Ok , I guess I'll start one ...

[T3hD0gg]

Fan delete isn't really needed, most people just remove the whole fan and just run a shorter belt that then just skips that spot where the fan was. It also allows for more room for the electric fan motor.

For those who are interested, Pure MS sells the serpentine belt for EFK users: http://www.purems.com/products/product.php/II=2171

[dougyfresh]

While we are on the topic of some 3d stuff, I got use one of these the last couple days... I can't show exactly what I've been using for, but I'll show some practice stuff I was working on in a lil bit.




Faro Arm w/ infrared profile scanner, IMO the most versitile tool you could have in this business. I was literally floored with the quality of detail and pick up. It would do automatic overlaying of your CAD to scanned model for you- to pick up any of your errors.

mmmm CMM measurement systems.

ATOS is another method.. Can get entire surfaces in one shot.

[mike-2ptzero]

For those who are interested, Pure MS sells the serpentine belt for EFK users: http://www.purems.com/products/product.php/II=2171

Yep, thats who I got mine from.

[Issam@INA]

Couple things I modeled up the last couple days to get machined... I'm getting a couple of the thermostat housings done ... I need one for the Dakar truck also.. they both allow -16 welded fittings for custom rad applications. I'll need one on my ABA B5 setup.

You could have used a MK1 VW thermostat housing.it is aluminum allready and allows for the use of a twin make AN-16 fitting.

[California Jay]

I'm not a fan of welding to the old castings in these two cases, i'll pass... but show us what you are referring to.

[jrock]

Updates and pictures?

[California Jay]

Very swamped right now guys, I'll probably give a pictorial of the swing arm completed very soon.... the machining was pretty pricey.

[California Jay]

A couple quick pics as the actuator sits on the car, I'm just now ready to get back on the road after all this mess. There is an inline -4 tee fitting at the oil block and the welded bung on the oil pan for oil return. I've been swamped lately with design and manifold projects. Hard to juggle lately.

[California Jay]

This made my day.... we started carrying Racepak products. I got my IQ3 logger dash today... one of the most important items in the car.



I should clarify this is for my B5... not for the TT .

[Don Supreme]

Nice..

[Kyle H]

Niiiiiiiice!

[Bic-Ball]

all those braided lines are purdy

[dwi_gti]

Came across this setup, any news on the gains from this divided flange?

[AudiA4_20T]

badass, thats just what we were looking for

[California Jay]

^I had been down this path, the fittment is the pits on the VW chassis in a setup like I'm working with... Ramhorn etc etc.. As it sits I have less than 1/2" clearance to raise the turbo to insert this piece considering the rain tray. I can see it working on a A4 setup with more space to utilize.
Quite the road block in flow IMO.

Starting back on the dyno tomorrow

[AudiA4_20T]

^I had been down this path, the fittment is the pits on the VW chassis in a setup like I'm working with... Ramhorn etc etc.. As it sits I have less than 1/2" clearance to raise the turbo to insert this piece considering the rain tray. I can see it working on a A4 setup with more space to utilize.
Quite the road block in flow IMO.

Starting back on the dyno tomorrow

I noticed that, its not very smooth more just like an abrupt halt in flow. Either way, the supra picked up 150wtq through the rev range

[California Jay]

true, the TQ was worth it .... I've not seen anyone install it that utilized more control with an SEM, maybe theres more to get out of it with a later "opening" rate, being able to do that here with oil pressure hopefully will do that. We'll see I guess.

[zerb]

im sorry if this is a stupid question but couldnt you just weld use that valve as your turbo flange on your manifold and weld it right to the collector? which would save you a few inches, not that itd make it fit any easier with that actuator hanging off the side and such but still...

[California Jay]

If the tolerance in the shaft of the flange is very tight I'd say no - I would say there is enough warp or pull in most flanges after welding to not get the flap shaft back in totally square, it may cause some unwanted binding. Plus the amount of time you may have into porting and squaring up the collector not to interfere with the flap may be quite time consuming.

I could say I had a good hour or two in fitting this flapper design with the collector of this ramhorn mani.

[chris164935]

This made my day.... we started carrying Racepak products. I got my IQ3 logger dash today... one of the most important items in the car.



I should clarify this is for my B5... not for the TT .

Any more information on these? Do they work with any stand alone (Autronic preferably)? How are you setting yours up on the A4?

[317ssayzarc]

You really have $ to blow on that Chris? I posted up the crank pin pics in your vortex thread, sorry it took me so long, I've been busy

[chris164935]

You really have $ to blow on that Chris? I posted up the crank pin pics in your vortex thread, sorry it took me so long, I've been busy

It's alright. I need to find a new crank first. I want to get a forged transverse crank. The tooth hole for the timing gear is trashed on my current crank as is one of the teeth on the oil pump gear.
The beginning of each month is slow for us because of bills. At this point, one of those or a bunch of sensors would be able to same, price-wise. And with that display, I don't have to worry about where to mount a tach or boost, fuel pressure, oil pressure, A/F, etc. gauges.

