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interbishi: Thanks...but already ordered. Our measurements seem to show something slightly larger...wonder if it will fit!

Our unfamiliarity of this powerplant is becoming evident...lots of trial fitting and to verify what we are missing...fun!

Temp installed our stage 1 GSC cams (should be rather tame) to replace the unknown Cosworths:



Close - certainly a nice finish!:



Interesting...is this 'crack' of concern? Is this the excuse for us to be looking at one of those new Force Performance cast manifolds...;-):



Close:



Starting to really look like a something...all temp installed...:

Can you please let me know whether the larger filter fits in the air box? If so, I would like to have the part number! Thx.

On the manifold, cracks are never good of course. I see two I think with one already at the outlet. Can’t see how far it runs into the collectors.

Do you have a change to have it pressure tested? Than you know what’s what.

Or just slap it on there and see what happens.. ;-)


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Discussion Starter · #123 ·
adwo: Will do on the filter - believe it to arrive this week.

Crack: pressure testing is good idea. May ask our machine shop their opinion/ability to pressure test it - thanks!

leeslancer8: Unfortunately, we spoke directly with Russ last week and he does not have a template for the straight muffler option on an Evo 5 (4-6?)...only the angled model. Maybe it will grow on me. The sound volume and performance is most important at this point. Got to be considerate of the neighbors!
 

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adwo: Will do on the filter - believe it to arrive this week.

Crack: pressure testing is good idea. May ask our machine shop their opinion/ability to pressure test it - thanks!

leeslancer8: Unfortunately, we spoke directly with Russ last week and he does not have a template for the straight muffler option on an Evo 5 (4-6?)...only the angled model. Maybe it will grow on me. The sound volume and performance is most important at this point. Got to be considerate of the neighbors!
Have you tried looking for the fujitsubo exhaust? Paul lopes on here may part with his spare?

Out of all the 5 evos I’ve had this exhaust Definitely is the best I’ve tried. Quiet enough to track days and not to annoy neighbours but great on boost
 

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Discussion Starter · #125 ·
leeslancer8: Appreciate the feedback...we took the easy route and ordered a Russ Fellows system today - quiet version. Cost is reasonably and check all the blocks except the visual, but it may grow on us. It will be a 3 inch with no reductions. Will come with a 200 cell cat along with a extended rear 'box' (silencer/muffler). Standard is a mid mounted resonator. Mr Felllows mentioned it is typically @ 5000 rpm holds at 96 dbs.

Also received our K+N filter for the intake system (PN: KNN-RF-1015). Obviously tried to get the largest filter...but our measurements were a bit optimistic! The filter just fit and even then had to finagle the install. Nothing larger will fit!



Installed:



Thumbs!



Another task complete...and the little lady is back in town...time for some progress!
 

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Looks great! Thanks for sharing.

I was looking into the possibility of getting a smaller, but longer filter with an angle into the opening that gives access to the fender. Did you by any chance look into that?


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Discussion Starter · #127 ·
adwo: That was a thought, but the opening is not substantial on ours. We leaned toward filling the main 'well' with filter instead. We have to flex it to install it so a bit lucky on the purchase.
 

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Just got caught up on your great progress. Although annoying the odd mistake and rectifcation is the best learning experince :) Doesn't look like it will be long before she's up and running again.

BTW I've got a Russ Fellows exhaust and I'm sure you'll be very happy with it!
 

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Discussion Starter · #130 ·
Gents - thanks.

Another oops...used an OEM grade 4 bolt that was too short on the engine mount...she kept turning it as the torque didn't change. Ok...lets investigate. Part of the fun of a bucket of bolts to a car we have no clue. Heck we aren't sure if all the bolts we have are for a Mitsubishi?

Russ Fellows seems to have no negative complaints - thanks for the reinforcement!

Put a few hours in today...finally.

Installed the head permanently with 80 ftlb torque on the ARP. She made it to 60 and I lent a hand after that:



Next oil pump plate gasket:



The balance shaft delete plug (shafts were already removed from the engine...new oil pump required a new factory delete plug - nice rubber coating)



The pump plate itself:



Oil pump pickup 'strainer':



She loves that digital torque wrench...interesting to see her realize the NM equals ft lb, etc.

Oil filter adapter:



The remainder is all temp installed...other than the waterpump - didn't get a image of that...she was moving too fast.

We are still waiting for more hardware and another set of 8 rocker arms...to complete the cam install and cam timing setup.

