, removed sound system, various other weight reduction

Interior and Exterior
Autometer Ultra-Lite 30 in hg/30psi boost guage
Autometer Ultra-Lite 0-100psi oil pressure guage
Autometer Ultra-Lite 120-240 water temperature guage
Guages in factory HVAC control spot, controls relocated to below where the radio is supposed to go

In The Closet
Comp 101200 cams (FP2's)
ARP headstuds
Walbro 255
ACT 2600 with a sprung 6 puck disk
ACT XACT chromoly lightweight flywheel

Wanted
DSMlink
JAW (DIY wideband o2)
2g MAF
Hard intake pipe
Supra SMIC with custom IC pipes
2g/Evo III/tubular 02 sensor housing
880cc/950cc/1000cc injectors
Aeromotive/Fuel Lab FPR
Custom SS lines from Jegs , fuel filter to rail, FPR install kit, turbo oil feed and return
FP 18g-6SL2
AGX/Prokit combo
Rear sway bar
Front and rear strut bars
4 bolt rear
Shep tranny
Harness bar or 4-6 pt cage
Racing seat, 4 or 5 pt harness
Smoked out bar lights and tail lights
Tint
Repainted body and wheels
CO2 IC sprayer
Direct port or wet shot nitrous

Goals
325 whp on the 16g, 375 whp on the 18g
<12.25 1/4 mile on the 16g, <12.00 1/4 mile on the 18g

[vanilla gorilla]

Haven't heard anything from this car in a while. Sounds like a decent plan you have outlined there. Ready to see some pics. I need to do an update on my car also...hmm

[Thor06]

As promised, heres the pictures!

This is the car after I finally got the head gasket done.


Here is working on the Talon after I spun a bearing.


Here is the parts car getting the engine pulled to get rebuilt for the purple car.


Moving the bottom end from the parts car.


Bottom end getting pulled apart.


Stock pistons/rods.


The Eagle/Ross combo .

[blk_srt]

Looking good man

[Thor06]

Heres an update for you guys. Operation: Dorm Room Rebuild commences! Yesterday I had some time and I got the bottom end ripped the rest of the way apart. It looked good, the bearings didnt have any crazy signs of wear and there was hardly any endplay (though I didnt measure it). I dont think the crank needs to be ground, I did the penny trick and all checked out fine. I am hoping for the best, hopefully all the bottom end needs is a re bore (pistons are .020 over). I am looking forward to the rebuild. I think I am going to have the bottom end and top end done at different times, mostly so I can spread out the cost. I cant wait to get that bitch on the road! Anyway, heres a couple pics.


Heres my new tools. I was sorta happy and sad to get them dirty for the first time. I think its a 155 pc and it was like 35% off. I like them a lot.


Theres my sitting in my lofted bed looking down on the floor. Yes, this is happening in my dorm. Its a good time. I was super careful though, not a spot of grease hit the carpet. All the work was done on cardboard or the lid to the box its being stored in. Its sort of a pain though, I think I am going to have to get a engine stand to do the build.


Closer up of the block/head.

[blk_srt]

looking good man

[NOFX0617]

Thats awesome that you are doing that in a dorm room. That is talent my friend. Good luck.

[Thor06]

Well, after a lot of thought I have decided to alter my plans. I realized I cant afford my 500 whp goals so I gotta be happy with a more normal car. I am limiting myself to the a 190 and internal gating. I will stick on the Big 16g until she blows in which case I will get an Evo III 16g. My new plans have cut a lot off the cost of my build, no more built tranny, expensive turbo, AFPR, external gate, big injectors, 4 bolt rear, etc. My new plan is not raging track monster, more moderate street terror . Heres the new plan:

Sooner
-Stock engine with my FP2's
-Stock flywheel?
-ACT 2100 or Exedy Stage II
-Big 16g until it blows then Evo III 16g
-3" exhaust
-FMIC
-Stuff to keep an eye on the engine (link, guages, etc)
-190
-650cc injectors
-strut bars

Later
-meth/h20 injection
-lowering stuff, either GC's with AGX's or Sportlines with AGX's
-alarm system
-tint
-decently good sounding and boomy sound system
-stiffer sway bars

Last thing
-paint
-interior (seats, 4/5pt harness, etc)

Goals
-300+ whp
-low 12's at the track
-Just fuckin shit up street style

I figure that way I dont have to build the shit out of everything and attaining my goal will be far easier. Also, I added a few things, namely the suspension stuff. I always wanted to lower it, but handling doesnt matter a whole lot to me. Well, oddly enough, I was inspired by Buschur's time attack Evo. He was featured in Modified Mag's March issue. Though hes been known to be a douche and his shit seems WAYYY over priced, I took a lot from that Evo. I realized to be a sweet car, you dont really have to be a fuckin crazy high power car to still be fun. And since I cant always have straight line fun but I can always have fun, I decided to alter my plans a bit.

