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"Project Dustbuster" Build Thread 1990 Galant GSX Auto 4g63 Swap PTE6266


rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111689 posted 03/05/13 02:06 AM     Remind Me!  Send Private Message   Edit Post      
I have been putting this off for a while but I decided to take the time to do a build thread on my 1990 Galant GSX 4g63t. First things first I will state that when I bought the car over a year a go, I was a DSM noob. I had just came from the Subaru community, and want a DSM since alot of my friends around here were having such crazy success with their cars at the track. We have a really awesome DSM community here in WV/KY and its growing (as of right now in our group of guys there are 8 cars that make at least 500whp some of those over 700whp). Needless to say I wanted to build a DD style car making around 350-400 whp but shortly those numbers would sky rocket thanks in part to those guys and my first DSM shoot out.


Build:
Built 4g63 balanced bored .020 over
10:5 Weisco HD Pistons
Manley Rods
Replacement Stock Crank knife edged since stock crank was shot
280 BC Cams
Q45 TB
H11 Headstuds
ARP Mains/ most bolts replaced with ARPs
BC Springs
AEM Cam Gears
AEM Meth Injection
Magnus Intake Manifold
ACL Bearings
BLE Tensioner
FIC Fuel Rail
Kiggly HLA
Head completely rebuilt SS valves +1mm
5 angle valve job
PTE 6266 CEA Turbo
Custom DMF Exhaust Manifold
Tial V44 Wastegate
Tial BOV
DSM Link V3
1600cc injectors
Custom fuel setup
Fuel Lab FPR and Filter
Aeromotive 700 EFI Fuel Pump
JMF Catch Can Setup
JAZ Fuel Cell in trunk
AFCO Radiator/ with fan
Custom DMF FMIC Setup, motor mounts, tune
Custom 3 inch exhaust
Jay Racing Alt Relocation kit with Saturn Alternator

Transmission:
2G Auto Swap 4500 Stall ITP
ITP Valvebody
ITP End Clutches
Kiggly Front Clutches
Custom Trans and Oil Cooler

Suspension:
BC Coil Overs
All bushings on vehicle replaced
All new Ball joints, tie rods

Brakes:
Reused 1g 2piston Calipers
All new Drilled Rotors, Pads
Goodridge SS Brake Hoses




Interior:

Carpet Completely Cleaned (took two trips to car wash and finally got 20 plus years of dirt out)
Custom LED lighting (I hate Halogen light bulbs all were replaced)
Full Prosport gauge assortment, AEM UEGO

Exterior:

91 VR4 Tail Lights
93 Headlights Already on car

VR4 front bumper (already on car)
Wingless Trunk (already on car)




Edited by rexwagon1909 (05/23/14 11:12 PM)

Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

Fiascoxl
Member +
740/1000


Galant VR-4 org Post #: 1111692 posted 03/05/13 03:12 AM     Remind Me!  Send Private Message   Edit Post      
I don't need pics... I know how nice it looks. Looking forward to seeing it run, hopefully at the shootout this year!



92 VR4 #740 Nile Black

Posts: 320 | From: Stuarts Draft, Va | Member Since: 01/26/13 | IP: (71.63.12.108) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111854 posted 03/05/13 09:51 PM     Remind Me!  Send Private Message   Edit Post      
thanks man you are the first one to see it other then my group of DSM guys

Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111858 posted 03/05/13 09:57 PM     Remind Me!  Send Private Message   Edit Post      
These are pics of the car right before I got it



Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

GSX_TC
295hp 35r BR4
550/2000


Galant VR-4 org Post #: 1111868 posted 03/05/13 10:13 PM     Remind Me!  Send Private Message   Edit Post      
There's Josh's car, I was wondering who bought it.



JZX90 Toyota Mark II Tourer V Twin Turbskie "Laura"
90 Nissan Skyline GTR "Tanya"
90 Eclipse GST "Kerri"
91 Galant VR4 "Samara" 550<

Posts: 3700 | From: Houston, Texas | Member Since: 04/07/11 | IP:
(208.54.83.130) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111895 posted 03/05/13 11:07 PM     Remind Me!  Send Private Message   Edit Post      


With Old Brakes back on:




Later with new rotors and goodridge SS lines







Had to use new hardline to allow the lines to get full movement in steering








Edited by rexwagon1909 (03/06/13 12:16 AM)

Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111898 posted 03/05/13 11:22 PM     Remind Me!  Send Private Message   Edit Post      
Rear Brakes (and rear parts painted and fender wells cleaned/painted)






Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111901 posted 03/05/13 11:35 PM     Remind Me!  Send Private Message   Edit Post      
Next I moved to the rear and removed the old worn Rear-end for rebuild and to install all new bushings etc:





Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111903 posted 03/06/13 12:10 AM     Remind Me!  Send Private Message   Edit Post      
More Rear of car:






Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111906 posted 03/06/13 12:43 AM     Remind Me!  Send Private Message   Edit Post      
Rear End was completely stripped cleaned primed and painted along with all other rear end hardware
All ball joints and all new poly bushings installed












Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111907 posted 03/06/13 12:46 AM     Remind Me!  Send Private Message   Edit Post      
More



Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111911 posted 03/06/13 01:04 AM     Remind Me!  Send Private Message   Edit Post      
Removed Rear Gas Tank (Switching to Fuel Cell and custom lines) Didn't want to hack up a really nice sending unit and tank so they were sold to good members on here. Cleaned and prepped everything for truck bed coating








Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1111912 posted 03/06/13 01:06 AM     Remind Me!  Send Private Message   Edit Post      
After several coats of sprayable truck bed coating











Edited by rexwagon1909 (03/06/13 01:16 AM)

Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

IncorpoRatedX
I'm an idiot...
1772/2000


Galant VR-4 org Post #: 1111943 posted 03/06/13 08:43 AM     Remind Me!  Send Private Message   Edit Post      
daaaaaaaamn! that's unlucky. I drove that thing everywhere, i'm lucky it didn't leave me stranded somewhere! I had a spare short block in my garage that I kept around just in case something happened between my two Galants. Had I know that issue would arise I would have just swapped it out, instead I wound up putting the spare engine into my wagon.