Little shocked at the price of a quality road race oil pan...ouch!
 

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Discussion Starter · #131 ·
Few items arrived yesterday...differential and transmission fluid:



And transfer case fluid:



More arrived today with bunch of arabic all over the package - some important pieces to the puzzle...more to follow. ;-)
 

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Discussion Starter · #132 ·
Time for some manual labor! Previous owner decided a spray bombed intake manifold looks good...until the paint starts to flake off. First thought was to take to the machine shop for their high pressure cleaner. But Europe is closed until September so let the young one go at it with a drill mounted wire brush. Wasn't exactly easy...an hour later with sore arms/hands...

Previous:



In-work:



Finished!

 

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Great build and attention to detail. Awesome you’ve got your daughter helping you. Will give her the skills that will last her a lifetime
 

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Discussion Starter · #134 ·
stu: Thanks...compared to many of the builds on this forum...ours is a bit ham-fisted, but we are enjoying it and hoping for the best at start up. No doubt it will continue to 'evolve' in future years...

Cleaned the throttle body and added a new IAC gasket - don't want any boost leaks!:



On went the intake manifold:



Looks pretty good...better than the black flaking paint previous!:



Next will be the valvetrain completion - 'bleeding the HLA's and timing the cams!
 

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great job!
well done to your girl and you!

just a question : can you explain your choice :
motul 300 75W90 for ??? (rear diff and gearbox?)
and redline for the transfer case ?

why you do not use the same oil in every transmission item?

best regards

Bastien
 

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Discussion Starter · #137 ·
babou88: You are correct on our intentions. We gleaned that info from this site on recommended fluids, but you are the second to inquire on the accuracy. We may have to go back and revisit - apparently the Redline is a bit much for colder climates...Do you suggest we use 75W90 for all?

Pushpex: Thanks...looks better in the pictures really, but after adding the fuel rail/injectors and tucked up near the firewall, it will be acceptable even if it tarnishes a bit.

We made a two night Scout trip to Bergtesgarden area to attempt to climb a smaller Alpine mountain (Watzmann)...so consumed the weekend.



But did received some oil from the local economy (Castrol for engine pre-lub and flush) and Valvoline VR1 from the states for engine break-in:



Also received a batch of new hardware for either missing or replacing old that seen better days - engine mount bolts, nuts, drain and fill plugs along with a new turbo coolant hose:



Threading them on - easy!:



Then to cutting up my Sears Craftsman (we found an exact replacement)...trimming off the 1/4 drive female end...she seemed to enjoy it even though quite a bit of safety precaution. (Yes the vise is in the garage...):



Result!:

 

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Discussion Starter · #138 ·
More parts arrived!



Evo 6 Thermostat hardware and lower o-ring seal:



New exhaust manifold hardware...original was crusty!:



And finally, to really clean up the appearance and apparently a good thing for the turbo - an OEM insulator:



Slowly, but surely...itching to fire this thing up!
 

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Discussion Starter · #139 ·
More parts arrived...Mitsubishi vacuum line manifolds are still available and quite reasonable in cost...knowing that air leaks are not good for drive-ability or engine survival...exact replacement parts with high quality Japanese parts - a joy!:



Throttle body install with new embossed metal gasket:



Rear main seal prep:



Rear main seal install...just enough room to slide it in:

 

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Discussion Starter · #140 ·
Pulled the cams to allow us to turn the engine over during prelube...had to enlist assistant #2 for a spell to get this moving:



We also pumped up the GSC 'No Tick' hydraulic lash adjusters (lifters)...that was mess and fingers sore after using a fine rod to push the plunger until air bubbles stopped...all while submerged in engine oil (no images - too messy).

In goes the 'flushing' oil:



Assistant to man the drill:



Took a bit to figure out if all is well...we were turning the drill too slowly...once we maxed the rpm, Old Faithful resulted! (We had also removed the OEM oil pressure sensor in hopes to remove any 'debris' on the initial prelube...it was reinstalled to fully prelube the engine while we turned the crank).



It was actually a good example of what interesting forces happen inside an engine and the engineering behind it. The slow pump rpm resulted in no oil movement...but once we hit a certain point, significant oil pressure/flow was created. And the force the oil came out the engine was quite impressive!

Cams reinstalled with all new rockers (not inexpensive, but if it builds a bit of reliability and quiet operation...) and torqued:



Careful...only 20 NMs!

 
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