By next summer I hope to have collected enough funds to support a complete rebuild of my 91 b230ft. It now has 215k on the clock and is running fine; I will be partaking in this rebuild for longevity and power-gaining purposes. My basic question is this: What components, aside from the pistons/rings, should be replaced? I am looking for about 200 rear wheel horsepower, which is attainable. I will be using a Mitsubishi TD04-15G as my turbo (from an 850R) and I want to run ~15 psi safely. I have the iPD 2.5" mandrel exhaust and an Enem v15 camshaft (11.9mm lift and a true turbo designed cam) that I'll run advanced, probably 6-10 degrees. I was leaning toward stock Mahle pistons in stock size.

I want this rebuild to be the end all of my performance goals; I am running completely stock now, and as I said before, am looking to get about 200 horse to the wheels. I am also looking to make this rebuild as rock solid as possible: this car is and will be a daily driver, and I need it to be as trouble free as a stock motor. I'm not looking to push the limits, just simply to make it more enjoyable.

The car now has iPD sway bars and bilstein shocks. I will be replacing all suspension bushings during this rebuild that have not been replaced yet, and the car will be lowered with iPD's sport springs.

I will also have the flywheel lightened and will use a centerforce clutch setup (I've heard nothing but good things). Any other suggestions are welcome. Thank you for any input.

Roguls
New York, USA