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It’s been quite some time since I’ve visited here. I picked up a rust free roller 91 LX a few months back. The car had been a little cut up, missing trunk floor, fender aprons, and lower radiator support. The rust free part was appealing, but the maximum motorsports HD torque arm rear sealed the deal. This is the perfect foundation for what I want to build.

I blew the dust off an old DDMI kit that I had purchased back in ‘09 and started figuring out what I need to make this project happen. Started with finding a wrecked ‘91 donor for all the sheetmetal and a bunch of odds and ends that were missing. After a few nights of work, the underside of the car was cleaned, epoxy primed, and coated with Transtar undercoat.

Another few nights got the lower core support fitted and welded up. I planned on using original aprons, but opted to go with the smooth panels instead since all of the Intercooler piping stays in the engine compartment with the DDMI Intercooler.

 

Replacement parts and trunk floor installation #ad
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Trunk floor all welded up, epoxy primed, seam sealed and floors coated. Rear suspension reassembled and installed. Motor, turbos, trans and exhaust mocked up for necessary chassis mods (K-member, and frame notch) prior to completing engine compartment fabrication and sheetmetal work. #ad
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The car was a factory auto car, so the tunnel hump was installed since it’s getting a TKO600. Also had to install factory trans crossmember mounts since they cut the original ones out. Looks like they had an LS drivetrain in the car at some point, or at least mocked up for it. I do LS stuff quite often through the shop, so I wanted to stick with a pushrod ford motor. This car as you will see it progress, is going to be the car I wish I could have had 20 years ago. Just a fun street cruiser, with a bunch of cool parts from back in the day.

The DDMI kit was set up with Garrett T25 turbos. One of them has a damaged compressor wheel, so I decided to step up to T28’s (cheapo CX racing
Journal bearing units) since they fit the bill for what this car will be seeing. I’ll be happy with 450 to the tires, and it should do that quite easily. All of the hot side components will get a bronze Cerakote prior to final assembly.

The front suspension is currently just a stock K-member, but will be upgraded to matching Maximum Motorsports like the rear once it’s up and running and I get all the bugs sorted out. Just prioritizing the budget at the moment. #ad
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After driveline mock up, we got the lower support grafted back on, notch final fitted and welded up, fender aprons prepped and welded in. Removed the dash and all firewall components, lightly bodyworked a few areas that needed attention and prepped for paint. Two coats of epoxy primer, with seam sealer as needed in between epoxy; basecoat factory Oxford white and two coats of good high solids urethane clear to lock it all in. Looking forward to starting assembly after making a few missing pieces and fabricating some unique parts for the upgraded turbos on this kit. Luckily we also have a true and very complete INCON TT800 kit to reference for a few questions I had. There is very limited info out there on the INCON stuff. There’s hardly anything on DDMI. #ad
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The motor is a stock 90 302HO. I’ll be running a 93 cobra intake and I picked up a set of Y303 heads locally; the heads will sit on the shelf until the motor comes apart, I don’t expect it to keep stock head gaskets in it for very long.

You can see the DDMI Intercooler outlet points up toward the alternator/strut tower, opposed to INCON that ran out the side and up through the factory Airbox opening.

I had to make wastegate actuator brackets, and new linkages since nothing from the t25’s were interchangeable. The passenger link is tricky, so I added a left hand thread to one end to make assembling and installing easy. Replicating as much of the INCON parts as I can, but adjusting as necessary to accommodate the differences in the compressor housings. #ad
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Way cool! When I first joined this site it was a search on the incon tt kit that led me here. Looks great.

 

in the 4th picture i was thinking to myself, i hope he don't run that as his floorboard.

 

yeah, there’s before and afters mixed in there

 

Very nice work the stock v8 k member is plenty strong and would be fine if budget doesn’t allow for the maximum motorsports k member right now . You don’t hear about MM k members breaking like other companies.The MM k member does free up a little space and has better geometry though. That’s the torque arm suspension setup id like to do in the future. I’ll be watching your build.

 

Those cast manifolds are sweet. Nice build!

 

Nice turbo kit!!

 

Nice build and thank you for saving a fox from yet another overdone ls build. I really like what you're doing with this. I helped with an incon install years ago, they do work well.

