Figured I'd put a sort of build thread up for my car cause everyone likes reading build threads.
I recently had a sh!t ton of work done. Ordered a lot of parts from Ziggy (RTM > *) and had the labor done by Ryan L (since I don't own a garage nor know how to do half this stuff).

I wanted to basically have my car refreshed before I move, hence why I spent all the money. Parts wise; new timing belt kit, OEM Water Pump, All lower end seals, BSE kit, ACT 2600, Fidanza Flywheel, SS Clutch Line, new TOB, fork and pivot ball, New OEM Master And Slave, new belts, new plug wires, valve cover gasket and ss bolts, 16 new lifters, HKS 272 cams, ARP head studs, Prothane motor mounts, 14b turbo, SS line for remote mounted oil pressure and temp senders, tubular manifold, new studs and 4 layer gasket, and most importantly DSM Link V3 Lite!

The motor before anything was done to it, nasty huh?


The motor, transmission and transfer case were pulled. Motor went on to the stand. The car was then pushed out of the garage so the engine bay could be cleaned up.




Engine bay all nice and cleaned up.


The head was pulled from the block and they were both cleaned up.



The old cracked manifold, T25 (still in great shape) and O2 dump.


All the little aluminum bits were pulled off the motor and brought in for Jet Washing. All nice and clean now.


[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0815.jpg[/img]

Timing parts and front case were pulled from the block.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0807.jpg[/img]
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0808.jpg[/img]

A/C was stripped out.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0819.jpg[/img]

Here's all the old parts/A/C crap which will be chucked.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0806.jpg[/img]

Then the motor was reassembled with all the new goodies.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0814.jpg[/img]
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0817.jpg[/img]

New manifold mocked up.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0818.jpg[/img]

The motor back in one piece. Filled with oil and primed, not a single leak.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0821.jpg[/img]
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0822.jpg[/img]
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0824.jpg[/img]

The car waiting for her heart back.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/2010%20Build/IMGP0823.jpg[/img]

Car is a totally different monster now, much more fun to drive. I've got some minor kinks to iron out, leaky exhaust gasket (ordering SS ones from Ziggy) and my front cross member is rusty! Bolts tore out so I have to fix that. Other then that all is good.

The 14B I put on the car is a little worse for wear so I picked up this to replace it.



A picture of it beside the stock Garret T25, just a bit bigger eh?


Bought a turbine housing from the link forums and a Punishment Racing O2 Housing with Tial MV-S Waste gate. Once that stuff arrives I'll swap the 16G one.

Also have to drop off some stuff for powder coating at Bright Side.

You got the car back!? Nice!

Let me know when you're going to work on the car, I'll see if I can come over and 'help'.

Snapped some pictures of the Talon yesterday.
Yes it's dirty but it only came back late Wednesday night from getting some work done and the weather has been sh!t since.








Here's an idle vid.
http://www.youtube.com/watch?v=b3RlwCTVRIw

I've also got to work on smoothing my idle out as it's a bit jumpy.

Sweet.
Your car sounds really mean.

Did you always have the 3" turbo back exhaust?

Yup, 3" Megan Racing Turbo Back.

That's quite the rear view mirror!

I see your air filter mesh is starting to rust. Keep an eye on that... I had the same filter and it started drawing in rust "powder" into the intake. Check the inside of you intake pipes for a reddish stain.

wtf is going on with that rear view mirror? lol

I saw that in person once and my mind was blown!!! It's a pretty intense mirror.

hahaha, it's a Wink mirror. Used on rally cars and golf carts.



Good to know, I'll look into replacing it soon.

Anthony, very impressive work you got there. I suggest power washing your engine bay and replace as many rusted bolts as you can with new. Ziggy got most of the bolts.

Looking good man. Just in time for summer

Thanks Alex.
I can't take all the credit, Ryan put in most of the wrench time so far. That will have to change once I move though.

Over the winter and next spring (more then likely next summer too) I want to strip the car down and do a full restore. Body work, clean everything up, powder coat a lot of stuff, etc.