I still want it to be a higher HP car, by higher I mean as much as I can squeeze from the Big 16g and Evo III 16g when its gets there. I wil be running meth/water injection later so hopefully I can eventually be running decent numbers on pump.

Since I have gone more towards the "street" car than the track car, I would like some luxuries I was going to cut out. Since the AC system is completely gone and since I dont plan on driving it during the summer, the heat and AC are going. Those are for pussies anyway . I think cruise control is going to stay, but mostly because I dont want to have to fine a non-CC throttle cable. I still wont use it.

I have decided that I want to put a system in it. Being a street car and all, I would still like to be able to jam out a bit. I am going to put in probably one sub and one amp to drive it and run the speakers off of deck power. I am going to make a quick detach for the sub box and mount the amp to it so that when I need to ditch it for track use, it wont be hard. Also, that shit is going to be obviously locked the fuck down, no one will be havin my shit. Tint will happen sometime before during or shortly thereafter to help stop theivery. Oh, and an alarm, that will happen same time as the system.

Ok, so thats luxury fun and power fun, what else is there? The one I have been neglecting for so long! TWISTY FUN! Thats really what inspired me about Buschur's Evo, I realized I can drop just a couple hundred extra for sway bars and strut braces and have a fairly curve worthy machine. I know DSM's (particularly 1g's) have been known for their crappy handling, but I think with some lower and stiffer suspension, front and rear strut tower braces, and some heavier sway bars, I can make this thing attack corners a bit better. Hell, just suspension did a shit ton for the Cavy and the DSM will be getting better stuff. I know it wont exactly be an autox machine but I know it will hold the road fairly well.

I am excited about this even more now with my suspension ideas. I sort of arranged it into "stages" like in NFSU, that way I can sort of take it a bit at a time with everything. I think I am going to try to tackle the list in summers, Sooner being this summer, Later being next summer, and Last being the summer after that. We'll see how it goes though, obviously if I can get a good deal on something or cant find a deal on something else, I will have to switch around the order. I cant wait! Killing corners, smashing straight aways, and pounding pavement. Anyway, I am done rambling.

[blk_srt]

Originally Posted by Thor06

Since I have gone more towards the "street" car than the track car, I would like some luxuries I was going to cut out. Since the AC system is completely gone and since I dont plan on driving it during the summer, the heat and AC are going. Those are for pussies anyway . I think cruise control is going to stay, but mostly because I dont want to have to fine a non-CC throttle cable. I still wont use it. .

Weight reduction is for pussies

Originally Posted by Thor06

I have decided that I want to put a system in it. Being a street car and all, I would still like to be able to jam out a bit. I am going to put in probably one sub and one amp to drive it and run the speakers off of deck power. I am going to make a quick detach for the sub box and mount the amp to it so that when I need to ditch it for track use, it wont be hard. Also, that shit is going to be obviously locked the fuck down, no one will be havin my shit. Tint will happen sometime before during or shortly thereafter to help stop theivery. Oh, and an alarm, that will happen same time as the system.

Ok, so thats luxury fun and power fun, what else is there? The one I have been neglecting for so long! TWISTY FUN! Thats really what inspired me about Buschur's Evo, I realized I can drop just a couple hundred extra for sway bars and strut braces and have a fairly curve worthy machine. I know DSM's (particularly 1g's) have been known for their crappy handling, but I think with some lower and stiffer suspension, front and rear strut tower braces, and some heavier sway bars, I can make this thing attack corners a bit better. Hell, just suspension did a shit ton for the Cavy and the DSM will be getting better stuff. I know it wont exactly be an autox machine but I know it will hold the road fairly well.

I am excited about this even more now with my suspension ideas. I sort of arranged it into "stages" like in NFSU, that way I can sort of take it a bit at a time with everything. I think I am going to try to tackle the list in summers, Sooner being this summer, Later being next summer, and Last being the summer after that. We'll see how it goes though, obviously if I can get a good deal on something or cant find a deal on something else, I will have to switch around the order. I cant wait! Killing corners, smashing straight aways, and pounding pavement. Anyway, I am done rambling.

