97 gsx build
 

Hello my name is Blake, and I am pretty new to style and to the dsm world. I picked up a stock 97 gsx last May with the intention of building a fun dd. My goal is to eventually have a 4-450 awhp gsx running e85 after I put on the finishing touches and get it tuned by shane at db. First off I would like to thank my good friend Mark (mark4g63t) for helping me with the build and letting me use his garage/tools in the process. This is my first build and without his help this build wouldn't be possible. Also I would like to thank Mark (tkrperformance) for giving me advice, building my shortblock, and steering me in the right direction.

The build:

- .020 6 bolt block w/ .020 2g pistons on 1g rods w/ arp rod bolts and acl rod & main bearings assembled by Mark (tkrperformance). Thanks Mark!
- arp head studs
- 2g head
- revised lifters
- felpro composite hg
- autometer boost guage, oil pressure guage
- h&r springs on kyb agx shocks
- itm gasket set
- bse kit
- ss clutch line slave to master cyl.
- ditch the pillar, going with gauge bezel with a gauge in the cigarette lighter location. (trying to keep it sleepy)
- comp fp2 272's
- mhi 20g hybrid (tdo6 comp cover) rebuilt by Justin from tuners
- Punishment racing external dump o2 w/ tial mvs wg
- fic 1600cc injectors (running e85)
- act streetlite flywheel, act 2600 pp, act sprung 6 puck
- 1g tb
- vrsf fmic
- 1g bov
- thermal r&d turbo-back (thanks cornfed2.4!)
- dsmlink v3
- MTX-L wideband
- afpr kit
- fuel lab fuel filter
- wally 255hp
- stm fuel pump rewire kit


I just about gathered all the parts on that list and am currently assembling the head and front case etc. I am currently working 60+ hours a week so finding time to build is becoming a challenge. As you will see I am going with a black theme for the bay. I plan on painting the bay gloss black in the process as well. Here are some pics on my phone (sorry in advance for the horrible quality) that I have of the car and parts. I will take more pics of the parts and process as I make some progress.:wink:

I used to be in the vdub scene. I then quickly got out of the vdub scene because I got sick of dumping endless amounts of money into it. However I guess the dsm scene isn't much different :rollinglaugh:. But anyways this was my gli before I got my gsx:

[IMG]http://i1215.photobucket.com/albums/...0318121924.jpg[/IMG]

gsx:

[IMG]http://i1215.photobucket.com/albums/...07131622_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...r24v/fbpic.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...131620_1-1.jpg[/IMG]

My buddy mark's talon:

[IMG]http://i1215.photobucket.com/albums/...07131619_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131613_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131612_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131610_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131609_1.jpg[/IMG]

Do these seats look familiar cornfed2.4? :wink:

[IMG]http://i1215.photobucket.com/albums/...07131601_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131557_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131606_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131604_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131558_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131600_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...131607_1-1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131616_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131615_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07132134_1.jpg[/IMG]

I got a really good deal on a hybrid 20g that was rebuilt by Justin 300 miles ago. So I ended up going with that rather than running the hx35 which needed a rebuild and bep bolt on housing. The hx35 is currently up for grabs!

[IMG]http://i1215.photobucket.com/albums/...05131813_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...05131815_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131623_1.jpg[/IMG]

Like I said, I am new to dsms and so far have learned everything I know from my friends and lots of reading on the forums. If anyone has any advice for me on the build please let me know. This is my first time building an engine so any advice would be awesome! Thanks for looking and I will include updates as often as I can.

Re: 97 gsx build
 

Looks like a decent mod list, good luck with her.

Re: 97 gsx build
 

^ thanks man

Re: 97 gsx build
 

Solid build for someone who is new to DSM's!

Re: 97 gsx build
 

Nice looking car!! And welcome!!

Re: 97 gsx build
 

Thanks guys! Just ordered a new front case/oil pump with gears, oem belts, pulleys, and timing tensioner. After those arrive and I find a black top cas, I will start assembling everything.

Re: 97 gsx build
 

Agreed. Looks like a solid start and should be fun when finished.

Re: 97 gsx build
 

Anyone have a spare black top cas lying around that they are trying to sell?

Re: 97 gsx build
 

Damn good build since not knowing anything a couple months ago. Time to get this thing outta my garage and into your car.:seeya: I have more pics I can put up once I find them

Re: 97 gsx build
 

Been really busy with work so I haven't had much time to work on it. I received my oem front case oil pump with gears, ss clutch line, itm water pump, and timing belt in mail this weekend. I assembled the front case and was about to put it on when I realized I had the wrong front case/block gasket. Apparently the guy that I bought the itm gasket set from thought it was a 6 bolt gasket set. Apparently not. Heading to Brookdale tonight to grab front case/block gasket and castle plug w/ oring.