Beautiful dsm!

Love the wink mirror! They are awesome.

Thanks guys!

UPS came by today with some more parts.

First is my turbine housing, set up for an external gate and ported.



My turbo is whole again.


I'll likely have to play with the clocking of it once it goes into the car but time will tell.

Next are more parts from Ziggy at RTM Racing.
First is this sweet exhaust gasket, not your regular 2 bolt 3" gasket though, it's cut from 14ga (.075") stainless steel and it's reusable. I plan to replace all my exhaust gaskets with these things but for now, I'm just replacing the one leaking on.



Also, after doing a few logs with ECM Link, I've found my car to be running rather warm in the 200-210 mark, I'd like to get her to run a bit cooler because as the coolant gets over 215 the car starts to pull timing out (bad thing). I'd like to get her in the 180-195 range.
I picked up a 170* t-stat and new OEM Mitsu rad cap.


Next purchase will be some slim fans to replace the stockers.
Punishment is still waiting on Tial waste gates, bit of a back order but should ship by the end of the week.
Why must I cut these things so close?

Last little update for a while, my Punishment Racing O2 housing with Atmosphere Dump And Tial MV-S Waste gate showed up.
I opened the box and jizzed in my pants, it's fracking sweet looking.



1/2" flanges are fracking massive!


Tig welds are nice and sexy too!


The Tial gate itself is fracking sweet, nice and beefy. Everything is very well made unlike those cheap Chinese knock offs. Oh and you know I had to have it in Purple




All in all, I'm very pleased with this purchase and can't wait to see it on the car!

Wait, why a wastegate for an internally gated turbo?

^^^
Look closer. It's not internally gated anymore.

Brandon you may be thinking of a turbo that's set up for an external gate off the manifold? In that case the flapper is still there and welded shut to block that passage.

In the case of an O2-mounted external gate the flapper is removed just like in this pic:

Yup, it's been set up for an external gate off the O2 housing.
Much better at controlling creep this way.

ohhh ok, I was thinking you were going to mount the wastegate off the manifold, I was going to be like what the hell. But I looked closer and see the way the setup is supposed to be.

No worries Brandon.

I had an axle shaft break on me about 200km from Fredricton yesterday. Lucky someone stopped, hooked me up with a CAA tow and a garage to do the repair. There's good people out there still, I was very impressed with how much the guy was willing to help.

I'll be back on the road tomorrow AM.

Holy shoot.

Good to hear you were able to find good people.

How did it break???

Well, it was my own fault really.

When all the work was done with the car, the front roll stop couldn't be re-installed due to rust issues. I was instructed to fix it ASAP and not beat on the car.
Of course, I did beat on the car and this was what happened. So I learned a lesson.

She's back up and running and I'm in NL now. Car will be going into the shop to be repaired tomorrow.

Your car is beatiful just like my 1G, black with black rims. Nice!!

Thanks Brian! One day she'll be triple black (black paint, wheels and interior. I know triple is usually for rag tops but whatever lol).

Alright, so I'm moved into my new place. I parked the Talon at my parents place and insurance is coming off of it at the end of the month.
My mom has an 03 Chevy Tracker that has been just sitting in the drive way so I've commandeered it to be my DD for the time being. Here's a picture of what it looks like (stolen from the net, I'm not actually going outside to take a picture of the thing).


It's silver and 110% boring, perfect for a DD imo.

