OSM Garage Posted August 17, 2008 Share Posted August 17, 2008 Hey people Just joined this site, and i am loving all the projects that are posted up on here. All the time and effort that you guys pour into your projects, gives me ALOT of motavation for my own. So, what better way to repay you guys, is to post up my project, and hopefully i do the same to another new member JUST GET TO IT! Saw this car on Trademe and couldnt resist, so i brought it because I had the perfect donor car. It was a factory GSR EX Lancer, so it had the disc rear diff, Starion struts, turbo instrument cluster, blah blah blah. I thought that this would be a simple swap, but boy was i wrong. Found a couple of pics of my lancer before i hacked into it. Not the best pics, but pics none the less Basicly, it was a 1200 BIG BLOCK, 4 on the floor, you know, all the good stuff. But parted ways with the goodies, to make way for the Evo 2 4G63T. I raped the orange EX for everything it had and sold it on to a guy who has the MEANEST looking EX ive ever seen! So this is where i was up to a couple of months ago 1 Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted August 18, 2008 Author Share Posted August 18, 2008 Pulled out the motor of the crashed lancer to find that the turbo took some of the impact. The wheels of the turbo didnt spin freely, so i had to replace it. I was hoping to get a good turbo like a Garrett GT28 or GT30, but i didnt want to modify the manifold or get new oil/water lines made, so i went for the EVO 3 TD-05 big 16g. Plus a Garrett is quite expensive. Worth the money tho Heres a pic of the dead turbo Had awesome help from my dad to separate the GSR wiring loom from the Microtech loom and central locking and alarm. The battery is now positioned in the boot but still need to buy a battery box. Im glad someone knows what theyre doin coz i dont! Also got new radiator because the old one took a hiding. Also the old one had a stupid pipe running along the top because the top inlet was on the wrong side. The new radiator is suited for this application better. Took some pics with the radiator Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted August 18, 2008 Author Share Posted August 18, 2008 Almost up to date. Trying to catch up! The weekend just gone, I decided to open up the front of the radiator area just to give it more air flow. Also hacked off little bits the got in the way of the radiator Before After Before After Also finished off the intercooler piping, ready for me dad to mount the new turbo and make suit the RWD top mount config Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted August 24, 2008 Author Share Posted August 24, 2008 Fitting the gearbox up, realized that the gearbox is a standard Sigma box modified to run hydraulic. I had a 1600 lancer box and thought if i swap the arm, thatl change it back to cable clutch, but 1600 lancer boxes are different to sigma Top one is Sigma modified to suit hydraulic, bottom one 1600 lancer So had to buy spare Sigma box, just for the arm. Notice the different lever positions Sticking with the buying bug, i brought an engine lifter, and a malpassi RRFPR I finally got stuck in to the car and mounted the oil cooler. I was going to mount it just behind the bumper, but decided it was to tricky. Had a mate come over and gave me a perfect place to put it. Because its running an Evo 2 engine, it has a 7 bolt flywheel. So i cant run a RWD flywheel. The bellhousing has been chopped up to suit this My dad came round to fit the turbo. He had to turn the exhaust housing and front to suit the top mount config. Took a lil bit but he got there. Here it is all made up sitting on the bench. Ready to bolt up, but i have to get the internal wastegate welded shut because of the Tial 38mm External Wastegate Now here are some pics of the engine bay with turbo setup. Almost there, i can taste it. But still ALOT of work to be done. Need to find someone with a welder, and who can weld aswell! Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted August 31, 2008 Author Share Posted August 31, 2008 Just a lil update Went to pick a part for a sroll and check out what goodies are there. If there was anything worth something, i wouldve brought it, and sold it on trademe. As i ventured to the Mitsi section, There it layed, a RWD Sigma wagon. So I raced back home to grab some tools, went back to pick a part to rip out the diff. Heres a pic of the Sigma wagon 10 bolt diff I heard a rumour that the Sigma wagons came out 10 bolt compared to the sedans (Sigma & Lancer) which came out 8 bolt. If this 10 bolt diff is the same as the GSR Disc 10 bolt, then ill have spare axles and diff head. I layed the diffs side by side to check if the lengths are the same And they were (Good start!) Ripped out the axles and diff head, ready to chuck the Sigma wagon diff housing away. Anyone want a Diff Housing? FREE!!! If this diff fits perfect inside the GSR Disc housing, im going to lock it. An LSD would be good, but im not forking out $1000+ for one. A lock diff would probably suit me better to what I want to do. Although, I heard that L200's came out with 10 bolt LSD? Is this true? Heres a pic of 10 bolt Sigma (Left) compared to 8 bolt Lancer. Hard to see the difference but the 10 bolt is much larger then the 8 bolt (As you would expect) I also tried to dummy up the muffler. What you guys think? Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted September 7, 2008 Author Share Posted September 7, 2008 Saturdays weather was to good to waste on working on the car, so not much happened on this day. Where as today (Sunday) the weather was crap and depressing. Looking at the Lancer wasnt helping either. BUT, i found some energy to do a lil bit of work on the beast. Decided to pull the engine out to attend to the welding duties. There are quite a lot of welding to be done in the engine bay. eg coil brackets, fuel filter mount, oil cooler mount, heater hose hole (Block it off), intercooler mount. And while the engines out, i can tidy up the imperfections. Finally got to use my new engine lifter. Worked a charm!!! With the engine out, i decided to take a few pics of it an display it on here so maybe others doing or deciding to do this conversion, can gets some ideas or tips. This picture is showing how the rear water inlet/outlet pipe comes around to the front Left side of engine (Intake side) Right side of engine (Exhaust side) Snapped a couple of pics of the car with the engine out. Gotta love the ride height in the rear. Looks lower in real life Got plastic ties holding the gearbox up. My cousin Antz would be so proud!!! Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted September 13, 2008 Author Share Posted September 13, 2008 Tiny update Ever since ive owned the lancer, there has been an uglu rust repair in the engine bay, along the chassis rail (Common). Decided to see how bad the rust was under the repair, so got out my friend, Mr Angle Grinder, and made mince meat out of it Who ever made the repair, didnt do a good job. They just basicly covered it instead of fixing it. Amateurs! Finally tried to finish the wiring for the central locking. BUT........only did 1 door. I got lazy. Ill finish the others later. Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted October 5, 2008 Author Share Posted October 5, 2008 Teeny, weeny update time Not alot has been going down at the moment. A combination of depression and no money mixed with a lil lack of tools, has lead the EX Lancer to a stand still. Anyone wanna donate there welding skills and welder to this pile? Man, i need to win that powerball!!! Anyhow thought id show ya the lil i have done. I brought a battery box for the boot. THATS IT! I dont even have a battery! Geez Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted October 19, 2008 Author Share Posted October 19, 2008 Update Tizzime Yet again, not much of an update, but a lil bit of progress has happened. This Sunday produced awesome weather. So, taking full advantage of it, I decided to bring the Lancer out of the dark dingy garage, and into the sunlight. Thought my best plan of attack was to get everything ready for welding. So, I went a little crazy with the angle grinder, cutting unwanted mounts, and exposing bare metal for the welds. God bless the Sanding discs for angle grinders. They are the SHIZZ!!! Axed out the battery mount. FINALLY! Cut a mount for the other side of the oilcooler Got rid of some unwanted tags that hold the wiper wires. Ive re-routed these. Before After I cut up a bit of panel steel to block off the heater hose hole. Im still gonna run a heater, but im moving where the hoses go thru. Just to clear the CAS abit better. Forgot to bring home the cordless drill from work, so i couldnt drill holes for the driveshaft hoop and oilcooler mount. Should be done during the week. Gaining a lil bit of momentum which is what i needed. Decided that im gonna hire a mig welder over the labour weekend and get some sparks going. Im so desperate to here this thing run!!! Didnt win $30million either Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted October 20, 2008 Author Share Posted October 20, 2008 Is it just me or is Daylight Savings AWESOME!? Got home from work today, sun still beaming, so i did some work on the Lancer. My main target was the driveshaft hoop. Since i brought the drill home, I made 2 holes through the floor for the hoop to bolt through. Didnt work out as I hoped, but good enuff Hopefully Mr Cert Man will be happy with that! Mucked around tidying up the wiring in the engine bay. Also, finally finished running the wires through the rear doors for the central locking. Cant wait for this weekend. Im gonna hire a welder, and get busy with it. If I get all my welding done, which is..... - Driveshaft hoop bolts - Fuel pump mount - Oilcooler mount - Fuel filter mount - Intercooler mounts - Heater blocked - Coil mount Then I can start piecing the car back together. Hopefully get it running, take for a hoon, THEN, pull it all apart again for panel & paint!!! Then Cert, Wof, Reg, CRUISE! Good Times! Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted November 1, 2008 Author Share Posted November 1, 2008 Not much happening this weekend. Still waiting for a mig welder. Ive got my eye on one but i have to sell some parts off the new EX Lancer 1st Please give generously to the "Save an EX" foundation!!! Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted November 30, 2008 Author Share Posted November 30, 2008 Update Time 30/11/08 Awesome weather + No cash = Stay at home and work around the house Got bored with the house work and pulled the beast out of the dungeon. Still waiting for the right welder to pop up, so theres not much i can do. Decided to swap the drum diff, for the disc diff. Been holding off doing this. Dont know why tho Ive bolted up one of my Recaro Fishnet buckets just for laughs, but I wont be using them. I like the factory seats too much. BEFORE Put diffs near each other to have a look at the difference. Cant tell by the pic, but the 10 bolt diff is HUGE compared to the lil 8 bolt AFTER So, still needing my welding done to progress. Cant wait to buy a welder. Purchased a little 40lt air compressor to do little tasks aswell. Hopefully, my next post will be the money maker post!!!! Watch this space! NOTE - I still have the crashed EX Lancer if anyone needs any parts Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted February 6, 2009 Author Share Posted February 6, 2009 UPDATE TIME! Been a while since I updated this thing. Done quite a bit of work on it over the weeks. Got the disc rear diff in and decided to see if the Sigma wagon axles fit in the GSR Diff.................PERFECT MATCH! Was a bitch to get the axle out! Brought myself a Chrismas prezzy. Autometer Pro-Comp gauges!!! I dont plan on using the Fuel pressure gauge, so its up for sale. The boost gauge had leaked the fluid that was inside, so i drained the Fuel gauge, and poured it in the boost gauge. Heres where I plan on mounting the gauges Got out the ol die grinder and started hacking at the dash. Was hesitant in doin it, but theres no turning back now! Here it is in place Took a coupla pics with no springs in the back. Dont know why Tried to swap a 200kph speedo out of a 1600 lancer into my 1200 das cluster. But didnt work Fitted the GSR steering box and didnt look right. Put side by side against the 1200 box and noticed the arm of the GSR is bent bad. Will have to swap this over Brought myself yet another present!!! Best present ever!!! Brought it with gasless wire in it. Couldnt get the hang of it. Then got a bottle from boc and some solid wire, and HOLY SHITBALLS its the SHIT!!! Fully recommend Gas. Throw the gasless shit AWAY! So, with the new toy, ive done my welding in the engine bay. Blocked of heater hole Oil cooler mount Intercooler mounts Coil mount, fuel filter mount and new heater hole made ENGINE IN TIME! Spent today bolting the turbo on, inlet manifold and engine plugs in. Anything i could bolt up, i did. This is how its looking like now Still a bit of work to do but its getting close to skid day!!! Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted February 13, 2009 Author Share Posted February 13, 2009 IDIOT REPORT! Just had a heart stopping experience. What a giant penis!!!! Was welding under the boot for the fuel pump, finished welding and noticed a cracking sound and lotsa smoke. huh, whats that? The boot had caught fire! Amp looks toasted. My JBL components are throw aways, carpet burnt to a crisp and the plastic trim melted. I feel like the worlds biggest idiot! So im now after boot carpet and trim if anyone can help. Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted March 8, 2009 Author Share Posted March 8, 2009 IM OVER IT!!!! Plugged up the wiring, and tested the electrics. Nothings goin right. Central locking isn't playing the game, computer turns on while the motor is cranking, and doesnt stay on when key is in the "ON" position. Put some oil in the bastard and tried to get some oil pressure. I cant get any oil pressure! Im over it!!! For sale maybe??? Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted March 21, 2009 Author Share Posted March 21, 2009 Decided to do something about this car today. Had a few tips and tricks to try to get some god damn oil pressure. I pumped oil back thru the oil feed for the turbo. Turned the motor backwards. NOTHING! So, thought id pull the motor out and have a look under the sump. ENGINE OUT..........AGAIN! Got it sitting on the engine stand As soon as i took the sump off, i saw silicon build up all on the pick up. Probably not the main cause of the lack off pressure, but mite have contributed to it. The pick up mite have been squashed up against the sump so i tapped the bottom out a bit Decided to do a few tests Took the pick up off and put some oil down. Turned the motor over by hand to see if the oil gets sucked up, and it did - Good start! Pulled out the pressure relief valve to see if its not stuck open. Was working perfectly - Good Kept turning the engine over whilst pumping oil in the pump to see if oil pumped thru to the relief valve. It was squirting oil out the fitting for the pressure gauge! - EVEN BETTER NEWS! So the pump works. May have been deprived of oil coz of the gunk and squishing of the pick up. Before i put the engine back in the car, im gonna fill up the pick up, and pack it full of grease. In other news, I locked my spare diff! Wont put it in till its running, for obvious reasons To Lowlancers Disgust, I mounted my rear muffler. I dont think it looks that bad Shes comming together. Just gotta sort out the electrical bugs, hope ive fixed the oil problem, then its BIG BURNOUT TIME!!! Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted May 24, 2009 Author Share Posted May 24, 2009 Winter weather is stink! Haven't been able to do much on the car lately, due to either stink weather or busy schedule. Managed to attack it today. Pulled it out of the dungeon for the first time in ages Looked rather sad We quickly checked the state of the main and big end bearings before putting the engine back together. They weren't in the best shape, but will do in the meantime. Mite have to rebuilt my spare VR4 block. Put the engine back together and slapped it back in the car. Spent most of the day pluging and connecting all sorts. I like it when its all back together Brought me one of those OTT monster tacho's. Had a warning light laying around, so put that on as well. Not too sure where to mount it. Here looks like the only place Still need to sort out the electrical bugs. Hopefully next weekend, it mite fire up!!! Not sure if it gets oil psi. Need some better rims! Till next time............................... Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted June 7, 2009 Author Share Posted June 7, 2009 This weekend we went hard out to get this thing alive. My first goal was to check if it had oil pressure. Cranking it over, it took a while, but oil started comming thru the nylon tube. At this point, I was wrapped. Spent most of the day attacking the wiring. I had issues with the computer not turning on while cranking. Sounds easy to get around, but the computer runs thru the alarm. Quite tricky! The ol man worked his magic on the ignition switch. I almost had to do what Ke36 had to do, and wire up a starter button, but the ignition works, finally. The computer turns on, while cranking, but had no spark. We traced the problem back to an earth not connected. Once that was put on, all I had to do was fill it up with gbox oil, and see if she runs. Today, I topped up the gbox oil, put some water in the radiator, plugged up the computer, rough wired the tacho in, plumbed up the gauges, chucked some fuel in it, tightened up the silicon joiners in the hopes that it might make some kind of starting noise. Ready to try and start And well...........Actions speak louder than words! Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted December 16, 2009 Author Share Posted December 16, 2009 Well...... Been a LONG time since i felt like touching this car. Still dont really. Have been hounded to get this thing on the road, so hopefully over the little holiday I have thru christmas ill "TRY" to get into it. Managed to take it for a hoon down the road a while back. Since that video it kinda sat in my garage. Today I finally pulled out the engine and gearbox to start the long, hard job of............Panel & Paint! So hopefully you'll get more updates during the silly season. If I can be arsed! Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted January 8, 2010 Author Share Posted January 8, 2010 Went up north for the holiday's and was hoonin thru the country roads thinkn "Man this would be so choice if I was in the lil Lancer" So i kinda got a goal of getting this thing up north by New Years. So ive got a bit of motivation. Spent a wee while stripping the engine bay out so i can make it look pretty. Getting rid of wires that arnet used, and re routing wires to hide them a bit more. Over the next coupla weeks ill be filling in holes and dimples to make it look all smooth. Decided to mount the washer bottle in the boot to get it out of the engine bay. My factory EX bottle had been smashed so I went n brought 1 from Pick a part along with some extra hose. Made a crappy mount And this is it all welded in place. No boot fires! Not much to do now really. Just gotta save to fund for wheels, paint, cert. Cant wait! Quote Link to comment Share on other sites More sharing options...
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