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4g64/63 Swap


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#41 devilsfutbol17

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Posted 15 November 2015 - 01:43 PM

I wont give up, its just going to take a little longer than I hoped.

Someone had asked me about the Jay Racing piece, so here's some details on it.

Here is the piece.

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You can see the little groove in the piece, that's where the thick washer is supposed to fit and keep it pressed to the cylinder head.


Looking at the head now.

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The hole with the bolt in it that is at about one o'clock from the coolant passage is where the thick washer is supposed to bolt in.

Here it is pressed into the head.

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The piece is rotated so the thermostat housing sits straight up and down, but the thick washer doesn't line up with the groove on the piece. If I rotated it so the washer lined up with the groove, the thermostat housing wouldn't be straight up and down. That may not be an issue depending on where the high spot is in your system and where you're filling it from. This is on a 2g head, I don't know if its any different on a 1g head, but I'll check one of my spare 1g heads and post back.
796/2000 Summit White Galant VR-4
1994 Pear White 3000GT VR-4
1997 Eclipse Spyder GST (Wife's car)
1988 Fiji Blue Conquest TSi SHP





#42 importwarrior

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Posted 15 November 2015 - 07:36 PM

Thanks for explaining. I always wondered about it.

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#43 devilsfutbol17

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Posted 13 December 2015 - 10:40 PM

Made some really good progress this weekend finally. It seems like I can't get any free time in the shop. I hate cutting and grinding metal, it makes such a mess and my car always gets covered in metal dust :(  Oh and I apologise to anyone looking at this expecting a clean fresh build. I'm pretty much using spare parts I currently have if they will work. Function over looks unfortunately, but eventually things will look nice. I'm trying to get this car running before my wife says its time to start trying for a baby. Once she is pregnant its bye bye car budget.

Started and finished my power steering bracket. Most of the welds are good, but my last one I made some adjustments to the settings and it got ugly. I'll clean up the edges, remove some material from it, and finally paint it later on down the road.

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Then I got the feed line to the heater core set up.

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Lastly I dropped the engine in again to start plumbing everything up. I know everyone has seen 4g63s in starions before, but seeing how everything is coming together in my own car really gets me excited/motivated.

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796/2000 Summit White Galant VR-4
1994 Pear White 3000GT VR-4
1997 Eclipse Spyder GST (Wife's car)
1988 Fiji Blue Conquest TSi SHP

#44 importwarrior

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Posted 14 December 2015 - 06:34 AM

really fits well! looks like it belongs in there.
i would love to do this swap someday.
great progress.

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#45 TexasQuest

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Posted 14 December 2015 - 10:34 PM

THE swap I would do if I ever decide to ditch the Astron. Very nice work!
88 Fiji Blue -TSi
Zoom clutch, Fidanza flywheel, Stedebani shifter, KSport coilovers, ST swaybars, abs delete, a/c delete, cruise delete, JVE, BSEK, TEP steel brake lines, LSP braided cooler lines, CX Racing radiator,  MK1 silicone hoses, MK1 pullies, *DM hard pipes & intercooler,14G turbo, ported exh. manifold, MAF Translator, 3.5" GM maf, Turbo XS RFL bov, *DM 3" exhaust, Cusco front strut bar, TEP rear strut bar, Enkei 92's, HKS turbo timer, AEM wideband, AEM boost gauge, AEM oil pressure gauge, SPA fuel regulator, Hallman boost controller
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View PostJohnnyWadd, on 04 March 2010 - 10:01 PM, said:

my shaft was big i dont know what your talking about.

<SOS> http://sosmanuals.minagera.org/
<SQ Garage> http://www.starquestgarage.com/

#46 devilsfutbol17

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Posted 28 December 2015 - 12:37 AM

I've been working on the car the past couple weekends, but I'm too embarassed to post all the photos lol. In case I haven't mentioned it, this is revision 0 of the build. Revision 1 someday will be much nicer.

My intercooler piping is looking pretty bad, but I'm using the stock intercooler so their was no sense in putting 2.5" piping between the intercooler and the turbo and between the throttle body and the intercooler since the stock inlet and outlet of the intercooler is so small. Its almost done and I'll post pictures of it soon.

I also worked on my fuel system which I am proud of, but I'm missing a fitting and hose. Once I finish it I'll post pictures. Perhaps I didn't have to yet, but I took care of the evo intake manifold before I mounted the fuel rail. I'll need to have the flange machined flat, but its good enough for mock up.

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I haven't finished welding everything up, but here are the pictures of the downpipe and o2 housing I made. I'm a poor welder/fabricator, so I'm pretty excited I was able to make this myself.

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796/2000 Summit White Galant VR-4
1994 Pear White 3000GT VR-4
1997 Eclipse Spyder GST (Wife's car)
1988 Fiji Blue Conquest TSi SHP

#47 importwarrior

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Posted 28 December 2015 - 06:13 AM

Thanks for the update!
i check daily for updates.

the wastegate is a tight fit but looks good.

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#48 Turbo Cary

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Posted 28 December 2015 - 10:33 AM

You say you're a bad fabricator but it all looks good from my house! Keep up the good work. Like import said, I check this all the time too.