As for the Talon, she'll be comfortable sitting for now. I've got quite a bit of work I want to do with it and I'll be slowly taking my time to do it. On the plate is:
- Rust repair, Wheel wells/rockers, Some in the engine bay, new rad support, some bubbling on the roof skin plus whatever else I find as I take it apart.
- New suspension. My rear shocks are toast so I'd like to do a whole new set up, likely going to be Hypercoil springs (550F/400R), GC sleeves, Koni Yellows and custom mounts and stand offs (ala http://farnorthracing.com/autocross/konis.html). On top of that I'll be doing all new bushings from Prothane and also installing aluminum sub frame bushings. Plus I'll replace the ball joints, TREs and all that fun stuff.
- De Power my steering rack.
- Clean up and tuck the engine bay. I'll likely be making my own harness. Scirocco rad and a bunch of other things I want to do to make things nicer.
- ABS delete.
- Supporting mods for my 16G. Some big ol injectors, 255lph, AFPR, FMIC, convert to speed density, etc.
- Some other minor motor things. Valve stem seals, maybe new valvetrain but I doubt bit. Might also do a cheapish rebuild with new 2G pistons and 1G rods just so the motor is fresh but we'll see.
- Most importantly, going to 2Gb Talon body style. Seriously, frack that Eclipse sh!t.

That's about it, or at least all I can think of for now. This will take me a while to do mainly because I'm headed back to school in a couple of months so that will be my main focus both time and money wise.
I'll update this as things slowly happen.

Cant complain about the eclipse front. The rest Talon FTW!

Figured I would through up some information on what I'm doing in the engine bay. For several months, I've done research on tucking and deleting the various systems I want to get rid of. I've read Eric's (turbosax2) thread on his fuse box relocation: http://www.dsmtuners.com/forums/hangout/298569-my-fuse-box-relocation-project-log.html Lots of great info and it's given me a lot of information for what I need to do with my car.
I've also spoke with Chris (16g-95gsx) about his tuck and fuse box relocation. He gave me some great info too and a killer location for my fuse box:


I've documented a lot of stuff, here's some of the stuff I'll be removing in the wiring. Refer to - http://www.dsmtuners.com/forums/art...g-engine-bay-electrical-connections.html

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
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
47. Power Steering Pressure Switch
52. Fuel Pump Check Connector
54. ABS Hydraulic Brake Unit
55. Left ABS Sensor
56. Right ABS Sensor

There might be more but that will have to wait till I actually dive into the harness.

I've also decided to do a brake line tuck (ABS delete as well). I will NOT be using aluminum AN fittings, I DO NOT trust aluminum to stand the test of time when subjected to the pressures of a brake system. Instead I'll be using steel AN fittings, in some cases they are actually cheaper then their aluminum counter parts.
I've made a rough diagram of the actual tuck with all the parts, only thing i haven't figured out is the banjo bolts I want to use at the Master Cylinder.


Beginning of August I'll be back out at my old man's helping him with his Shed. Between that I plan to start on the car. I'm going to start by labeling all connectors in the engine bay, I'll be using this to help me: http://www.dsmtuners.com/forums/art...g-engine-bay-electrical-connections.html

Once all the engine bay connections are labeled, I'm going to dive into the interior and pull the dash and start labeling stuff under there.

I'll update then with pictures.

Got some work done when I was out at my parents place, not a bunch of stuff unfortunately.

I pulled all the interior out minus the dash, carpet and seats for now. Looking at all the stuff I had in the Tracker, I doubt the dash would have fit in there along with everything.



I'll start cleaning everything and dying it next week.

On my trip of here my bumper suffered some damage and was cracked in the middle.



I got my hands on a 2Gb Talon bumper and lights locally for a steal. Still needs to be painted of course plus I will transfer 1 set of my FX-R projectors to the other headlights.



With the interior out I started poking around with a screw driver and found some more rust (ARG!), I'll have to make up a couple patches for the rear floor.




Also pulled the wing off too see how bad the rust is on the hatch, I'm hoping I can patch this for now to save having to buy a carbon fiber hatch.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/Body%20Work/IMGP1062.jpg[/img]
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/Body%20Work/IMGP1061.jpg[/img]

Some good news in regards to the rust, the lower rad cross member is the only piece that is bad/rusted out. The surface rust will get ground down and hit with POR15.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/Body%20Work/IMGP1056.jpg[/img]
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/Body%20Work/IMGP1057.jpg[/img]
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/Body%20Work/IMGP1060.jpg[/img]

That's where everything sits now. I'm going out again on Saturday and hope to get the complete harness labeled. I might bring the dash home but it's still got to remain drivable just a bit longer so we'll see.
Rust repair won't happen till spring time but I hope to get the skirts off to see how bad the rockers are.