Build looks great so far, the previous owner was out of Iowa and lived on a dirt road, that might explain the dirt/dust/rocks, previous to him the owner was from colorado, could further explain the dirt and rocks as I don't think they use salt in CO, just dirt.



-Joshua Adventure Driven Design
Resto-mod squad.
1973 RWD 4G63T Galant Wagon
1979 4G54 Galant Sigma Wagon (air con)
1984 Turbo Diesel Mighty Max 4

Posts: 5559 | From: Arizona | Member Since: 05/28/03 | IP: (24.11.254.179) | Report this post to a Moderator

quato
Member
32/1000


Galant VR-4 org Post #: 1112008 posted 03/06/13 02:42 PM     Remind Me!  Send Private Message   Edit Post      
Quoting rexwagon1909:







Is that the hood that was on the car when you bought it? I have that exact hood on my GVR4 and am wondering if your car is where the hood came from. No I am not a fan but I don't have the time to fix it...maybe soon =/

Posts: 230 | From: San Antonio, TX | Member Since: 01/31/12 | IP: (132.3.45.82) | Report this post to a Moderator

IncorpoRatedX
I'm an idiot...
1772/2000


Galant VR-4 org Post #: 1112013 posted 03/06/13 03:32 PM     Remind Me!  Send Private Message   Edit Post      
That's the hood on your car.

Your car once belonged to my room mate, the hood on his kensington grey one was dented up and after I found a stock hood at the junk yard, had it repainted and swapped it out, that hood was in our garage, rather than dealing with a dented up hood he swapped that one on.

No one is a fan of that hood, I wasn't, my room mate isn't, the guy that bought the car from him didn't like it and now you don't like it. Even the guy that did it in iowa said 'yeah it was a stupid idea' when I first asked him about it. Hopefully someone eventually sends that hood to the scrapper!



-Joshua Adventure Driven Design
Resto-mod squad.
1973 RWD 4G63T Galant Wagon
1979 4G54 Galant Sigma Wagon (air con)
1984 Turbo Diesel Mighty Max 4

Posts: 5559 | From: Arizona | Member Since: 05/28/03 | IP: (24.11.254.179) | Report this post to a Moderator

IncorpoRatedX
I'm an idiot...
1772/2000


Galant VR-4 org Post #: 1112015 posted 03/06/13 03:36 PM     Remind Me!  Send Private Message   Edit Post      
Look familiar?




-Joshua Adventure Driven Design
Resto-mod squad.
1973 RWD 4G63T Galant Wagon
1979 4G54 Galant Sigma Wagon (air con)
1984 Turbo Diesel Mighty Max 4

Posts: 5559 | From: Arizona | Member Since: 05/28/03 | IP: (24.11.254.179) | Report this post to a Moderator

quato
Member
32/1000


Galant VR-4 org Post #: 1112021 posted 03/06/13 04:00 PM     Remind Me!  Send Private Message   Edit Post      
Haha, that's funny. I plan on cutting it out and doing a GT500 as has been done on here before. I figure that I won't lose sleep if I screw it up or if I don't like it. It can't get much worse than it is!

I actually have most of those pics saved that have been posted on the forum. I even saw the "build thread" where the fuel cell was being put in. 32/1000 has been around the block a bit it seems!

Posts: 230 | From: San Antonio, TX | Member Since: 01/31/12 | IP: (132.3.45.79) | Report this post to a Moderator

G
obsessed with the turds of others
486/1000


Galant VR-4 org Post #: 1112071 posted 03/06/13 07:32 PM     Remind Me!  Send Private Message   Edit Post      
That uni body looks pretty clean, definitely looks like it was from CO.



www.japanesenostalgiccar.com
www.nostalgic.co.jp

Posts: 8800 | From: zompton | Member Since: 02/24/04 | IP: (98.144.74.199) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1112117 posted 03/06/13 10:11 PM     Remind Me!  Send Private Message   Edit Post      
After engine was pulled I started on engine bay and front end rebuild


Cross Members removed



Front A Arms removed


Underneath the front subframe lots of dirt oil etc

Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1112124 posted 03/06/13 10:35 PM     Remind Me!  Send Private Message   Edit Post      
More front end pre rebuild:












Edited by rexwagon1909 (03/07/13 01:49 AM)

Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1112125 posted 03/06/13 10:49 PM     Remind Me!  Send Private Message   Edit Post      
More pre rebuild







Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1112127 posted 03/06/13 11:13 PM     Remind Me!  Send Private Message   Edit Post      
Front Subframe Out


Power Steering Rack Out




Power Steering Rack had been leaking for along time, covered in about 3 inches of gunk

Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1112129 posted 03/06/13 11:31 PM     Remind Me!  Send Private Message   Edit Post      
Power Steering Rack clean up:



And finally super clean!! Took about 3 hours


Edited by rexwagon1909 (03/06/13 11:43 PM)

Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator

rexwagon1909
impatient cutter


Galant VR-4 org Post #: 1112138 posted 03/07/13 12:55 AM     Remind Me!  Send Private Message   Edit Post   
Front Subframe rebuild continued:











Posts: 165 | From: Hurricane, WV | Member Since: 01/22/12 | IP: (75.109.129.21) | Report this post to a Moderator


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