In-house projects for customers from racing and rally to custom street cars. Take some time to look through the gallery. DSG has a wide breadth of experience gained from working on all types of cars.
Conducting a full teardown of the Super Production STI which captured many Rally-America wins in both 2011 and 2012. Few people know that this car used to be Ken Block's "Trax" car and was outfitted with tank tracks in a prior life. Scot is overseeing rebuild duties.
Revamping a proven race machine with a completely new wiring harness, Dry sump, Motec PDM, Carbon dashboard and more. The old harness has been modified and adjoined so many times that a new harness needs to be constructed to make this machine reliable once again.
Kihurani brought us his Evo VIII for a Rally America Super Production class build. A year later the project took a new direction as he chose to become more competitive in the PA Hillclimb Championship. In 2010 the car was stripped and a full cage was fabricated. In SP Class, only the engine management and exhaust can be modified. A 34mm restrictor has to be installed which requires machining of the compressor housing. A Vipec V44 ECU was installed and Bill fabricated a Group A type exhaust with double slip fit connections, a 100 cell catylist and a small resonator.
This year we're starting a new stage of development, no longer restricted by Rally America Production class rules we're upgrading the turbocharger to a Garrett GT3076/ Tial Housing, tubular manifold, custom downpipe, AMS moustache bar eliminator, removing EVAP system, Ralliart bushing kit installation, Bosch ID 1000cc injectors and remapping. We'll be adding all power-supporting parts to the build along with an intercooler and pipe kit from AMS.
Building a new motor for Chris' STI street car. Full Specification for DSG related work-
Pauter Rods/CP pistons, new 2.5 block
Blouch Dom III Turbo
Tomei 252 degree Poncams
850cc Side feed injectors
Aquamist HFSIII Meth injection
ARP head studs
Killer B oil pickup
ACL race bearings
DW300 fuel pump
Perrin Fuel Rails
Perrin crank pulley
Removing and rebuilding the engine on this 993 TT for the sake of upgrading to stronger internals. The engine block will remain untouched. New twin plug heads, evo cams and JE pistons will be installed prior to retuning for more boost and more power.
DSG is building a new motor for NASA and COM racer Dan C. This is his second race motor from DSG and we're taking this one to the limit! We're starting out with a Darton Sleeved EJ25 block, ACL racing bearings coated by Calico, Tomei Rods, Cosworth pistons and Cosworth 272 Cams. Full Specification to come.
BMW 2002 Custom. SR20det S13 engine, Mitsubishi Evolution X turbocharger, custom exhaust manifold, cooling package, subframe, steering system, electronics and Vipec ECU. about 2000 lbs and just under 300whp on low boost.
Rebuilding Ron's RA SPEC Evo 1 after a big crash at Philo Hillclimb last year. In this gallery we see a teardown of the damaged shell and preparation of the new shell. The next stop is for media blasting and repaint.
Building a big spec street car for Charbel. The shell is the cleanest E30 we've seen. He and his father painted the car together, engine bay and wheel wells. It looks new. Charbel installed an EvoIII rear spoiler at the same time. We will be finishing the VAC 2.5 liter motor with Titanium retainers and stiffer valve springs. Other parts involved in the build are Motec M4, fully enabled, ATL spare wheel fuel cell, dual disk clutch and light flywheel from VAC, Fikse wheels, Tilton Hydro TOB, aluminum radiator, Mocal Oil cooler, big brakes and more. This gallery will be updated once the build is underway.
MGC GT Sebring Replica circuit race car powered by a Toyota 1JZ
Phill's Evolution VIII hillclimber. Rebuilding cylinder head, transmission and installing Vipec PNP computer, GT3076R turbo, roll cage, race seats and associated safety gear.
Mercedes' venerable " Cosworth" 2.3-16 190e. This is the limited production W201 Chassis Mercedes built for the purpose of rallying initially by Mercedes, then used for touring car racing. Cosworth was hired to design the cylinder head and pistons for this 16 valve motor. At DSG we gave this Cossie new life by installing new custom Ground Control Suspension, a roll cage, rear differential rebuild for higher lockup, shifter mechanism rebuild, racing seats and other safety items.
DSG is hired to construct a hillclimb spec roll cage for this PA competitor. The cage is legal for Mt Washington hillclimb and events in PA and New England
Preparing and changing this Group N Evolution for open class competition in 2011.
Burak's SP Class Subaru driven by Ramana Lagemann to 3 wins out of 4 events. The car is serviced and prepared by DSG.
Mitsubishi Montero/Pajero/Dodge Raider... whatever you call it don't call it slow. This Raider packs a 1jzgte effectively quadrupling the power of the original G54b motor.
Building a track day motor for Dan's bugeye Wagon. We will be using an Axis block with Tomei Arms turbocharger, new fuel rails, MAF pipe, injectors, TGV delete and some head work.