Do you still driver the car in the winter ?

Not anymore no.

Still waiting on a bunch of parts, once everything is here I'll do one big update and share the stuff I've gathered so far.
I was out at the car the other day and temptation got the best of me so I took her for a drive.
http://www.youtube.com/watch?v=YWE9u3YboA0

I also removed some more things from the interior, some things I want to work on and some things are for the garbage pile like the SRS and ABS computers and components.


I'm going to be working on mounting my secondary fuse boxes this week. Then I need to figure out how to secure my passenger air bag cover in place. Maybe Dzus fasteners or something.

A couple weeks back I unwrapped my dash harness of all the electrical tape on it, thinking back I'm sort of regretting it but at the same time it's allowing me to repair somethings. When it comes time to put it back into the dash I'm gonna wrap it with some braided sleeving from Cableorganizer.com.
First is where I had the Pro Sport gauges wired up, they were tapped into my hazard and rear defogger switches, this was a really half ass way of wiring gauges imo. I've now got the fuse boxes to run my gauges and other stuff so I cut the Pro Sport harness out, cut the wire, stripped it, put some heat shrink over, twisted the wires together, soldered them and then shrunk the heat shrink with my heat gun.




Both plugs all cleaned up.


I also took the time to start wiring the S2000 cluster connectors into the DSM dash harness. I'll be doing away with the OEM connectors so I can clean things up, all unneeded wires will be terminated to prevent any problems and also make it easier if I want to go back to the DSM cluster. All the connections are soldered and heat shrunk, so far I've done all the various warning lights (CEL, E-brake, Oil Light, Battery Light, turn signals, etc). Anything connected to power or ground will be done next week, this also includes some warning lights like the SRS and ABS which need power or ground signals to be turned off. I've also depinned some unneeded wires that serve no function outside of the S2000 chassis, just to clean things up.
Since the Talon doesn't have a trunk open light and the S2000 does, I'm going to be adding a pin in the hatch so I will have one.

You can see my helper is hard at work lol

I'm thinking about depinning the Cruise control and Fog Light plugs from the harness since I have neither of them anymore then I can just slap in the block off plates and be done with it.

Grabbed some stuff to start on the body work on the car.
I will definately be getting the trunk floor repaired over the next couple days. I don't think I will start on the rockers or the under carriage as I want to buy some other products for that (Rust bullet, Eastwood products, etc).

I did however buy the following:
U-Pol Zinc Weld Through Primer (supposed to be the best on the market)
U-Pol Self Etching Primer
Transtar Ultra Flex Black Seam Sealer
Plasti-kote Roll bar and Chassis paint



Brake cleaner (to clean before welding)
Cutting wheels
Flap disc
Wire brush
Grinder wrench (I lost my old one some where)
22ga Sheet Metal



I'm still trying to figure out what to do with the rest of the body work and under carriage, some sort of rust preventer will be present, most like Rust Bullet or some Eastwood products.

Looks like a ton of work done and to come. I've forgotten how bad the rust gets on Ontario cars!

Hows the car feel with all the reduced weight ie: A/C and the like?

I haven't noticed any difference. It might be .001 faster though lol
That weight will get replaced when I redo the sound deadening in the cabin.

if you don't want to die, don't use brake cleaner before welding.

^^^
No kidding!
http://www.brewracingframes.com/id75.htm

you must have some special feeling about your dsm since you don't give up no matter what project you have to do. Well kinda like me!

Wow, I didn't know that.

Thanks for the heads up guys, this might have been the last update on my car if I hadn't known.



I've abandoned so many projects over the years for dumb reasons, I'm tired of doing it. Plus there's just something about DSMs.