I knew you couldnt resist the ICE

[scottsee]

I've also got a 6bolt build going down. Good luck...

[Thor06]

Well guys, after a breif lapse, I am back to workin on the project. Parents wanted me to get rid of it, but I cant. I'll just take it slow. Since I love planning and shit, heres the new list of parts. * = have, the rest I need to get yet.

Engine/Performance
-Stock 6 bolt bottom end*
-Semi built head, FP2 cams*, possibly beefier springs/retainers
-Walbro 255, some aftermarket FPR, bigger injectors (probably like 750's or 850's), running E85
-DSMlink or maybe Greddy Emanage Ultimate
-Extrude honed intake mani*
-FP exhaust mani*, ported o2 housing*, 3" turbo back exhaust*
-FMIC, Type RS or SSQV
-Evo III 16g
-5" tach, oil pressure, boost, water temp, and various other guages
Drivetrain
-sprung 6 puck ACT 2100 or a Exedy stage II
-4 bolt rear if/when the 3 bolt blows
Suspension
-Ground Control coilovers with KYB AGX shocks
-Front and rear strut bars
-Rear sway bar
Brakes
-possibly putting the early 95 slotted rear brakes in*
-2g AWD big brakes up front*
Rollers
-300zx rims, repainted black or gunmetal, once the Yokos burn off I'll be rocking the cheapest decent performance tires I can get*
Interior
-Racing seats, 4 pt harness, and harness bar
-CD player, component speakers up front, coaxial 6x9's in back, 1 10 or 12
-Possible entirely flat black interior, keep 'er low key
-Random purple neons (yep I am a ricer)
Exterior
-Painted like stock, repainted stock purple with the silver stripe on the bottom
-Like 25% tint
-Purple underbodies (ricer again, I know but I dont care)

So yeah, basically I am going to keep working at it and hopefully a year or two after college I will have my dream car! Hopefully on the E85 I can be running near maxed out all day everyday and be decimating the competition. When its done I am going to try to get it in a magazine and enter it in a few shows but probably I will just end up tearing up back country roads and Mustangs from a light all day . I'll keep ya'll updated as stuff happens.

[2.3L_turbo]

nice talon dood i have one to its the exact same color and averthing but i was wondering if u had any sugestions on chap power aders though lol thanks

[kittay]

Why so big of injectors? I realize you want to run E85, but you're still wanting to run a 16g right? Have you checked out the sleeper 16gs?

[Thor06]

Well, I am just going to need 850s. My plans have been bobbling recently and I have decided to stray from the 18g or bastard 20g and stay with a 16g variant. I've been a bit busy with my website (just making a site for my car club) and I just havent updated this one. Since the Evo III 16g maxes out at 39 lbs/min and since the E85 needs more fuel, it needs more injector. The table found here tells of the max airflow different injectors. The 850 max at like 47 lbs/min, but since you dont want to go over 85% IDC, they work perfect for 39 lbs/min.

Like I said, I have looked at the 18g's and bastard 20g's and all that, but I am going to go with an Evo III 16g to keep cost down. I am going to be acquiring direct port nitrous here next week so the extra few cfm's wont be too much needed .

[kittay]

Originally Posted by Thor06

Well, I am just going to need 850s. My plans have been bobbling recently and I have decided to stray from the 18g or bastard 20g and stay with a 16g variant. I've been a bit busy with my website (just making a site for my car club) and I just havent updated this one. Since the Evo III 16g maxes out at 39 lbs/min and since the E85 needs more fuel, it needs more injector. The table found here tells of the max airflow different injectors. The 850 max at like 47 lbs/min, but since you dont want to go over 85% IDC, they work perfect for 39 lbs/min.

Like I said, I have looked at the 18g's and bastard 20g's and all that, but I am going to go with an Evo III 16g to keep cost down. I am going to be acquiring direct port nitrous here next week so the extra few cfm's wont be too much needed .

Understandable, I just saw the 1000cc's and was like wtf.. In the summer, I'm running 750s w/ the e316g on E85. I haven't even came close to maxing those. I was running 650s at 70% duty cycle. Since then, I added quite a bit more timing (24-25 degrees), tuned it better, and turned the boost up (had it tuned to zero knock at 24psi). So I'm probably around 60% IDC on the 750s.