[California Jay]

Yes its for my A4... It can tie into many SEM's that are on the market. I'm sure you could get it to work with SM4... Racepak has an AEM harness that is plug and play, with a bit of time wiring you can do the same. This unit will log 72 paramters/sensors. In my case it will replace all my dash and engine ECU wiring. ABS and lights will remain stock.

Heres a couple screen shots, I like the "best potential lap" feature the best. It will gather the best times broken down by corner/straight/etc etc and give you a lap time you can realistically achieve.
These two pics don't relate, but it shows a few screens you have access to within the program.

[Don Supreme]

Did you hit the dyno?

[solowb5]

Looks like a log from the Racepak

[Don Supreme]

Looks like a log from the Racepak

Not talking about the graphs posted above. In an earlier post Jay stated they were going to hit the dyno again (yesterday).

[California Jay]

Well after a few weeks and getting some manifolds out I've gathered some more parts for the B5. These AEM coils are a real nice fit... they are a perfect depth for the valve cover. You can also see I got a few machined parts from NLS... oil distribution block and crank vent cover in aluminum. I couldn't pass up the price, their run of the parts was cheaper than I will ever do some one off parts for. They fit great.



The TT is doing fine, I'm on the dyno hopefully again on monday for some final results. The head certainly stays a lot cooler with this lifter issue remedied. I could never put my hand on the valve cover after a spirited run b4 all these issues. Now its not bad at all.

Random manifold candy from this week:

[Kyle H]

oooo prettty.

[michael66899]

Dayyum! Looks great man, any ETA on some flapper results?

[California Jay]

Its looking promising.. after some runs I'm hitting 26psi at ~5100rpm, still on 91 oct pump gas. Graphs and more progress soon.

[AudiA4_20T]

nice, what kind of timing is it running?

[California Jay]

In quick...
Close to my original map below- but about 3* less aggressive from just under 3k rpm and on.

[California Jay]

Thought some of you would get a kick out of this ... we had a Lancia Delta pass through the shop... got into talking about a quote on a cage and turbo upgrades. Don't see these very often for sure. It was in mint shape.

[Bigjuice]

Nice, I haven't seen one of those in a while..

btw, Jay i'm putting everything together in a couple of days will post up on Vortex

[t1demont1]

lancias are cool, but that engine bay doesnt look fun at all to work in.

[California Jay]

Nice, I haven't seen one of those in a while..

btw, Jay i'm putting everything together in a couple of days will post up on Vortex

sweet action...

yeah Lancias are tight tight cars... We have four of them we see off and on for track days.

TT side note.. I've got full boost down to 4700rpm... tuning after its super hot is getting tricky.

[jrock]

Been waitin 6 months to see the end of this project but mainly a spool at 3k rpms. Whats goin on?!?! We need updates!

[California Jay]

Well I'm in my most busy time of year. I won't sing a sad song about how many projects are on the go, but I'm well occupied.

The last session on the dyno I found some more flaws in the setup as a whole. I've got more engine torque than the last coupe sessions and I'm twisting the engine enough to pop power steering lines on the steering rack. I'm in the middle of replacing them and making them more low profile to make it stronger and more out of the way of heat and the dp. My second hurdle is keeping heat down in the rain tray. Not a big deal, I just now see a few plastic pieces starting to melt slowly after hard on the dyno for a couple hours at a time.. As far as power goes so far... spool is @ 3200 and 17psi at 3800rpm it seems, still at 91 oct. I'm actuating the flapp in the turbo at 4k.

[sean1.8t]

Well I'm in my most busy time of year. I won't sing a sad song about how many projects are on the go, but I'm well occupied.

The last session on the dyno I found some more flaws in the setup as a whole. I've got more engine torque than the last coupe sessions and I'm twisting the engine enough to pop power steering lines on the steering rack. I'm in the middle of replacing them and making them more low profile to make it stronger and more out of the way of heat and the dp. My second hurdle is keeping heat down in the rain tray. Not a big deal, I just now see a few plastic pieces starting to melt slowly after hard on the dyno for a couple hours at a time.. As far as power goes so far... spool is @ 3200 and 17psi at 3800rpm it seems, still at 91 oct. I'm actuating the flapp in the turbo at 4k.

good to see your shop doing well and busy in these times. this recession seems to be weeding out the shady shops from the prominant ones

but this 17psi @ 3800rpm, this is on the 40r on the A4? or are we talking about the TT again?

you have any pics of the A4's progress?

[California Jay]

Thanks...

The issues surrounding the PS lines, heat, and spool characteristics are in regards to the TT. With more and more tuning the spool seems to get better and better.