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My 4g63 and t-56 swap (TONS OF PICTURES


TsTKl
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I decided to post this up here for those of you who don't get over to project zero g that often.

 

I bought this car back in feb 2008 off jason (boosted88tsi). All I knew is I liked how it looked and I could put a 4g63 in it. It drove and I needed a daily driver, so I bought it with the plan of "eventually" doing the 4g63 swap. Here she was:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_9486.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_9505.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/P1010055.jpg

 

Well as some of you may know, this only lasted about 4-5 months. This happened:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/PIC-0077.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_3472.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/PIC-0074.jpg

 

My original plan was to daily drive the conquest while I turned my 1990 eagle talon tsi awd into a road race car I could be proud of. I had sent the motor out to be "fully built" only to find out the guy I sent it to was a crook and took my motor and a chunk of change. I had also bought a 1993 plymouth laser fwd turbo which I had parted out. I made some money off it and still had the motor sitting around, so I decided to get my talon running again with that motor. No more road race car I guess.

 

Here she was:

 

http://i81.photobucket.com/albums/j223/tstkl/talon/p1010081.jpg

http://i81.photobucket.com/albums/j223/tstkl/talon/P1010104.jpg

http://i81.photobucket.com/albums/j223/tstkl/talon/P1010090.jpg

I still can't get over this car

 

After I got the talon running I was driving one weekend only to get run off the road by a drunk driver. I totalled my talon and was devistated.

 

http://i81.photobucket.com/albums/j223/tstkl/talon/DSC_3075.jpg

 

so now I had a car with no motor and a motor in a totalled car. Seemed easy, right?

Edited by TsTKl
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I spent the next year or so reading up and playing around with what I had, wiring and such. I didn't have any money so I kindof just let things sit. I was in school. I test fitted the motor and thought it would be soooo easy.

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0455.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0457.jpg

 

Then I decided to take a year off of school and got a 60 hour a week job. when you work 60 hours a week its hard to spend your money on stupid little things, so this happened:

 

bought a t-56 off an ls-1

http://s81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0304.jpg

had an evo 8 intake manifold welded so the injector bungs were closed

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0383.jpg

bought bill's t-56 adapter

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0440.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0439.jpg

got a cosworth crank scraper

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0567.jpg

picked up an evo 8 crankshaft which is 5 lbs lighter

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/P8290027.jpg

kiggly HLA pressure regulator:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0589.jpg

Edited by TsTKl
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aem cam gears that work with a 95 eclipse cam position sensor

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0609.jpg

kelford 272 cams:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0610.jpg

evo 8 oil pump with 1g 7 bolt timing belt tensioner:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0622.jpg

part of my balance shaft delete kit:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0465.jpg

oem ralliart 170 degree thermostat what?

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0466.jpg

ferrea valves:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0575.jpg

check out that nothing special unshrouded combustion chamber! (I don't remember if this was the final product or not)

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0573.jpg

eagle rods (they are lighter than most aftermarket rods and can take the power I'm planning on, although we did re-size and hone the big end as it was slightly out of round:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0621.jpg

mahle 9:1 compression pistons:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0641.jpg

bored and decked block:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0645.jpg

Edited by TsTKl
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during this time of purchases left and right, I was also porting the hell out of my cylinder head, as well as removing the flashing from the cylinder block.

 

new ferrea valves, kiggly beehive valve springs, ITM hydralic lifters, and kelford cams installed in a freshly decked head I ported with new manganese bronze guides and oem valve stem seals:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0681.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0682.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0685.jpg

 

apparently I don't have any photos of my combustion chambers or ports on my photobucket. I know I have them somewhere if someone is dying to see them, They look like any other ported head though... So we mocked everything up, crank scrapper, clayed the motor for valve piston clearance, etc.

 

some clearancing was needed for the evo 8 oil pump to bolt up to a 1g dsm block and tensioner arm:

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_0786.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_0793.jpg

 

as well as the cosworth crank scraper:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0829.jpg

 

brand new oem freeze plugs really bring out the bling:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0879.jpg

 

Finished product, You should have seen the smile on my face:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0883.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0898.jpg

 

 

more too come...

Edited by TsTKl
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not even close. I just got tired of typing and copy/pasting

 

thanks for the compliments guys. The wing is black because I'm guessing jason painted it black. I love it though so I'll probably re paint it black when I eventually get the car painted.

Edited by TsTKl
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I think they normally go for around 500 or 550, but I asked for no clutch fork, throw out bearing, etc, so I got it for a little cheaper. I'm also only the second person to use this bell housing because its the long shaft version of the t-56 and not the short shaft lt-1 version. The transmission was about 1000, the internal hydralic throw out bearing I'm using was around 300, the adapter plate I had made for said tob was 60, the short shifter was 200 and the master cylinder was 90 plus about 20 or so for lines and fittings.

