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#1350/2000 DD project build


raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 856500 posted 12/09/09 01:17 AM     Remind Me!  Send Private Message   Edit Post      
A bit late in the game, but figure why not. I bought 1350/2000 back in June 08', upon arrival from deployment, I knew from the beginning that this car was going to be requiring a good amount of TLC with the rust underneath. Come to find out when I changed out the rear subframe, on the right side where it mounts to the car, it was cracked through the metal to the bushing, just about all the way to the top (somewhat scary after you realized you had just autocrossed on that a week prior). Despite what friends had nagged me on to sell the car and just find a rust free body, I chose to stick with this car and not simply give up on it, then watch it be added to the scrapped list of GVR4s.

Long story short, from the day I picked her up I've made a good amount of progress on the car bringing her back to road worthy condition as well as minor upgrades here and there with keeping up on maintenance.

Specs at time of purchase
142k on the clock
Stock Motor
ABS Disabled
4WS Lines plugged
Stainless Steel Braided lines Front/Rear
No Radio
Faze boost installed in one of Curtis' 2 gauge din panel
3" one piece Exhaust consisting of a Megan Racing Downpipe welded to some off brand High flow cat and muffler
Evo 8 Suspension swap
OEM Sunroof Wind Deflector
Peppered with hail dents
Rebuilt Salvage title
Clear coat gone on Roof and rear bumper
Cracked front windshield
Cracked front bumper on Passenger side
Broken Left foglight
Rusted Rear subframe and all suspension components
Slipping Clutch - went out on return trip back to VA, first thing I fixed.
Timing belt done at 108k - this was good to know
1G Shifter assembly and shift knob
Came with original owners manual in mint shape and the "diamond care road service" card.
Driver's seat has usual tears on the bottom, came with seat cover though.
Steering wheel has the normal wear and tear.

Early on Pics

broke down just outside Statesville, NC, this is when the clutch went out, half way back to VA.




Rust is bad mmmkay




Hey those are my fuel lines


Upon taking heat shield off I find my exhaust leak source...the stock exhaust manifold is cracked in a few spots.




Current Specs/Mods

Motor/Engine Bay/Drivetrain
170k on motor
Timing belt job done at 158k, also did the valve cover and spark plug seals at this time as well
Removed Cruise Control
Removed Emissions Canister
Removed and plugged all unnecessary vacuum lines
Aeromotive A1000 Fuel Pressure Regulator
FP Exhaust Manifold Studs
Evo3 Exhaust Manifold
MHI Big 16G
Evo3 o2 Housing
LC-1 Wideband o2 sensor
Replaced Faze boost gauge with Prosport boost and water temp gauge (18yr old connectors break easily)
Mesh Screen over turbo inlet
Oil catch can installed
Speed Density conversion - completed this back in January
-GM 3 bar MAP sensor
-GM IAT Sensor
-Ostrich 2.0 Eprom Emulator
-Full Throttle Speed GM IAT & GM Map Sensor to MAF connector harness for plug n' play purposes
ETS Anodized Black GVR4 FMIC with black 2.5" piping.
Lower Shores Performance Manual Boost Controller
Rebuilt Alternator

Tuning/logging
DS-Map/Jackal
Dsmloggers.com datalogger cable

Steering/Suspension
4WS Removed
PS Pump & belt removed - Dry rack for now
R/R Rear Subframe, including all control arms and sway bar
R/R Both Trailing Arms
R/R Left Rear Caliper
R/R Right Rear caliper
R/R Left Rear Lower Control Arm - I had the trailing arm failure a few months back, it warped the crap out of the arm.
New Rear Rotors from Rockauto
R?R all ball joints on rear arms
R/R Rear diff for 3 bolt LSD when Left rear axle went out.

Exterior/Interior
JDM Front bumper
JDM Projector fog lights with projectors swapped out for the yellow ones.
JDM Clear Corners
Curtis made bumper brackets for JDM bumper
Clear coat is coming off the hood now
1G shifter assembly and shift knob
89' LS Underdash w/ pocket

Wheels
AMG Type 1 Wheels
Stock 91 wheels - awaiting to be restored at some point

Brakes
Replaced Right Front Calipers - 1 rusted sticking piston =
Replaced Rear Calipers
New Rear Rotors
Raybestos OE pads for now


Parts not yet installed
Gas tank - waiting till I get new fuel lines
Walboro 255lph pump - waiting to install the gas tank
E-Brake Cables
New Front Rotors
Right Rear Dogleg

Right now on my things to do next are the rear wheel bearings, rebuild driveshaft and replace carrier bearings, replace the leaking Oil Filter housing with a 90 OFH w/ oil cooler, replace front axles, and swap out the dry rack for a manual rack. The car still has AC, though I'm debating on removing that as I never use it. It used to work, but upon changing belts I found out the tensioner bolt head was broken off and the rest of the bolt is rusted to the bracket and thus that bracket came out and stayed out.

