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1987 GLHS#0896 Project log

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#1 · (Edited)
1987 GLHS#0896 Project log

OK; I've been on TD for a few years or so and, I've talked and discussed, and rambled on about the GLHS I own and how I intend to make it an incredible vehicle.

I'm starting this log today because I'm beginning the
"resto-boostaholic-adgenda".
I've been planning, educating myself more thoroughly, making contacts here and more planning for three years now.

The intentions are pretty detailed at this point and here's the "vision":
A GLHS rivaled by no other!
11 second 1/4 mile with the license plate on the back.
Total vehicle weight of 2200lbs(or less), with me in the driver's seat(170lbs).

I've been in contact with several TDers here and this vision is VERY-VERY achievable.

I bought the vehicle from Forward Motion Inc - Specializing in FWD Dodge Performance Parts (Mike was selling it for a guy from Texas), and it was a beauty! 67930 original miles! Here's what it looked like the day I brought it home:




The vehicle had already had a few mods done by Mike at Forward Motion Inc - Specializing in FWD Dodge Performance Parts. An "Enforcer I" turbo, "Enforcer I" cylinder head with +1mm valves, +20% injectors, MP stage 2 module and a 3" complete exhaust with "blow through" cat.
After a few modifications to the factory air intake system(Factory air box removal etc) and an upgraded coil and wires, she was pretty "pissed"(exactly the emotion I like my cars to have(lol). But low and behold, I blew the a525.
I was already aware of the "weakest link" in the GLHS's character make-up, having had a GLHS years ago that did the same thing. So, I knew it was just a matter of time until the 525 pooped the bed on me(lol).

At this point, the vehicle is on blocks in my driveway and has been there for a while now. Here's a pic:

(even in this condition, you can see how "clean" this vehicle is)

I'm starting the project with the brakes and suspension in mind first so I can get the vehicle into a "roller" in case I need to ship it anywhere for something(or just to move it around with ease).

I have FINALLY got my hands on the parts required to do the SLH3 four wheel disc brake modification(well, they're in the mail anyway).
I had been in touch with THREE different people here at TD that had said they had the parts but, when it came time for me to purchase them, these people all kind of "disappeared"(lol).
Oh well, Mike at Forward Motion Inc - Specializing in FWD Dodge Performance Parts to the rescue! Mike had what I needed and shipped the parts today!

As I go through the steps of the build, everything will be documented here.
As I said before, the SLH3 upgrade and suspension system mods will be first.
These two systems will be addressed kind of simultaneously.

I've been in touch with Koni and, their prices are a bit "steep" but, suspension upgrades have been quite difficult to find. The Konis seem to be the very best system for the "L" body cars.
Here's a pic I found from a guy who had his done:

It cost him right around $600.00 for this but, the result speaks for itself! Wouldn't you agree?
I've been in touch with Koni and, YES, they are still rebuilding these today. So, if you want yours done, simply go to Koni: Koni: us-na-redirect

For today, I'll end it there. By the weekend(Hopefully), I'll be removing the rear suspension, cleaning and modifying it and, reinstalling with the SLH3 brakes.

I'll post any info as I go along.
Thanks for looking and have a wonderful day!!!:hello2:
 
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#72 ·
Thanks 92TurboTona; Well, the thanks should go to DetroitTurbo.
He's like some kind of WIZARD with the PhotoShop!

"Forum Junkie" that I am, I picked up a few parts for the project.
Initially, I hadn't planned on going Alky but,
with the price I scored this kit for, I HAD TO!
(Like a message from Ma Mopar!)

(Adds a bit of weight to the rear of the car^. Weight is my ENEMY! But, I feel it'll pull it's weight and then some.
If not, into the For Sale section it'll go! lol)

Here's a couple gauges I bought as well:
I planned on using all white faced gauges and, to my surprise, there was someone selling all the ones I needed)


And a wideband set-up:


Haven't updated anything in a little bit.
The weather is getting cold here in PA but,
I'll be working through the winter on the GLHS.
The projected date of October 2014 is coming quickly!

Keep checking in.
My updates happen at all kinds of different times.
And, thanks for looking! :D
 
#75 · (Edited)
Back in post #54, I began explaining the coilover conversion I was doing.
Well, it's changed a bit.
Still using the coilover conversion kit but,
using 2005 SRT-4 struts rather than the 2nd Gen struts I originally converted.

