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Build thread: 91 tsi awd

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Old Nov 17, 2011 | 11:17 AM
  #1  
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Build thread: 91 tsi awd

I know this is not really the same level or interesting for many of you but, thought I'd share for those who do. Im not going crazy with the build just a few basics and hoping to make a fun weekend car out of it. I hope I can update this as I go as much as Id like, but between school and working on a degree Im kinda of busy.

Picked up a completely rust free roller in northern Ohio, body is completely straight and doesnt even has any surface rust underneath, which if you know 1g's its getting harder and harder to find.

Plans so far include:

-Stock bottom end (for this upcoming summer, plans in the works already for a 2.4)
-3 angle ported head
-272 cams
-3g lifters
-springs and retainers
-hx40
-custom 3in exhaust
-Methonal injection
- Evo 8 ecu
- 1000cc injectors
- dual 255 pumps

I plan on running low boost for the time being until I can get a little bit better rearend (currently has a 3bolt) and beef up the trans and transfer case a bit. As of right now the motor is almost complete and will be in the car in the next week or so. Ill be loading pictures of the progress later tonight.
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Old Nov 17, 2011 | 12:40 PM
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From: deltona
pics? I cant read.
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Old Nov 17, 2011 | 03:04 PM
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Originally Posted by localtoys73
pics? I cant read.
Theyre coming, gotta get to the shop and take a few
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Old Nov 17, 2011 | 03:40 PM
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Sounds like a great car, can't wait for some pics.
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Old Nov 19, 2011 | 02:11 PM
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Well finally got some time and grabbed a few pictures, sorry for the bad quality. Ill search around and get some that i took earlier and show the progress.

Here is how she sits right now, jackstand holder.


The motor as it sits now.




Turbo before polishing.


And the patch harness, ugly, very very ugly but just for the time being.


The ebay manifold will be on the car for a little bit but will get some alterations. As of right now Im waiting on a valve cover to get back from the powder coater and an oil filter housing gasket.
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Old Nov 30, 2011 | 08:41 AM
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Not a whole lot of progress lately. Oil filter housing went back on and the motor is back at my house sitting next to the car.

Still have to get all these before i can drop the motor back in:
-Valve cover
-evo 8 knock sensor
-polly motor/trans mounts
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Old Dec 2, 2011 | 11:38 AM
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Keep us posted. I've had thoughts about my next project and a DSM would be fun. I'm curious to see how yours goes.
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Old Dec 12, 2011 | 02:53 PM
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Car looks good man...keep working at it. I need motivation to finish mine, well money wouldn't hurt either lol.
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Old Jan 12, 2012 | 07:45 AM
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Ive gotten motivated again lately and its starting to come together a bit. I have the transmission painted, radio surround made, got a great deal on a catback exhaust, motor and transmission mounts are in the car and I'm getting the rest of my fuel system today. I have some pictures I need to upload still. But progress is finally being made again, hopefully I can keep this thread a updated more often.
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Old Jan 13, 2012 | 06:20 AM
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Originally Posted by o hai
Ive gotten motivated again lately and its starting to come together a bit. I have the transmission painted, radio surround made, got a great deal on a catback exhaust, motor and transmission mounts are in the car and I'm getting the rest of my fuel system today. I have some pictures I need to upload still. But progress is finally being made again, hopefully I can keep this thread a updated more often.
Awesome! I just sold my Evo 9 to pick up a used DSM for my project. I was pondering the idea before but now I have my mind made up.

For mine I'm going to most likely go with the HX35 and run a true twin-scroll dual wastegate setup and shoot for the best spool I can get for a street car. Coming from a 9 with MIVEC and a twin-scroll manifold kind of spoiled me with the great spool and drivability. So I'm looking to maintain spool yet make a little more than 400whp. I've went back and forth against the FP68 but I'm thinking the HX35 is what I want.

I'll be keeping an eye on your thread. Tell me more about your exhaust manifold.... I can't tell from the pics what it is.
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Old Jan 14, 2012 | 07:20 AM
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Originally Posted by acidtonic
Awesome! I just sold my Evo 9 to pick up a used DSM for my project. I was pondering the idea before but now I have my mind made up.

For mine I'm going to most likely go with the HX35 and run a true twin-scroll dual wastegate setup and shoot for the best spool I can get for a street car. Coming from a 9 with MIVEC and a twin-scroll manifold kind of spoiled me with the great spool and drivability. So I'm looking to maintain spool yet make a little more than 400whp. I've went back and forth against the FP68 but I'm thinking the HX35 is what I want.

I'll be keeping an eye on your thread. Tell me more about your exhaust manifold.... I can't tell from the pics what it is.
Good luck with your project, but just a warning these cars turn into an addiction lol. It will save you so many headaches to start with a good shell or car that hasnt been beat on or messed with, it makes all the difference. The hx35 was an option for me as well but couldn't pass up the deal i got on my 40 with a fresh rebuild.

As for my exhaust manifold, the one in the picture is an xs power t3, and of course the compressor housing doesnt clear the block. So not i have to decide whether to start building my own or just alter the ebay xs power manifold thats in the picture.
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Old Jan 15, 2012 | 06:24 PM
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Originally Posted by o hai
It will save you so many headaches to start with a good shell or car that hasnt been beat on or messed with, it makes all the difference.
Thank god someone else feels that way. You have no idea how many people tried to say I was stupid for modding my car.
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Old Jan 15, 2012 | 10:26 PM
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Originally Posted by Buschur_TSI
Thank god someone else feels that way. You have no idea how many people tried to say I was stupid for modding my car.
My last project car turned into one nightmare after another after picking up where someone else left off.

As of right now im stuck modding my sending unit to fit the duel 255s. Once im done with that the motor and trans are going to meet the charismatic for the first time.
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Old Jan 16, 2012 | 06:00 PM
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why an evo ecu?
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Old Jan 17, 2012 | 05:45 AM
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Originally Posted by rightaway
why an evo ecu?
Using the evo ecu with evo scan. Its a much cheaper solution to other tuning devices out there, its also much more unique as opposed to AEM or dsmlink. After playing with a buddys 2g with an evo ecu i was convinced.
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