Pics from along the way of my progress

Subframe Removal and Replacement - Removed and replaced it 3 days prior to the DSM/Evo Shootout 08'



Oh look rust is removing itself for me already


So that's what the pumpkin with the 4WS pump looks like


Only pic of the Engine bay I have in stock and messy form


I think this thermostat is bad


Rice rocket sounding muffler


Vibrant



Random Pic


JDM Corners and yellow projectors & install



3 Bolt LSD Pressure washed, drained old oil and filled with new oil



From the trailing arm failure fiasco



compared to new arm



Left rear control a little warped? Just enough that the ball joint would slip out on its' own.




While waiting on sourcing a new control arm I thought it would be a good idea to do the Right Rear rotor, boy was I mistaken! Everything came off as one piece just like when I did the left side.




Sweet Trailing arm Connecting Rod



Fixed


The bad Right Front Caliper - rust just sort of fell out of the piston


89' Amber turn signals in place


JDM Front Bumper - chrome trim slot is filled in, can't even tell the trim belongs anywhere


with Yellow projectors installed in fog light housing


I had a Evo3 16g at one point, but for whatever reason it seized up and this was the result







Parking lot maintenance FTW



Catch can Had been relocated to where the Charcoal canister was located.


This is how much was cut off from the original bumper core


JDM Bumper painted


Gauge placement


This is the only time the car was ever sitting on jackstands and it wasn't even enough time to qualify for JSB.



JDM Bumper and Fogs installed. I wired the inner fogs to the parking Lights and the projectors to the stock switch



Pretty sure to do my front rotors I'm going to have to do replace the front hubs. After doing the rears and underestimating the rust, it will be easier just to replace the front hubs altogether. When I replaced the right front caliper, it was just the caliper that got replaced, the bracket bolts had no intention wanting to come off and I didn't feel like snapping bolts off. This is my Daily for now, so when it requires down time I make sure I take the time off to do the job and have new parts and bolts ready to go on immediately.

In the long run for Horsepower goals I'm only looking towards 400hp and that's still a ways off for me I got more maintenance to do first and get a hold of another block to build. I'll try to keep this upgraded.


Edited by raptorreed (12/13/09 02:23 AM)

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

4thStroke
Spence knows tools
786/2000


Galant VR-4 org Post #: 856505 posted 12/09/09 01:47 AM     Remind Me!  Send Private Message   Edit Post      


Way to keep on and not throw in the towel.

Posts: 1864 | From: Vancouver, WA | Member Since: 10/22/07 | IP: (71.214.89.2) | Report this post to a Moderator

DougPorcaro
Member
?/2000


Galant VR-4 org Post #: 856521 posted 12/09/09 06:47 AM     Remind Me!  Send Private Message   Edit Post      
Looks like a ton of work. Good job.

Posts: 100 | From: Racine, WI | Member Since: 06/15/06 | IP: (144.13.238.183) | Report this post to a Moderator

ScreaminE
Just don't like an idiot


Galant VR-4 org Post #: 856525 posted 12/09/09 07:12 AM     Remind Me!  Send Private Message   Edit Post      
Nice! I grew up in Statesville, NC.



-Scott H.
1267/2000 - sold

Posts: 646 | From: Pittsburgh South Hills | Member Since: 09/04/08 | IP: (160.81.81.162) | Report this post to a Moderator

Lonewolf64
Obviously the answer is......
889/1000
1247/2000


Galant VR-4 org Post #: 856604 posted 12/09/09 11:40 AM     Remind Me!  Send Private Message   Edit Post      
It's nice to see 1350 running strong! Are you still in the VA area? Maybe we should have a little go kart repeat this January?



1992 Galant VR-4 #889
1991 Galant VR-4 #1247
2007 Civic Si DD

Posts: 1197 | From: Birmingham, Alabama | Member Since: 05/18/06 | IP: (141.166.236.124) | Report this post to a Moderator

raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 856683 posted 12/09/09 03:27 PM     Remind Me!  Send Private Message   Edit Post      
Not anymore, I'm living in 4thStroke and Wop country (WA).