Here's the progress thus far:
Got a set of factory SRT-4 struts(blown).
Bought them on craigslist for $30 SHIPPED!
(No springs but, bearings, mounts and, dust shields included)

I started with measurements here because I'm posting in a Neon forum where there's a Bilstein mod I'll be doing to these struts.
Link: www.neons.org • View topic - DIY Bilstein upgrade - Rebuild your old KYB struts

Here are the measurements:
50.72mm O.D.:


46.42mm I.D.:


Overall length 350mm(13.75")
(from the top of the housing to the bottom where the hole for the strut insert will be drilled):


I removed the lower spring mount as I'll be using a coilover kit with these:

(Note; If you do this same operation, be sure to cut ABOVE the spring perch weld;
Thus leaving the weld intact to the strut casing; It is used to support the coilover conversion sleeve)






A surprising and interesting find on these struts was twofold.
First, the top bracket thingy is removable and thus, reusable once the replacement insert is installed:
(It takes a bit of coaxing,(lol) with the hammer and chisel but, it DOES come off there)




Second, the top of the strut housing is simply bent in, in four places to contain the strut cartridge:

So, if you're pretty good with the hot wrench, you could bend these out and,
not have to cut any of the casing.
I will be cutting but, having this material will surely allow me to choose one of several different strut inserts.

I won't cut yet. First, I'll figure out which inserts I'll be using;
get the measurements from them and,
then I'll modify the casing accordingly.

Just for grins, I'll post a pic of the pipe cutter I'll be using to cut the strut case:

24" long and weighs about 20lbs!!!
Definitely older than me, my Dad or, his Dad!

Cleaned the threads in the wire wheel of the bench grinder;
Added wheel bearing grease to them;
Sprayed the hinged parts and rollers with PB Blaster;
Sharpened up the cutting blade with the die grinder and, it's ready to go!

When I find the right inserts, I'll be sure to return and post the Part#s,
Supplier and, price I pay for them. Wish me luck! :woot woot:

Update(kinda) lol

Cut the tops off of the struts:








And, removed the factory, non-replacable inserts:


I've found the strut insert I'll be using.
It's a Bilstein 34-050224:

Haven't found them for a price I would be comfortable paying yet but,
they are readily available.(Prices range from around $140.00ea. to $190.00ea)

The insert slips into the factory SRT-4 cartridge and,
the stud at bottom of the insert goes through a hole drilled in the bottom center of the casing,
Then a nut and washer are installed and torqued.
Also, the strut comes with a cap that will press onto the casing to further secure it in place.

Here's a pic of the insert with the boot removed:

Need I say more? lol

Coming along nicely.
I may even replace the Koni inserts with a set of Bilsteins as well.
Understandably, the Konis have adjustable dampers.
I'll just have to weigh the differences later.

I must thank gyrol at neons.org for the information,
part#s and, for the detailed outline he posted at the forum.

Great stuff. :D
 
#249 ·
Update/Changes to post #75
I'm posting in a Neon forum where there's a Bilstein mod I'll be doing to these struts.
Link: www.neons.org • View topic - DIY Bilstein upgrade - Rebuild your old KYB struts

When I find the right inserts, I'll be sure to return and post the Part#s,
Supplier and, price I pay for them. Wish me luck! :woot woot:
I got Bilstein Strut inserts from AJUSA, online for $129.01 each; with FREE Shipping!
I've only bought one so far, but I'll get another ASAP.
The Bilstein part# is, 34-050149

They work great with the Tokico SRT-4 strut casings.
I have more details, but just wanted to quickly get this is here.
The number I thought I'd be using is still in post #75;
I can no longer edit it.
So, hopefully no one orders that number for this mod.

Best wishes,
Donnie :D
 
#76 ·
And, I finished up the "A" pillar dual gauge pod fab as well.
It's basically 2 generic "A" pillar gauge pods mounted to the "A" pillar trim and,
molded into the trim with plastic weld and epoxy.
Then painted with Textured spray cans.

First, I attached the pods to the pillar trim with screws.
Then cut or grinded the heads off of them(Note this actually melted the plastic of the trim around the bolt)
Not a bad thing. Now the blots are perfectly formed to the plastic(or the plastic is formed to them)lol
I also cut off the end of the screws on the inside of the trim.
Now they're just reinforcement "beams" if you will.

Here's some of the early pics from when I began.
I lost a whole bunch of pics I had but, you'll see how I marked under the pods to cut:




And, here's a few early pics after the first shot of plastic weld went on.
I screwed through it after it dried to prevent flexing.







Drilled a hole in the pod for the factory trim screw into the "A" pillar ^

This was a LONG, DRAWN-OUT process that took me FOREVER.
The main reason is that the Plastic weld or epoxy must dry completely before it can be sanded.
So, here's some pics of the process:


















I would apply the epoxy, allow it to dry then primer the part.
When the primer dried, I would sand where necessary and,
apply more epoxy:






This process went on endlessly.
I wanted it to look like it came this way!