Nates 600+ WHP 2.2L stroked 2002 Subaru Impreza WRX.
3" quick release exhaust for 34mm restrictor/SP or Open Class Impreza with FIA/WRC Cat and small muffler.
Invidia 80mm Catback
R34 N1 Turbos
Replacing bushings, front bumper, dyno test and suspension installation.
Rebuilding Eric's 2004 STI with a new shortblock and some other small modifications after a spun rod bearing.
CP pistons, new 2.5 liter block
Silicone turbo inlet pipe
Deatchworks 750cc injectors
Cold-air intake pipe and large MAF housing
Walbro 255 fuel pump
Jackson Auto Machine 2.0 build with HKS GTII 7460R turbocharger, cams, twin plate clutch, tuned by Matt Koestner.
Built 2.5 Liter S14 powered E30 M3 3.0" exhaust featuring swain coated Group A header, 2-1 collector/velocity tube, slip fit connections with low profile/oval under subframe section, burns muffler and factory looking outlet.
Replacing a leaky cam seal at the power steering pump on this track driven 964. DSG was also hired to replace the oil cooler lines and hoses earlier last year.
Downpipe back titanium exhaust including hand made muffler. Total weight is 8 lbs.
To tune this S2000 Nick installed one of the first KPro S2K conversions using RSX sensors. Bill fabricated a new exhaust using a J's Racing muffler and we installed headers. The car made 211whp on our Dyno after Matt tuned it.
Nick's E30 is powered by a very built M20 with lots of nice parts from Sweden. VEMS management will be running the new setup with a Precision Billet turbo. The car previously made over 450whp with stock rods.
Building a Cosworth STI engine for a 2007. This engine really has it all. Cosworth shortblock, Cosworth heads with oversized valves, TI retainers and upgraded valvesprings, Cosworth headgaskets, cosworth Timing belt guide, Moroso oil pan, Cosworth pan baffle, Cosworth oil pump, Gates Kevlar timing belt, FP turbo.
Voltex wide body kit with carbon fiber bits.
Robert brought us his pristine Civic hatchback to make it go around Lime Rock Park faster. We took some steps in the right direction.
On the first visit to the shop the car had an engine prepared by another company. We have since removed that D Series motor and we're installing a K 24 with no turbo this time. The k series motor will make more power with no turbo than the D series did with a GT30. The K series is a collaboration between the best Honda builders in the country. We are working with Benson's, Laskey, Endyn and Hi-Tech. Benson's did the sleeving. Laskey built the short block. Endyn is completing the cylidner head with a custom set of cams and a matched header by Hi-Tech. It does not get ANY better than this for Honda. DSG is completing final long block assembly in house and conducting tuning on it's dyno under Matt Koestner.
Russ Fleming's drift machine.
Subaru Rally car preparation for 2010- repairing crash damage, and re-prepping car for this coming season. The car will be completely cleaned and revitalized over the next few weeks. Stay tuned.
Nissan 240SX GT30 engine build and tune using Power FC.
We fabricated a manifold, exhaust for the Lotary, and installed a GT3071R, Tial 44 and PowerFC.
Tuning will commence soon.
Daily Driven hillclimb car
DSG hired to install perhaps the most esoteric exhaust made for the M3
Kippys SCCA T2 racecar
Servicing suspension and engine oil leaks on this silver BMW M3
Bill builds a rally-inspired light bar for this street-going 323 gtx
Rally Car we starting building about 2.5 years ago. It's back now for re-prep before it's first outing. This is the first rally car we did start-to-finish. It will be a great car for the new "Open Light" class starting next year.
DSG was hired to install some serious hardware on this FC. We installed and tuned a Haltech stand-alone ecu, new intercooler, big turbo, radiator, injectors, new Enkei Wheels, gauges, Nardi Steering wheel and more. This was one of the best FC's we've seen.
We install a Version 3 STI engine in Chow's GC8. He also bought seats and some nice interior parts for the car. DSG removed the dash and constructed the harness properly
Performing updates to Dan's Galant Vr-4 GR-A
We installed an original long tube Hartge Header, Lee's Massive front brake kit, Recaro SRD seats and an oil cooler kit.
4G63 Powered BMW E30
Adding this to the album for nostalgia. This car was built in my driveway in Newton MA. It spawned a new confidence in what could be achieved on a low budget and taught us a lot about cars, in more ways than one. The bimmubishi was built with basic tools and a 135 amp mig welder.. nothing special. It was a decent early attempt that sub came to constant gearbox problems (no one made transmission adapters back when I built this car) I am of the belief that it's the very first 4g63 powered BMW in the world.
It held it's own but proved far too unreliable for a race car of any stature. It was retired and the shell was reused for phase II, the SR20det motor which worked much better but was only a small step up in the large scheme of things.