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (166.216.224.13) | Report this post to a Moderator

raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 857501 posted 12/13/09 02:30 AM     Remind Me!  Send Private Message   Edit Post      
so in light of earlier tonight trying to make it down to the South end of the state for a meet, I had the lucky of 1350 deciding it didn't want to go an hour into my venture. Possibilities is it is either A)The alternator crapped out, but I was still able to crank it over twice and drive the car to a safer spot in a shopping center parking lot than on the shoulder, or B)The battery had was just too low on life and couldn't maintain a charge. Now is it possible for the latter to happen? I was having some weird voltage issues the day prior, sometimes it would sit at 13.8v at operating temp, 15 minutes later is would be at 11.0v and my idle would sit just above 500rpms floating.

On the good side of things, I am able to source the first and last sections of a rust free driveshaft, manual rack, and external oil cooler for my 90 OFH that arrived the other day, thanks again Ed(BluFalcon).



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

NateCrisman
Fisheye Hoodpins
418/2000


Galant VR-4 org Post #: 857747 posted 12/14/09 12:07 PM     Remind Me!  Send Private Message   Edit Post      
Chances are the alt took a dumb, that's extremely common. Far more common than a battery failure, especially if the alt was ever the recipient of a power steering leak.



GVR4 #418/2000: [email protected] - pump/alky -
GVR4 #431/1000: [email protected]+
GVR4 #139/1000: T3T4: [email protected] - 14B: [email protected] (sold)

www.PerformancePartout.com

Posts: 2054 | From: Blairstown, NJ | Member Since: 11/22/08 | IP: (76.6.50.229) | Report this post to a Moderator

raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 857778 posted 12/14/09 02:26 PM     Remind Me!  Send Private Message   Edit Post      
That's what I was thinking, just wanted to look into every possibility, I just got it rebuilt in May/June timeframe. I don't have to worry about a powersteering leak, I haven't had that since about a month after owning the car, caps on the 4ws lines started leaking. It will be fixed soon.



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 861180 posted 12/28/09 09:37 PM     Remind Me!  Send Private Message   Edit Post      
My Scoobie alternator arrived today and in the midst of installing it right now, only got a couple more things to do then I'm done. A big thanks goes to Curtis and his Awesome fab work yet again








92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 861206 posted 12/28/09 11:05 PM     Remind Me!  Send Private Message   Edit Post      
All finished up, allowed the car to warm up, then logged the volts at idle. Before I would see about 13.1-12.9 @ idle and if I turned my headlights on and had both fogs on it would drop to 12.1-11.5. Everything seemed to be running great until I noticed some oil under the car.. I still think it's partially my OFH blowing it out on the road, but tonight at idle, I'm thinking it is the Oil Pump starting to go. I had a nice small puddle residing by the Crank pulley, looked at the pulley and I could watch it drip off the pulley about every ~10secs. .



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

turbowop
Hard Snarker
1051/2000



Galant VR-4 org Post #: 861214 posted 12/28/09 11:17 PM     Remind Me!  Send Private Message   Edit Post      
Just replace the crank and oil pump sprocket seals, as well as the seals that go to the OFH.



-Mark

A face only a grocery shopper could love.
1051

Posts: 11959 | From: Yakima, WA | Member Since: 04/29/01 | IP: (97.90.49.2) | Report this post to a Moderator

raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 861223 posted 12/28/09 11:38 PM     Remind Me!  Send Private Message   Edit Post      
I'm switching over to a 90' oil cooler setup, but I'll have to deal with it some more this weekend. I also have to play with my shifter linkage and get a flat fixed. I just have to take my time taking the belts off, it will be my first time by myself doing the timing belt(done about 10k ago) while I'm down there.



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

Whoodoo
buff guys = good time but my dream is to fondle 1051
62/2000


Galant VR-4 org Post #: 861445 posted 12/30/09 12:16 AM     Remind Me!  Send Private Message   Edit Post      
Hmmmm. I've been putting off doing my t-belt... Guess I'm a little wary about screwing something up. The old camaro was much much easier to work on, not that these are terrible, but that pushrod V6 was bulletproof.

I've been playing with my shifter a lot lately, what's wrong with yours?



62/2k

Posts: 925 | From: Binghamton, NY | Member Since: 07/11/09 | IP: (98.111.95.191) | Report this post to a Moderator

Jesse_W
Unregistered


Galant VR-4 org Post #: 861580 posted 12/30/09 04:53 PM     Remind Me!  Send Private Message   Edit Post      
Just saw this awesome job thanks for not killing another just becuase of rust! keep us updated.