 

way to make me realize how much I've spent on a stock 6 speed transmission, hahaha

Edited by TsTKl
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So during all this time of engine building I had a car with no engine in it. It was really dirty and at one point or another the brake master cylinder had leaked all over the frame rail and it was missing a lot of paint. I don't like rust so I decided to paint it. I cleaned it a ton, heres how it looked:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0648-1.jpg

 

Then I decided that wasn't enough, so I went a little further:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_0764.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_0763.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_0761.jpg

 

I could only work on it during the weekend so thats why I painted it with whatever paint I had lying around after I was done for the day.

 

I then decided the wheel wells were nasty and decided I'd paint them too. So I started stripping the rubber liner crap off them

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_0780.jpg

 

I don't have any finished pictures on my photobucket but moving on, I then borrowed my buddy's barn/garage and built a paint booth. Check it out:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0799.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0802.jpg

 

and then, there was the finished omg product:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0810.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0834.jpg

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A "barn/garage paint booth" now thats something I would like to have....haha.

Preping the engine bay and front end is the least you could do after spending all that money.

 

Those trans adapter/bell housing from Bill are doing great things for RWD 4g63 swap...so many options.

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unfortunately this was my first time every spraying anything with a professional spray gun. I now know that it takes practice..... A LOT OF PRACTICE.

 

Its much better than before so whateva

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Didn't know I was in the super secret swap club. Ooooooops. Good stuff with this swap either way.

 

Original post edited for awesomeness spoiler.

 

I was joking, you didn't have to edit your post since I mention it in the first sentence of this thread, lol.

 

Its the internet so people are going to find it, I'm mainly making this for myself so everything is more orginized, relevant, and all that rambling I'm so good at isn't here. People don't like to read rambles that often.

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romeo and juliet,... adam and eve,... angelina jolie and brad pit,... harry and lloyd,... jay and silent bob,...

 

starquest and 4g63:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0901.jpg

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0904.jpg

 

on a freshly powdercoated subframe none the less:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/DSC_0795.jpg

 

ok so I might have gone a little crazy with the bead blaster, can you blame me?

 

lower control arms:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0935.jpg

 

tow hooks and torque rod mounts:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0936.jpg

 

hood latch:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0932.jpg

 

and probably some more.

 

but it was time to start thinking about the transmission. I didn't want to have to look at that ugly brake booster in the engine bay anymore, and I knew I was re-doing my brake lines for non abs. My buddy who used to work for tilton suggested this solution:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0057.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0907.jpg

 

for those of you who can't tell because of the horrible picture, thats a tilton engineering overhung brake and clutch pedal assembly with dual brake master cylinders and adjusting bias bar for driver controlable front to rear brake bias. The second picture is of my tilton engineering internal release bearing assembly. It replaces the slave cylinder, clutch fork, and throw out bearing all in one. Its a good deal shorter than the oem unit, but its much higher quality and much easier to bleed. Here is my prototype custom spacer:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0927.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0928.jpg

 

And now were in business. Just gotta slide that transmission into place all easy like and then make a crossmember for it, right?

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I have great friends by the way. A buddy of mine let me tow my car to his shop and leave it on the lift for what was supposed to be a week or two at the max. I got the car all ready.

ported the turbine housing:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0926.jpg

put the turbo on:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0933.jpg

installed the flywheel (and later the pressure plate and bell housing):

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0924.jpg

sprung for this short throw shifter which I thought would make the transmission install go more smoothly:

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0797.jpg

 

And then towed the car over to his shop. For those of you that don't know, a t-56 does not fit into the tunnel of a manual transmission starquest. I was under the impression it did. I was very very wrong. Countless hours with a hammer proved fruitless, and I eventually faced the inevitable:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0953.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0956.jpg

 

A big huge hole would be required to fit that bad boy in there.

 

for the crossmember we bought an energy suspension polyurithane transmission mount for the t-56, then welded a flat plate over the stock cross member and drilled it to bolt up to the energy suspension mount. Then we built a two surfaces to weld nuts to at the correct height so the factory cross member could be bolted up a-la oem.

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0971.jpg

 

This is why the car is having such slow progress. I don't know how to weld and my buddy understandibly had to charge me for welding in a tunnel and adding a cross member while I was in texas. I don't know how to weld, as much as I want to learn, and didn't have the time to simply do it on my own. My buddy did charge me an astoundingly low rate, however he didn't get much done while I was in texas and I ended up doing nearly everything that didn't involve the plasma cutter or the welder. Never the less 30-40 hours at the lowest fab rate on earth still puts a dent in your pocket. And thus the project is suffering a little right now. However I'm making progress where I can. Heres how the tunnel turned out:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0955.jpg

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0997.jpg

 

This is the most recent picture, spoiler alert, I decided to tackle a major wiring project:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0109.jpg

 

I'm really happy with how the tunnel turned out. We made it boxy for simplisty's sake, however I think it turned out really nice and goes with the dash quite well. We added an opening so I can unbolt the transmission easier for removal. Even though we made the tunnel larger, removing this huge box is hard work, especially when you don't have a lift. I towed the car, this time to my parents house, since I have moved out of the san luis obispo area and will be going to school at UCSD in the fall.