 

I like it! Most of the spark plugs look acceptable. Are there a couple that are hard to reach? How long do you think it will take you to change the plugs once its together?

 

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Plugs are pretty easy to access, considering how busy the area is. I’ll have to update you on the service time, but I don’t think it’s going to be all that bad.

Made some more progress this week. Painted a bunch of misc bits and pieces, got the actuator brackets wrapped up and coated all of the cast hot side parts in a bronze cerakote.

Coolant feeds from block to turbos are done; Oil drains are done. Oil supplys to the turbos are on, and water returns are on and just need to be cut to length. K-Member is back in place and we are ready to start mocking up Intercooler and cold side piping.

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Nice build man.

 

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Thank you sir! Just trying to have some fun, and put in the work to make it look good while we are at it. This one will probably stick around for a while, so I’m just trying to cover as many bases as I can while it’s apart. Getting excited at this point now, it’s coming together quickly and I’m just a few more pieces of the puzzle away…..

Got the floors epoxy primed and seam sealed. Dynamat is installed from the cowl down to the rear seats; Heater core done, HVAC box installed and ready for the dash to go back in.

Sprayed another round of black parts tonight; booster, pedal assembly, a bunch of little engine compartment and dashboard brackets and some more hardware. Also prepped a few items for white paint tomorrow- hood hinges, prop rod, latch bracket etc.

Fuel tank is complete; stuffed a 400LPH pump in the tank. I’m hoping the 1/4” return line can handle the volume. I stuck with factory feed and return lines for now, knowing they will be fine up to the 450hp target; I’ll be ready to run some lines if I need to up the feed and return. Again, this car is not going to be full biscuit. Just a fun streetcar, that I can enjoy and show off a bit at the local cruise events. Running 5lb springs in the actuators, and I’ll run an EBoost to run it up to 8-10psi and see how it does, if it even needs it. Curious how it will be with the gt28’s.

 

Oh you're most welcome. I am back in a '92 coupe myself and recently built a new twin turbo kit for it when I almost bought an INCON kit from a good friend of mine and still might do so. I'm just looking for 550-600 possible HP using the stock cam for now since it was done with an INCON kit back in the day........I think they made 525 RWHP with GT40X heads, GT40 intakes and stock cam.

So you did all the paint work yourself.......kudos to you. I am needing a paint job (color change) if you're interested.

BTW, what fuel pump is that you have that a drop in at 400LPH?

 

The stock cam works great for a street turbo car, when the turbos are appropriately sized. The T28’s seem to have been a perfect match and I’m looking forward to the power curve with this combo.

back in the day, my 93 had AFR185’s, stock bottom end and cam, trickflow street heat intake, and a BG single kit with a master power T70 & .81 exhaust housing. That car made 480whp and 502tq in full street trim at ~11psi. Torque was over 450 from 3200rpm to about 4800. That thing was so much fun as a daily driver.

I’m really looking forward to the Holley EFI on this one. Tuning was always a headache on these things back 15-20 years ago (for the ham and eggers like me) so I was playing with the Megasquirt 2 stuff back then. I’ve done a ton of Holley stuff through the shop over the last few years, and I’m really excited to have a car of my own to play around with it on, especially with boost.

As for the paint stuff, I’ve been into body and paint for a long time; the past 6-7 years I’ve switched focus to mostly mechanical & swap/restomod stuff as a full time occupation & business-owner. As much as I want to just slam this one together and have fun with it, it’s too nice of a car and the parts are too good to not spend the time and make the effort to do it right. A lot of people will see it locally, and it needs to represent our abilities and quality.

Paint and body is tough especially up here in the northeast. There’s not a whole lot of quality work to be found, and the guys that are out there doing it that are good are both an arm and leg in cost as well as years out in backlog work. I’d love to offer to help you on that aspect, but I’m barely set up to get away with the minimal amount of paint work I’m doing as it is, never mind a full body. Even this one will get bodyworked and sprayed elsewhere, I know enough body shop guys that I’ll rent a shop & booth for a weekend to get the body done….. maybe this winter.

 

Here’s the pump. It did require cutting the bottom of the hanger off, but it does fit through the stock tank opening

https://x-ph.com/walbro-universal-4...m_term=4586406600476373&utm_content=Catch All