I just traded a guy a 7 bolt valve cover for a black top cas so that should be here tomorrow. I came to the conclusion that I will not be attending pg this weekend, and instead I am going to finish assembling the block & head. Also going to remove actuator & flapper from the 20g and port the flapper hole to match the PR o2 housing. If i receive the arp washers this weekend I will bolt my head on as well. Hoping to make a lot of progress this weekend.

I will include updates with pics

Re: 97 gsx build
 

Well, change of plans as of yesterday. Last night I picked up a black 98 2gb awd spyder with 65k on the body (rust free) from bigboostingst. Currently it has a 2.3 stroker w/ wiseco pistons on crower rods with 5k on it, mhi 20g, vrsf fmic, and a 255.

Tachyon came over this morning to help me change my lifters, timing belt, and swap in my 272's. I am going to be swapping over my wheels, suspension, and link from my gsx into the spyder. Also I am going to be putting on my rebuilt 20g w/ pr o2 housing and tial wg, afpr, stm rewire kit, and bm 1650's.

I will update soon with some pics of the new ride!

Re: 97 gsx build
 

Woo. You will have to bring it buy

Re: 97 gsx build
 

Will do, hopefully I can start her up today. Finished the timing belt job and installed the 272's yesterday. Took the day off from work today to: pull turbo, port the new 20g and install the wastegate setup, install link, plasti dip gsx wheels, swap suspension, and bl test.
I will post some pics today

Re: 97 gsx build
 

Finished putting her together yesterday. Fp2 272's, 3g lifters, link, new mhi 20g, pr wg setup, afpr, springs & struts, timing belt, gsx wheels, thermal r&d turbo back, bm 1650cc injectors, fp intake, and some more goodies. Plasti dipped the trunk because paint was faded.

This is how she looked when I picked her up last Friday:
[IMG]http://i1215.photobucket.com/albums/...02131337_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...02131338_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...02131334_1.jpg[/IMG]

Now:
[IMG]http://i1215.photobucket.com/albums/...-07_162814.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...7_162909-1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...0_094121-2.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-07_162750.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-07_162720.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-07_162631.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-07_162624.jpg[/IMG]

I will take some updated engine pics when I get home. It is having trouble holding boost when I blt it. The compressor is set to 28 psi and when I blt it the boost gauge only reads 2 psi. I spent 3 hours fixing small boost leaks but nothing major and the boost gauge still reads 2psi. It's at 30* past tdc. For some reason a ton of air is exiting the exhaust during the test. After doing some reading I am going to go check the pcv, egr, and leak down test it after I get off work. Anyone else experience this problem?

Re: 97 gsx build
 

Egr was still on the car with the the emissions lines deleted. The valve was stuck open which was causing air to exit the #4 exhaust port in the head, thus allowing air to enter exhaust when doing a blt. Just ordered a block off plate and it should be here either today or tomorrow.

Re: 97 gsx build
 

Looks good. Glad you swapped the tailights out. Car looks sweet!

Re: 97 gsx build
 

Ah okay the egr makes sense! Car looks good!

Re: 97 gsx build
 

Thanks guys, I am hoping the block off plate fixes the issue. All I need to do is install the block off plate, tighten suspension, do a final blt, and fill some tanks with e85 and dial in my injectors and I should be ready to go.

Re: 97 gsx build
 

Here are some updated pics. Sorry I do not own a camera so I am forced to use my cell phone.

[IMG]http://i1215.photobucket.com/albums/...10131120_1.jpg[/IMG]


[IMG]http://i1215.photobucket.com/albums/...10131117_1.jpg[/IMG]


[IMG]http://i1215.photobucket.com/albums/...10131118_1.jpg[/IMG]


[IMG]http://i1215.photobucket.com/albums/...10131115_1.jpg[/IMG]


This will be my speed density setup once I am ready. I am going to my running the maf for a while since I am new to tuning and e85. However, if anyone would be willing to lend me a hand tuning sd I would give them some $ and rock it.

[IMG]http://i1215.photobucket.com/albums/...10131114_1.jpg[/IMG]


[IMG]http://i1215.photobucket.com/albums/...10131116_1.jpg[/IMG]


I am hoping this was the problem and why the car wouldn't go into boost. I will find out tonight after I install the block off plate.