 

We used 16 gauge sheet metal for my tunnel, but also included a bracing bar that goes across the bottom from one side to the other. Its extremely sturdy, and the metal is coated with something that prevents it from rusting until I get around to painting it. This was the only sheet metal available to us on short notice in san luis obispo. Its a small town. The local mcarthy steel is open from 9am-3pm. Talk about an easy job.

Edited by TsTKl
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thanks boho, although this isn't a show car, I'm just tired of getting dirty every time I work on this thing, and I hate rust.

 

 

DHM, I picked a 2g head, mainly for three reasons: I'm using an evo intake manifold and the ports line up. The whole 1g head thing is over rated, look at how much power evos on stock cylinder heads are putting down. 2g heads have better coolant passages or so I'm told.

 

It should spool up quicker etc but I don't think a human could really notice it. Maybe and hopefully I'm wrong.

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While the car was at my buddy's shop, I had a few other things done. Theres a 10 picture limit, so thats why I decided to split these up into two posts.

 

While we had the car up in the air we made an exhaust and had the driveshaft made. The exhaust is a 2.75 inch first bend and flex section with everything else 3 inches. Pictures explain it better:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0987.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0990.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0992.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0991.jpg

 

I don't have pictures of the back half of it, but thats the important part. The rest looks like a conquest exhaust. See:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0210.jpg

 

Heres the driveshaft. I painted it with some gray spray paint I had. I didn't have any black paint and I'll never see the driveshaft, so it won't bother me. Again, no rust is the objective here.

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0002.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0102.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0168.jpg

 

I also completely disassembled and reassembled my oem throttle body. I was able to get ahold of some stainless steel button head screws so I could do the half shaft mod.

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0098.jpg

 

The majority of the stuff left is the small stuff. Its those little details that really make this build take longer than just bolting a motor into a car.

Edited by TsTKl
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alright guys, so I've got a clean engine bay, an engine, a transmission, and thats about it. What about the small details? Well I went ahead and got a b&m 8 x 11 inch oil cooler. Thats a good start. Here it is:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0103.jpg

 

and then I needed a bracket to mount it. I found this when I was making my front crash beam lighter. Ironically the bolt spacing of my oil cooler is the same as the bolt spacing of the middle two bolts on the crash beam. The offset was exactly what I needed, and so I modified it to work. Heres the bracket with the painted oem radiator bracket:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0169.jpg

 

Here it is mounted:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0175.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0156.jpg

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0155.jpg

 

It has -8 an lines to the evo 8 oil filter housing.

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0205.jpg

 

Staying on the topic of cooling, I decided to re-wire my radiator. I discovered a dsm thermo-resistor thingy will thread into a stock starion radiator no problem. I like this idea much more than the oem because the dsm thermo thingy doesn't ground through the radiator itself, it has two pins. I think this will cause less electrolisys in the long run. Hopefully I'll get an aftermarket radiator before this thing is running but its not looking like that so this thing will have to do. Both fans turn on at the same time, and stay on until the temp has dropped 7 degrees F or so. Its a more advanced unit which is also slightly smaller so it will allow for more flow through the end tanks. I'm looking for a plug for the other side so I can remove the stocker one thats doing nothing.

 

Picture of it wired up:

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0184.jpg

 

Along with the radiator mod I needed to modify the stock water pump. I called up jay racing and asked them about a product they make. Specifically, this:

 

http://www.jayracing...products_id=216

 

they make a ton of cooling solutions for 4g63s. If your doing a swap I suggest checking them out. I asked for one of these with no fitting welded on the end. This was so I could put a normal barb end on it for the radiator, as well as having my turbo coolant drain, throttle body coolant drain, heater core coolant drain flow directly into this. This allows your water pump to still flow coolant while the thermostat itself is closed during warm up. Prevents the water pump from killing itself. Here is mine modified. I'm going to chop off the turbo side and have a -6 an welded on, since I found some an fittings and SS line for my turbo. The other side is for both the throttle body and heater core. I'll get pictures of that later.

 

http://i81.photobucket.com/albums/j223/tstkl/conquest/motor/DSC_0177.jpg

 

in the background you can see my inline oil filter for the turbo. Its from forced performance. It only comes in red for journal bearings and black for ball bearing turbos. I can't wait to get a ball bearing turbo so I can not have red in my engine bay. Cops LOVE red.

 

I'll come back and add the thermostat housing here soon

Edited by TsTKl
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