another quality piece of fabrication (EBC content)

[dougyfresh]

I think I originally got this idea from Charlie's AVant.


Got the dremel tool out today and hacked apart my ash tray. My Apexi AVC-R now resides there

Very carefully took the ash tray apart:



With some help of the small end-mill on my dremel this photo shows most of the material removed. A little at a time. Trial fitting. More cutting. etc..


Electrical tape around the outside of the EBC to prevent plastic-on-plastic rattling. I've also got tons of double-sided tape on the bottom. Its solid and doesn't move when you push on the EBC or push the buttons.

Fits like a glove:


Cover installed (I had to trim this little piece off the underside of the cover):



Recall out ash tray cover automatically goes up and automatically goes down. You push on it in the down position to allow it to open. Well, this little piece is what allows the cover to stay in the down position. I broke it when trying to reinstall.



After brainstorming on how to reinforce, and glue, the piece I broke I decided not to use it.

How to keep the cover closed? Some rare earth magnets holding it closed? Nah. When I was reinstalling the cover I accidentally put one of the torsion springs (that open the cover) in backwards. Hmm. Idea!

Driver side is installed correctly (aiding in closing the cover) [dust cover off]:


Passenger side is installed opposite (aiding in opening the cover) [dust cover off]:

I also increased the tension. Note the relief I cut out for the EBC wiring.

What does this do? It allows the cover to stay closed on its own and also aides in opening the cover. I push on the back of the cover to get it partially open. I then push on the front of the cover to fully open it. Not as 'cool' as the original operation but it works just as good.


Everything installed in the car. Very clean!

[Grenade]

Nice.

[Coderedpl]

Nice and clean install, but I'm kind of wondering how would you be able to see whats on the screen?

[RLB6]

How's that boost gauge coming along?

[dougyfresh]

How's that boost gauge coming along?

Still working on it. Well, been procrastinating on the boost gauge. The mirror is in pieces on my kitchen table. I've found other things to do in the meantime (EBC, pull motor from car, etc..). Hoping to get back onto it now that I've got the EBC mounted.

[jojoampt]

looks really nice doug! good job on a clean install.

[absolutegtr]

Looks great and seems like a super clean install....but, the visibility of it seems a bit iffy...

[jon102034050]

nicely done

[[email protected]]

Nice install!

I was going to put my AVC-R in there too but my radar head unit takes up that spot.

[7speed]

I was gonna put mine there, but I like using my ashtray for change

[dougyfresh]

The way I see it. I'm not looking at this all the time like I would the instrument cluster. Therefore the ash tray is a good location.

I don't want anything to be visible when sitting in the car. Everything has to be concealed in some form.



BTW: When cutting plastic with a dremel tool, I forgot to mention to wear safety glasses and ear plugs. It will make your life so much more comfortable.

[audiminiac]

Will you be so kind and share with us how to connet wires of AVC-R to ECU, please ?

[dougyfresh]

Will you be so kind and share with us how to connet wires of AVC-R to ECU, please ?

I am working on that next. The EBC is installed and the wire is hanging in my dashboard. I didn't have time last night to fully wire everything up.

As I get it working I'll post up what I have physically done. In the meantime this is what I've been told:

You only need to connect the power to a switchable 12V source in the fuse box. Ground to a ground in the fuse box. Then connect the RPM wire to the RPM signal in the ECU (purple wire I believe). Some cars (I think the 2002s specifically) don't have that RPM wire so you have to connect to one of the coil pack wires. To get the boost-by-gear to work you have to get some form of adapter to convert the ECU signal into a signal the EBC can understand. Then you can have different boost settings for gears 1 through 5.

[audiminiac]

Any updates ?

[dougyfresh]

Any updates ?

On what? The wires?

I snaked the wires through the ECU compartment from the engine bay on Sunday. Used some WD40 to cut down on the friction and was able to add them into the main engine harness rubber grommet where it enters the ECU compartment. The wires are now hanging under my dash board waiting to get connected.

I have to install my engine and transmission first. That takes top priority over wiring the EBC since if it was wired I have no way of testing and verifying its wired correctly.

[audiminiac]

OK I got it... GL with the engine and tranny :)

[dougyfresh]

An update.

Here's where I mounted the solenoid valve for the EBC. On the passenger side frame rail as close to the turbo as possible. Wastegate line goes to the 'COM' port on the solenoid. Boost signal line goes to the 'NO' port on the solenoid.



The wires were snaked through the ECU box and rubber boot the engine harness goes through (upper right of the picture below).


The boost valve is mounted on the box in the lower right next to the throttle body. The empty box that contains stuff for the automatic vehicles. The boost valve can not be seen in the image above. I also hid the wires within the engine harness to keep things clean looking.

Wiring... Power was taken from the switchable power in the steering column like Martini describes in this DIY.

Ground was used at the fusebox like Martini also uses.

I have yet to hook up the RPM wire.

You can adjust solenoid duty cycle to adjust how boost comes on and meets requested. Pages 55-56 discuss what exactly duty cycle is here: http://mkiv.com/techarticles/avc-r/i.htm

There is some good info from Jeff Lee about adjusting feedback (once the RPM wire is hooked up) here: http://www.audigeeks.com/forums/index.php?topic=2880.0

That is about where I am at now. I haven't really been using the EBC for high boost since I've been running my car off the wastegate (using the off setting). Late September / Early October I'll play around with it more since my car will be re-tuned and I'll actually be able to run high boost (safely).

[AudiA4_20T]

nice spot dude

[starfriend]

where did you get your EBC from? Who has the cheapest? :)

[dougyfresh]

I found it in the vwvortex classifieds.

[G Men 08]

ha.. sweet!! nice lil surprise when you pop open the lid haha good work