Finally, when it was done to my satisfaction, I began painting it dark gray with
textured paint from Rust-oleum:


And, here's what I ended up with:








Hope that covers it well enough.
Getting a pic of the entire "A" pillar trim is tough with my cell phone camera and,
it's all I've got.

I'll be painting all of the interior parts like this but,
this is the only one I needed to modify(THANK GOD!)
Surprisingly enough, this paint I'm using just happens to MATCH(nearly perfectly)
the color of the dash pad.
So, I think it'll be pretty SCHWEET looking when done.

Stay tuned! :D
 
#80 ·
Absolutely but, it takes some real patience.
In addition to the Plastic weld, I used a couple different epoxys.
Being my first shot at something like this,
I was searching for the best method.
I found that the 20-30min. epoxy is best.
Gives time to fiddle around with it.

As I said in the post, it's a long and drawn out process but,
surely there are ways to speed it up a bit.
I was applying the epoxy in pretty thin layers to be precise.
But, if you mix the epoxy and, let it just barely begin to set-up,
you could lay down 3/4" thick layers!

I'm pleased with the final result. :thumb:
 
#84 ·
So, winter is upon us here in PA and, I'm not a fan. :mad:

But, it does give me time to think.
The latest thoughts I've been having are interior related and, I think I may have found the answer.

I'm not going to use carpeting.
So, I needed a way to protect the floor boards inside.

I chose to use bedliner!

Rust-Oleum Truck Bed Coating - How to Apply - YouTube

Yep, bedliner!
I'll have to find out what the weight is first and,
find one that's light!

I'd also LOVE to do the plastic trim pieces with it as well.
We'll see. :D

As for the wiring that was so neatly tucked away under the carpet;
I intend to come up with some kind of conduit for the wiring.
Maybe plastic tubing(like 1" I.D.).
Run all the wiring, which really isn't much(Probably get away with 1/2") and,
even use "T" fittings where wires come out for their intended use.
(I'd paint the conduit with the bedliner too) :thumb:

And in other news;
If there's anyone near zip code 18708 who's got a common block for sale, PM me.
Thanks! :D
 
#86 ·
New parts arrived yesterday!
(Well, "NEW" to me anyway.lol)

These are the parts required to do the SRT-4 ACT clutch mod explained here:
http://www.turbododge.com/forums/f4/f62/465081-air-charge-temperature-sensor-street-racing.html

Here's the parts:
SRT-4 "flywheel" and ACT pressure plate# D017
(The difference in weight is ASTOUNDING!!! compared to the factory flywheel) :thumb:






I also got the 6-puck disc from the seller as well.
Thought I would use it for mock-up but, now that I see the damage, it may be fixable.
This disc is $142.02 and, it's nearly new.


Other than this crack:


Probably not worth the risk really.
For the $142.00 I'd be taking a HUGE chance on wrecking alot of what I'll have invested.
Yeah, I'll just get a new one.
(Anyone else notice the conversation I just had with ME!)lol :rolleyes:
 
#89 ·
The progress has come to a screeching halt! (mostly)

I have been limited to the work I can do in the shop.
(which is basically my front porch)

See, I bought a car port that is 12'X25' and 10' high.
However, after assembling it, the wind had other ideas.

This area isn't known for powerful winds but,
the very night I finished assembling the entire car port,
the wind got so heavy, it lifted the car port off of the ground and,
threw it over the power lines in front of the house.

It has eight 6 foot legs that the pictured roof mounts on top of.
At each of the four corners, I had a 40lb. weight attached.
The entire port weighed around 260lbs and,
the wind picked it up off the ground and threw it like a rag doll!

Here's the roof:




I have since used the side tarps as covers for the car and,
attached them to the GLHS with the car port's bungee cords.


Didn't like it at all but, had to get it somewhat protected. :shrug:

Surely, I'll have some updates here and there but,
until Spring they'll be mostly inside work.

For example:
I bought the SMEC and harness for it and,
- I'll be doing the 87 LM/PM to SMEC wiring inside.
- I have the dash panel out and, in the shop. So, I can work on it.
- I also have the NON-A/C box to modify for vents to operate.
- The fuel sender that I did a TON of work to is no longer an option;
I have to modify it.

Recently I was bored and, knew there was SOMETHING I could do;
So, I got to modifying the GLHS accelerator pedal and combining it with the ULTRA-COOL(IMHO) SRT-4 pedal.
Here's the result of that:





Got the SRT-4 pedal cover for $8 at neons.org and, modified the GLHS pedal to accept it.
Not all that difficult. The hardest part was "thinning down" the GLHS pedal.
Narrowing it was a snap but, thinning it down was kind of tricky.