Jesse

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raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 861938 posted 01/01/10 09:32 PM     Remind Me!  Send Private Message   Edit Post      
Quoting Whoodoo:


I've been playing with my shifter a lot lately, what's wrong with yours?



Just the No 5th and Reverse woes(I've done my searching and bookmarking ), Things to do tomorrow consist of pulling the End Case off cover off to check for any looseness and installing skate bearings on the linkage side. Also be adjusting the linkage as well.

The bushing closest to the motor was pretty narly and the outer is perfectly fine.
Here's the bushing, the center bushing that is suppose to be on there is still attached to the car.

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

Polish
Dr. Pilosh Haagenscodyberger


Galant VR-4 org Post #: 861941 posted 01/01/10 09:42 PM     Remind Me!  Send Private Message   Edit Post      
Amazing the amount of work you've put into this thing. It's looking good man.



My car site
Old GVR4 #1186/2000

Posts: 8936 | From: NE, IN | Member Since: 01/10/05 | IP: (72.86.72.8) | Report this post to a Moderator

raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 861947 posted 01/01/10 10:14 PM     Remind Me!  Send Private Message   Edit Post      
Thanks guys, I'm waiting on the water line delete plugs to arrive before I go ahead and install NT water pipe. I believe I'll be able to adjust the Scoobie Alternator positioning a little bit more once the line from the water pipe to the OFH is gone.



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 873046 posted 02/10/10 07:45 PM     Remind Me!  Send Private Message   Edit Post      
Figure I could update this..
Got some vacation coming next week that is devoted just to 1350, so far this is what I have on my to do list

Reseal Oilpan - since I need to drop the transfer case for this, now will be better than ever to find out what the spline count is.
Install 90 OFH and cooler
If I can get a hold of 4 lug front hubs/spindles, then I will swap those out.
Install the E-brake cables I have put off for so long.
Install NT Waterpipe
Block off water lines to turbo
Complete the Non ABS Conversion, rid the car of the pos lawn mower motor. I need to talk to call Paul(thedsmguy) for the non ABS lines and prop valve
Q45 Master Cylinder upgrade
Fix any other leaks I may have
Replace rear wheel bearings.



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

ItsAliiive
Unregistered


Galant VR-4 org Post #: 873118 posted 02/10/10 11:10 PM     Remind Me!  Send Private Message   Edit Post      
Great job so far, tackling that kind of rust is a bitch, I know this.

What is that old car with round lights, looks like a ford or bentley, rolls...?

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raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 873122 posted 02/10/10 11:22 PM     Remind Me!  Send Private Message   Edit Post      
Thanks. The green car? A 54' Chevy Wagon. One of my brother's project cars.



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR


Edited by raptorreed (02/11/10 12:22 AM)

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

ItsAliiive
Unregistered


Galant VR-4 org Post #: 873156 posted 02/11/10 01:51 AM     Remind Me!  Send Private Message   Edit Post      
This one in the garage Here

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raptorWagon
less than one year to my birthday
1350/2000
362/1000


Galant VR-4 org Post #: 873230 posted 02/11/10 10:10 AM     Remind Me!  Send Private Message   Edit Post      
31' Model A, it still runs. There's a few other nice cars in there as well.



92 Galant VR-4 362/1000
76 Galant Hardtop
79 Galant Sigma Wagon
88 Fiji Blue Starion
94 Montero SR


Edited by raptorreed (02/11/10 02:48 PM)

Posts: 2786 | From: Oak Harbor, WA | Member Since: 05/17/07 | IP: (98.203.132.229) | Report this post to a Moderator

ItsAliiive
Unregistered


Galant VR-4 org Post #: 873259 posted 02/11/10 11:25 AM     Remind Me!  Send Private Message   Edit Post      

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866galant
Junior Member
866/2000


Galant VR-4 org Post #: 873441 posted 02/11/10 07:22 PM     Remind Me!  Send Private Message   Edit Post   
Nice work so far. What did you use to fill in the bumper chrome slot? Just regular body filler?



98 ITR #131
91 GVR4 866/2000
92 GVR4 766/1000
95 Montero SR

Posts: 32 | From: TX port arthur/beaumont | Member Since: 05/31/08 | IP: (99.128.240.224) | Report this post to a Moderator


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