#49 devilsfutbol17

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Posted 28 December 2015 - 04:26 PM

Thanks guys. Yeah the wastegate is a tight fit, I have about 3/4" between it and the firewall. I hope the motor doesn't flex that much, but I may need to dent the firewall there a little bit. I'll post a picture of how close it all came out to be. I didn't have any nice turbine housings or I would have tried to stay internal gate. That and I had that ebay external wastegate sitting on my shelf for the past 4 or 5 years so I figured I'd put it to use.
796/2000 Summit White Galant VR-4
1994 Pear White 3000GT VR-4
1997 Eclipse Spyder GST (Wife's car)
1988 Fiji Blue Conquest TSi SHP

#50 autotr8er2

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Posted 31 December 2015 - 09:02 AM

The welds will get better with time.  Strength and function is far more important than being pretty. Are those MIG welds!

Edited by autotr8er2, 31 December 2015 - 09:03 AM.

Does anybody offer Lay-away anymore?

#51 devilsfutbol17

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Posted 31 December 2015 - 11:05 PM

Yeah they are MIG welds. I should really be practicing, but all my practice is a few trials on spare pipe then I dive right in lol.

I finished up welding the downpipe and most of the o2 housing. I just need to put the bung in the o2 housing and finish the welding on the o2 housing flange.

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796/2000 Summit White Galant VR-4
1994 Pear White 3000GT VR-4
1997 Eclipse Spyder GST (Wife's car)
1988 Fiji Blue Conquest TSi SHP

#52 autotr8er2

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Posted 01 January 2016 - 08:57 AM

Looks good, bro!
Does anybody offer Lay-away anymore?

#53 importwarrior

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Posted 02 January 2016 - 09:17 AM

Looks good are you going to run a egt aswell?

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#54 devilsfutbol17

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Posted 02 January 2016 - 11:06 PM

I dont plan to use egt. I don't really see many people tuning with them anymore. Im no expert by any means, but most the tuning I see using link is using a wideband.

As of right now I have a boost gauge and a wideband, but I'm debating on getting an oil pressure gauge. I'd rather install all my gauges now since I'm going to remove the dash, so I'll probably have an oil pressure gauge soon lol.

I didn't get any work done this weekend because we traveled to visit family. But I did pick up my old carbon fiber hood, black leather seats, dsmlink, two auto 4 bolt rear diffs, and 3 pod a pillar gauge pod for my 1g.

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Next weekend I plan to finish my o2 housing, finish my fuel setup, and start and finish my power steering lines. Those are the goals, we'll see if it all goes as planned.
796/2000 Summit White Galant VR-4
1994 Pear White 3000GT VR-4
1997 Eclipse Spyder GST (Wife's car)
1988 Fiji Blue Conquest TSi SHP

#55 importwarrior

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Posted 03 January 2016 - 07:58 PM

Good deal.
Looks good so far.

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#56 devilsfutbol17

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Posted 04 January 2016 - 01:54 AM

I finished the o2 housing tonight. Nevermind the weld quality.

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Then I started messing with the coolant lines to the heater core. Does anyone know if I'll have any problems running the coolant lines through the heater core in the opposite of the stock direction?

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796/2000 Summit White Galant VR-4
1994 Pear White 3000GT VR-4
1997 Eclipse Spyder GST (Wife's car)
1988 Fiji Blue Conquest TSi SHP

#57 devilsfutbol17

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Posted 10 January 2016 - 02:11 PM

Finished the AN lines for the fuel setup. Just need to get a rubber hose for the return.

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Completed the power steering high pressure line. I've never made one of these hoses, its different than the typical AN hoses and hose ends.

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Then I made a bracket for the power steering reservoir.

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796/2000 Summit White Galant VR-4
1994 Pear White 3000GT VR-4
1997 Eclipse Spyder GST (Wife's car)
1988 Fiji Blue Conquest TSi SHP

#58 TexasQuest

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Posted 10 January 2016 - 09:47 PM

Lookin good, keep up the good work!
88 Fiji Blue -TSi
Zoom clutch, Fidanza flywheel, Stedebani shifter, KSport coilovers, ST swaybars, abs delete, a/c delete, cruise delete, JVE, BSEK, TEP steel brake lines, LSP braided cooler lines, CX Racing radiator,  MK1 silicone hoses, MK1 pullies, *DM hard pipes & intercooler,14G turbo, ported exh. manifold, MAF Translator, 3.5" GM maf, Turbo XS RFL bov, *DM 3" exhaust, Cusco front strut bar, TEP rear strut bar, Enkei 92's, HKS turbo timer, AEM wideband, AEM boost gauge, AEM oil pressure gauge, SPA fuel regulator, Hallman boost controller
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View PostJohnnyWadd, on 04 March 2010 - 10:01 PM, said:

my shaft was big i dont know what your talking about.

<SOS> http://sosmanuals.minagera.org/
<SQ Garage> http://www.starquestgarage.com/

#59 importwarrior

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Posted 11 January 2016 - 06:20 AM

looks great!
what did you do to the EGR? weld shut?
are they on different sides of the intake and head ?

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#60 techboy

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Posted 11 January 2016 - 08:26 PM

What a build! Awesome, I love it. I hope to follow on your footsteps someday.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

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