Many car enthusiasts ponder the question, “What’s the fastest I can go without spending a fortune?” Often, the answer lies in purchasing a vehicle with a robust aftermarket scene. However, some individuals possess a strong desire for uniqueness, prompting them to chase speed in unconventional ways. Such is the case with this remarkable 2004 Hyundai Sonata, which boasts over 500 horsepower by combining mostly stock components with parts sourced from other vehicles.
This outstanding build comes from Hurst Built, a one-man speed shop located in Huntsville, Alabama. The owner shared with The Drive that despite the Sonata’s 162,000 miles and the lack of a significant aftermarket, assembling the performance setup was simpler than anticipated. These four-cylinder Sonatas feature a 2.4-liter engine known as the G4JS, which is essentially a license-built version of the Mitsubishi 4G64. This engine is closely related to the famed 4G63T used in the Lancer Evolution and other performance-oriented Mitsubishis. Unlike the single-cam 4G64, the G4JS is equipped with a twin-cam head, a cast-iron block, and factory-forged steel connecting rods.
Thanks to the G4JS’s impressive tolerance for boost and its mechanical similarities to the Mitsubishi 4G63T, Hurst Built was able to attach an exhaust manifold and larger injectors meant for the Lancer Evolution directly onto the G4JS. Additionally, a Precision 6266 turbocharger was utilized, generating 30 pounds of boost. After some additional modifications and using an ECU from the owner’s 715-horsepower Eagle Talon, this high-mileage Sonata was dyno-tested, achieving just over 500 horsepower while retaining its original internals at that stage.
Since the video was posted, Hurst Built’s Hyundai has gained an impressive following in Korea, where this generation of Sonata was as common as the Ford Crown Victoria was in the United States. Over this time, the vehicle has also covered more than 1,000 miles with its tuned engine and stock transmission, showing no signs of reliability issues. Future challenges may arise as Hurst Built aims for 600 horsepower with an E85 tune and a new aftermarket cam, but given the progress made with such minimal modifications, there is strong hope that he will reach this milestone in grand style.
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