[IMG]http://i1215.photobucket.com/albums/...10131112_1.jpg[/IMG]


90* boost leak tester :)

[IMG]http://i1215.photobucket.com/albums/...10131113_1.jpg[/IMG]

Re: 97 gsx build
 

Good news, the egr was the issue. I installed the block off plate and was able to build 12lbs during a blt before the cap on my boost leak tester flew off. I think I have the line for the external wg setup wrong because I have to cover the top nipple in order to build boost. I will be fixing that and some small boost leaks after work, and hopefully starting the car for the first time tonight! I just put 13 gallons of e85 in last night :)

Re: 97 gsx build
 

Nice, getting work done

Re: 97 gsx build
 

Last night I fixed all my boost leaks and was able to hold 25 psi no prob! She is all ready to go and I will be starting her for the first time tonight when I get off work. I hope these bm 1650's are easier to dial in than the old bosch style injectors. I am going to be taking it easy until I can get a tune from Shane because I don't want to f*** anything up considering I am fairly new to tuning.

Re: 97 gsx build
 

Update:

Well I drove the car for a couple weeks and for the most part she ran pretty good. It leaks oil from where the dipstick tube sits in the block, oil return, and oil filter housing. Also, I was experiencing knock when ever going wot. Before I had time to look into it, the clutch went out (that's what I think anyway). I was leaving my house in 2nd gear then all of the sudden my car just revved and wouldn't accelerate. Also, when the car is off and in gear the wheels don't lock and it starts to roll so I have to pull the e-brake.

I got the car towed to my buddy's garage and started taking her apart. We both work until 8 so I haven't had much time to work on it. Axles were just rebuilt and were fully seated in the trans. Drained gear oil and t-case fluid and everything looked good. Axles, t-case are out so all I have to do is remove the mounts and drop the tranny. I will know for sure tonight what went wrong and what I need to buy in order to get her running again.

I am going to be going with a street disc and if the pp needs to be replaced I am going to go with a 2900. I am hoping the the trans and flywheel are in good shape. While I am waiting for parts to arrive I will be installing the full ss clutch line, black top cas (hopefully fixes the knock issue), dual gauge bezel and removing a pillar, oil pressure gauge in cigarette lighter location, rewire fuel pump, and switching to speed density. Also I just picked up a shaved vc that was powder coated black :)

Here are a few pics of the process:

[IMG]http://i1215.photobucket.com/albums/...07131157_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07131156_1.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-07_000155.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-07_000213.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-07_000122.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-07_000240.jpg[/IMG]

http://i1215.photobucket.com/albums/...-07_000110.jpg


I will post some more pics up tomorrow of what I find when removing the trans. After I get her running I will be installing a 1g aluminum radiator with slim fans, delete a/c, and delete cruise control box and install non cruise cable.

Re: 97 gsx build
 

I gather you never made it to the dyno before you issues?

Re: 97 gsx build
 

This happened less than 24hrs before the tune time.

Re: 97 gsx build
 

Unfortunately not, I did trade a guy a spot for the 21st. Not sure if that is going to happen or not due to this unexpected surprise and the knock issue. Hopefully I figure out the drivetrain issue tonight. Before this happened the TOB was making a very loud squealing noise when the clutch was engaged. I am guessing that the hub ripped right out of the middle of the clutch disk. Perhaps the transmission was falling out, and as it became less aligned to the transmission, the more it destroyed the clutch disk(TOB noise).

Re: 97 gsx build
 

As I expected, the center of the disc separated from the rest of it. Here are some pics of what i found when I removed the tranny:

[IMG]http://i1215.photobucket.com/albums/...-08_000622.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-08_000637.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07_2355341.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...07_2355051.jpg[/IMG]

Does anyone know what pressure plate this is? It doesn't have and numbers on it or anything. I believe it is a 2600:

[IMG]http://i1215.photobucket.com/albums/...07_2355141.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-08_000849.jpg[/IMG]

[IMG]http://i1215.photobucket.com/albums/...-08_000920.jpg[/IMG]


There is a lot of build up inside then bell housing. Is this normal? I was just going to power wash it and remove as much as I can:

[IMG]http://i1215.photobucket.com/albums/...-08_001107.jpg[/IMG]

Input shaft looks good, no damage from what I can see:

[IMG]http://i1215.photobucket.com/albums/...-08_001058.jpg[/IMG]

Flywheel looks great as well. I am going to get it resurfaced just to be safe. I am going to buy a 2900 pp and street disc tonight. If all goes well, I should be able to make it to the cookout no prob!

