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Joel's 2003 FS635 Evo build thread

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Old Dec 11, 2009 | 09:04 PM
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Joel's 2003 FS635 Evo build thread

So, this will be the rebuild thread. I bought a "complete" car (LINK TO THREAD) which ended up requiring a complete restoration. The only thing i kept from the car I bought was the chassis, transmission, exhaust mani, and TC. EVERYTHING else is now replaced.

Joel's mod list:
  • Buschur FS635 cast kit
  • ID2000 injectors
  • Full Blown double pumper -10 feed -8 return
  • Aeromotive FPR and fuel rail
  • Buschur Race FMIC
  • Buschur UICP/LICP
  • Tial BOV
  • Buschur mini-battery kit
  • Exedy Triple cerametallic clutch
  • Wilson W2.4 custom intake manifold for the 2.3L
  • 65mm ported TB
  • Buschur twin-muffler v-band exhaust
  • Buschur 2.3L
  • Shwitzer stage 5 head with FP 4/5 staggered cams
  • ARP L19 head studs
  • CBRD Radiator
I know I am probably missing some things but i'll add as I remember.

Some parts pictures:






Wilson intake manifold (awesome piece! thanks 9sec9/Indy)








The ID2000 (thanks Tony @ T1!) / Full Blown / Aeromotive Fuel setup:






The turbo setup (buschur cast FS635 kit + shearer mani)





Buschur V-Band dual muffler exhaust (thanks Nick!)

Last edited by joel(PA); Dec 29, 2009 at 03:09 PM.
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Old Dec 11, 2009 | 09:05 PM
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Good luck with the built. Keep us posted with some pictures, I hope everything works out for you. Subscribed

Cheers
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Old Dec 11, 2009 | 09:08 PM
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Assembled the motor tonight with help from Phenem... its coming back together, I am really anxious to get it running again.







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Old Dec 11, 2009 | 09:11 PM
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ooooohhhh ****....

Get the manifold polished or somethin dude... **** looks in worse condition that the car when u bought it...lol
injectors are tasty!


y would u let phenem touch the car?!?! that guys just a problem!
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Old Dec 11, 2009 | 09:15 PM
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intake mani is one of my favorite pieces. It is a work of art IMO.
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Old Dec 11, 2009 | 09:17 PM
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Originally Posted by joel(PA)
intake mani is one of my favorite pieces. It is a work of art IMO.
Does look very nice.. similar to stock but with great flow characteristics im sure.. what made you go with this vs ams f1 or any other?
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Old Dec 11, 2009 | 09:21 PM
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Originally Posted by 4g63smokinall4s
Does look very nice.. similar to stock but with great flow characteristics im sure.. what made you go with this vs ams f1 or any other?
a side by side comparison pic may be coming. it is actually quite different, especially in the plenum area.

I chose it because it has all the stock provisions AND has great power potential.
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Old Dec 12, 2009 | 04:24 AM
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Nice parts. INterested to know if that mani is the one that Wilson cut in half to port and weld back together? COuld you pm me what you paid to get it done. Thanks.
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Old Dec 12, 2009 | 07:01 AM
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Originally Posted by chu
Nice parts. INterested to know if that mani is the one that Wilson cut in half to port and weld back together? COuld you pm me what you paid to get it done. Thanks.
Yep. its cut open, and a bunch of work done, the plenum is enlarged, the port work is amazing. I hope Indy doesn't mind me telling what they all do, but you can tell the put a ton of work into them. Contact 9sec9 here on the forums for pricing
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Old Dec 13, 2009 | 09:13 AM
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Motor is close to drop-in point.





Full blown double pumper install with -10 feed and -8 return. Turned out REALLY nice. i love doing fuel systems.

routed into the engine bay


shot where i took the lines up into the bay


full length shot


down from the pump (i bent the tab down, removed the stock lines, and it fit well)


clean routed


the full blown double pumper

Last edited by joel(PA); Dec 13, 2009 at 09:35 AM.
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Old Dec 13, 2009 | 09:47 AM
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Looking good man!
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Old Dec 13, 2009 | 01:30 PM
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injectors and rail installed. beautiful!





ready to go!
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Old Dec 13, 2009 | 02:47 PM
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Good luck with the build! Is that a used timing belt :/ tisk tisk
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Old Dec 13, 2009 | 02:53 PM
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slightly used greddy belt, it'll be fine.
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Old Dec 13, 2009 | 02:59 PM
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Keep it coming, good work
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