The screws in the side are to ensure it doesn't come off when MASHED TOO THE BOARDS! :thumb:

Thanks for checking it out.
Have a great day! :D
 
#91 ·
Thank you.
I think it'll work out well.
The coilover conversion makes a lot of room in the wheel wells and,
the SRT-4 components allow for many-many more braking upgrades.

There are several front coilover kits and, replacement struts for the SRT-4 but,
in building them myself, I'm able to choose every detail and set the ride height as I like it. :D
 
#94 ·
Here's the latest purchase for the GLHS:


Yep; Thanks to our on-call machinist acannell,
I have now made the definitive decision to reverse cool the engine.
(The engine that I don't have yet.lol)

BIG plans for BIG mods with the cooling system I'll be using for the car.

More to come; Thanks to all who follow this thread.

PS: Randy(RGL10) has a build thread as well and,
he has opened my eyes with HIS invention of Variable Cam Timing for our 2.2/2.5.
I will be employing his idea in my engine as well.
Here's a link to his thread:
http://www.turbododge.com/forums/f4/f279/450674-1985-glh-t-restore-build.html

He begins mentioning it earlier in the thread and,
by page 10 or 11, has it built, installed and running!
Definitely worth checking out.

Best wishes! :D
 
#100 ·
Anyone who's been around a while and,
has had transactions and/or conversations with me remembers
how I kind of "disappeared" for a few years(Dec. 2009-Dec. 2012).

Well, during this mandatory vacation, I had begun to clean-up the wreckage of my troublesome past.
However, there was one issue that I wasn't able to address and, over the past year I have been focused on it.

This issue is a DUI(Driving Under the Influence) conviction from 2007 which I had ignored for years.
During my "vacation" I attempted to remedy the License suspension but,
the laws in PA do not allow license suspensions to be credited during a "vacation".

It has taken me an entire year to cut through the red tape that had amassed due to my negligence but,
the situation is back on track now.

However, due to the conviction being my second in a ten year time span,
part of the sentence is a 1 year Ignition Interlock System being installed in any vehicle I may own.
(This is an automatic Breathalyzer with a tube one must blow into to start the vehicle)
My vehicle, in its current condition, isn't able to have said equipment installed;
So, my licence simply is suspended for the additional year.

It is this coming month, February, that my 1 year will begin.
So, after all of this story, the simple reason behind this post is to advise of the change in completion date of the Resto-Boostaholic-Agenda.

The new date for completion is now, February 2015
And, "I don't like it anymore than you men do but,...... some men you just can't reach"; I used to be one of those men.

I do my best to see the good in everything and, for this,
I see it as an opportunity to be even more thorough than I had already intended.

Thanks for checking out the log and, updates will ensue regularly. :thumb:
 
#109 ·
I await spring to work on mine also
 
#110 ·
Well not sure whether I should thank you or curse you. Giving me more ideas for when I tackle my charger (85). Well if nothing else you have added more ideas to my idea and have provided links and steps for how I can incorporate them in mine. Now I just need to get out of college and get a job to pay for these mods as well as my other projects in the pipeline.

On another note truckville isnt located along RT.422? If so then I have to ask if you previously had 4-5 chargers sitting in your driveway?
 
#111 ·
No man, not on 422.
But I'd like to know how close that is to me.
It's places like that where owner's are sometimes trying to "unload" these old K's. :D

It's a passion which requires A LOT more money than I have to spend on it but,
when the ideas are in the mind, it just seems silly and foolish to do things any other way.
So, it'll be a while but, it'll be something special when done. :D
 
#114 ·
SHHHH :wink: New stuff a'comin'

I know a few pages ago, I promised to use the Turbonetics unit I had.
But honestly, for the price, the HE351CW is the better choice for me.







Oh, there's also a set of forged Venolias in the works too. :brows:

With the sub-zero temps here lately, my progress has been inhibited(to say the least).
But, keep checking in, soon(I hope) I'll get some actual work done around here. :D
 
#117 ·
I just LOVE when that big brown UPS truck stops in front of my house!


Work out for the project ahead and, SLAM the protein shake!!!
Lots of planning and, work to be done.

This Holset has an extremely small amount of play in either direction.
I'm seriously considering not rebuilding it but,
my "condition" won't allow me to pass on the opportunity to get inside this beast.




Above, ^you see a mark in the housing; it's dirt. I haven't even cleaned it yet.



9cm turbine housing NEVER TOUCHED!


S/V not even ported yet.


I tried to get close-up pics of the wheels inside the housings but,
they came out awful. Once I have it apart,
it'll be much clearer of how incredible the condition is.

There's no kind of damage to any of the blades or the walls of either housings.
The turbo Gods smiled upon me with this one for sure.

Thank you for an incredible turbo at an incredible price tmef!!!
You DA MAN!!! :D
 
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