Re: 97 gsx build
 

That kind of buildup is normal on high mileage dsm's. It's just dust from the organic clutch disks over the years. So you don't know what brand that is at all? I would guess it may be a XTD (eBay) pressure plate. I would guess by the falling apart of the disk like that, the disk is probably an XTD as well.

Re: 97 gsx build
 

There isn't any writing or anything on the pp. And yeah I was thinking XTD as well. The pp is still in really good shape but I am going to play it safe and go with a 2900 so I don't have to worry about it.

Re: 97 gsx build
 

I was judging that by the red PP and the shape of the sticker that used to be on it. XTD puts a sticker just like that on their PP's.

Re: 97 gsx build
 

I think a 2900 with a 6-puck might be overkill and could do damage.

Re: 97 gsx build
 

I was planning on going with a 2900 pp and a street disc. I know a 2600 would probably be enough but I just don't want to deal with a slipping clutch. Plus I will probably upgrade to a bigger turbo next year.

Re: 97 gsx build
 

Shane's right 2600 and a good puck style clutch will hold more than enough even if you upgrade to a larger turbo. At that point though I'd start looking into twin disc setups.

When Shane said "damage" I think he's referring to crank since the 2900 with put more force on everything.

Re: 97 gsx build
 

I just decided that I want to go with a street disc rather than a puck style disc since it is mainly going to be a street car. I have just read good things about the 2900/street disc setup and that it holds over 550hp and people have had success with it in their dd. Apparently the new design (2900/3200) results in a softer clutch pedal than the 2600 pp after it's broken in. I am not knocking the 2600 at all, it's just my buddy mark has a 2600/street disc setup and his slips in 5th and he is only running 20 psi and I just don't want to deal with that. However I have read that people have ran 10's with the 2600/street disc setup so idk. I mean the 2900/street disc is only like $30 more so I would say it's worth it.

What do you guys think?

Re: 97 gsx build
 

I have never had a problem with a 2600 and a street disk. You just need to make sure the clutch and peddle are set up right so it does not drag.

Did mark ever replace the p.p. with all the problems he was having with the tranny input seal leaking.

Re: 97 gsx build
 

I've always had slipping issues tho.... :(
Mark- Yes it was all replaced. 2600 and street disc with resurfaced flywheel from proven force.

Re: 97 gsx build
 

Got a good deal on a used 2900 pp with 1000 miles on it and just ordered a new act street disc with oem TOB. Everything should be here by the end of the week. While I am waiting i started relocating my gauges, installing autometer oil pressure gauge, install ss clutch line, and rewire fuel pump. My goal is to be driving it by the end of the weekend.

Re: 97 gsx build
 

Well, unfortunately I didn't finish in time to make it to the cookout :(. Last night I got the car all back together and ran into some issues. Firstly, whenever I turn the key the left turn signal always flashes no matter what. The right turn signal doesn't come on, however both flash when I turn the hazards on. Also, when I attempt to start the car it doesn't even attempt to turn over. While the tranny was out I installed a black top cas and 6 bolt swap harness and I am wondering if that is hooked up wrong causing the car not to start.

I work until 1 today and during that time I am going to look up all the possible fixes for the issues I am having since I am on a computer all day. Today I start school as well, and fortunately for me the first part of the program is electrical 1 so perhaps I can get some advice from my instructors.

Other than that, the clutch pedal feels nice and firm and everything else looks good. I installed a full ss clutch line while I was in there. Also I relocated my boost & wb gauge from the a pillar to in the dash and will be installing my autometer oil pressure gauge in the cigarette lighter spot in the nest couple days. While the car was down I had Mark repaint my hood gloss black and it looks awesome! Just want to be able to drive it.... Here a few pics I have on my phone and will get some better quality ones up shortly.

[IMG]http://i1215.photobucket.com/albums/...26130724_3.jpg[/IMG]

New oem TOB:

[IMG]http://i1215.photobucket.com/albums/...26130724_2.jpg[/IMG]

Aftermath of using 3 cans of brake cleaner to the bell hosuing:

[IMG]http://i1215.photobucket.com/albums/...26130724_1.jpg[/IMG]

Re: 97 gsx build
 

After doing some research I am almost positive that the end of my cas harness is plugged into the a/c connector and not the crank connector which would cause the car not to crank at all. Apparently both plugs are the same shape and look identical so I am hoping that's the problem.

Re: 97 gsx build
 

Yeah that damn ac plug. If its plugged into that one that will definitely happen. Good way to tell is the length of the wires after they come out of the main harness/loom. The ac plug will be a lot longer since it needs to go low to plug in. Where the cas plug is shorter.

Hope that helps.