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

[Kyle H]

I check this thread everytime I come near a computer!

The question is, do you go near a computer more often then poopie poops?






we may never know.

[Poopie]

psh i doubt it

[Kyle H]

So.... dyno!?


seriously though, I'm assuming all is well?

[California Jay]

I had a factory oil pressure connector/ground let go... set me back a bit. Its the single wire pressure sensor off the oil distibution box. Oil pissing right through the center of it.

Other wise all is ok

[t1demont1]

thats good that all is good besides that minor issue.

[blkb6a4]

any updates yet?

[California Jay]

Yeah heres an update..

Some of the lifters have stopped rotating... this equals nice lobe and cam journal failure.

Don't trust machine shops with little 1.8t experience

[Don Supreme]

Yeah heres an update..

Some of the lifters have stopped rotating... this equals nice lobe and cam journal failure.

Don't trust machine shops with little 1.8t experience

Wow!

Stock cams?

[kovalevandrew]

[QUOTE=Kyle H;3044120]The question is, do you go near a computer more often then poopie poops?


----->> poopie poops? <<----- Hahahahahaahaa!!!! I just spat coke all over my laptop.

[California Jay]

The lifters are still doing their job, but not spinning as they should... when working properly it prevents the cam from pushing on the same spot repeatatively on the lifter.

Eurospec cams. I have just found out now that the machinist uses re-furbished lifters in their rebuilds.

[Don Supreme]

The lifters are still doing their job, but not spinning as they should... when working properly it prevents the cam from pushing on the same spot repeatatively on the lifter.

Eurospec cams. I have just found out now that the machinist uses re-furbished lifters in their rebuilds.

I don't care much for euro-spec cams either.

[California Jay]

well really have no issues with the cams... just the lifters. Ill let you know how it pans out

[onemoremile]

Good luck.

[California Jay]

Thanks...

I've got to do a rockwell test and measurement on the currently damaged lifters to see if the refurbished ones are at all reconditioned in a way that it would alter from the way they would come as OEM. The company that reconditions the lifter is claiming that their methode should not at all alter the integrety/performance of the OEM piece.

[dougyfresh]

What clued you into this being a problem prior to pulling the valve cover? What were the symptoms? curious.

[California Jay]

I was doing routine check in for a fresh build... re-torque of the head studs, valve to lobe clearance and oil change. Even b4 total failure you can detect if the lifter is not spinning by the soot collecting on either side of its face from the width of the cam lobe.

[California Jay]

Update....

I got the lifters out and at the same time purchsed OEM new Audi AEB lifters.

Below, right off the bat after looking at the two, you can see the refurbished lifter (left) is not the same finish. I had a quick hardness test done today and the top of the refurbished lifter is ~30% weaker than the OEM piece. You can see the repeated stroke of the cam lobe on the right lifter..notes of no rotation. This is after 260kms. I also did a measurement and the OEM piece is ~.5mm taller than the other (2nd pic). This can obviously cause slap.






For the machinist having 30+yrs experience I wonder why he would use a lesser of a lifter after knowing the amount of $$/time going into the rest of the car... $11 for the reconditioned lifter, $40 for the OEM. There was no specified budget for the build. I never winked at the cost. For each head that is brought in the lifters are sent for exchange for the weaker of the items shown above.

Sad.

[quattro16]

Damn these engine builders. There has been so many problems on these forums with these idiots. Dosen't matter if its a small block or a 1.8t. An engine is an engine and it seems there is noone around who can build one!!!

Crossing my fingers mine holds up, 4k+ and counting.

[onemoremile]

That was a hack move on his part. It is all too common too. The $17k RDI 427 (aluminum 351w small block) in the Cobra suffered a similar fate when a cheap beehive valve spring broke at the top and dropped a 2.25" stainless valve into the chamber. The valve and seat got destroyed and the pieces went back up through the open hole and spread through the rest of the cylinders. It was a pointless tragedy and happened just after the warranty expired.

[AudiA4_20T]

That was a hack move on his part. It is all too common too. The $17k RDI 427 (aluminum 351w small block) in the Cobra suffered a similar fate when a cheap beehive valve spring broke at the top and dropped a 2.25" stainless valve into the chamber. The valve and seat got destroyed and the pieces went back up through the open hole and spread through the rest of the cylinders. It was a pointless tragedy and happened just after the warranty expired.

in your car? that sux

[dougyfresh]

That sucks Jay. Are the cams okay and just the lifters damaged?

[California Jay]

Yeah the exhaust cam is done, cyl #2 lobes got it the worst... Seems the damage was kept in the area of the head.. I've taken the bottom end apart and found no etching on the crank/rod bearings.

[dougyfresh]

Yeah the exhaust cam is done, cyl #2 lobes got it the worst... Seems the damage was kept in the area of the head.. I've taken the bottom end apart and found no etching on the crank/rod bearings.

That sucks. Its always something. Can be frustrating at times. Esp on a customer's vehicle. Judging by your posts I'm guessing the customer is understanding.

Just went back to the first post to refresh my memory on which cams are in the engine. Which model CAT Cams were you using?

[California Jay]

The customer is very understanding and patient. He has spent good money and should have it right.

The Cat cams are for my build... these are Eurospec - .410's ex .355's int

[dougyfresh]

The customer is very understanding and patient. He has spent good money and should have it right.

The Cat cams are for my build... these are Eurospec - .410's ex .355's int

I know how that is and can relate 100%.

Oh, Eurospec. Guess I missed that somewhere.

[Wizard-of-OD]

Jay who did the work?
Did you go to Graham?

[bassed]

The customer is very understanding and patient. He has spent good money and should have it right.

Good business plan, keep it this way and you will be golden. To many builders/tuners are shady these days in the Audi community. I know several DSM builders/fabricators/tuners and they have a much different approach than the vast majority of those in the VAG community, an approach I long for actually.

[California Jay]

No I didn't go with Graham... we have a couple 2.7t heads here done by him, hes not bad. The shop we used is another gent who uses the VTI brand re-manufactured lifter. We have a give and take business with him and is already setup in our system/account. Basically i'm "informed" to use him to utilize saving time while I do other things and for liability.

Good business plan, keep it this way and you will be golden. To many builders/tuners are shady these days in the Audi community. I know several DSM builders/fabricators/tuners and they have a much different approach than the vast majority of those in the VAG community, an approach I long for actually.

thanks!

[AudiA4_20T]

No I didn't go with Graham... we have a couple 2.7t heads here done by him, hes not bad. The shop we used is another gent who uses the VTI brand re-manufactured lifter. We have a give and take business with him and is already setup in our system/account. Basically i'm "informed" to use him to utilize saving time while I do other things and for liability

saving time and liability huh? ... I hate trying to cut a corner only to find out I have to spend more than just doing it right the first time, I can feel your pain, especially because it wasnt even your fault

[California Jay]

Bit of an update... some goodies for me and some stuff back together for the TT. I've been quite busy lately doing a bunch of instruction manuals for the sprintboosterusa.com, along with some turbo mani orders.

The TT is getting some love... no turbo back on yet... but getting there... all new lifters too. I've had struggling argument after struggling argument with ppl the machinist has got involved that don't even make parts for the vw community... holy shit balls. Anyways, quick pic.




I've also got the internals balanced... looks like I needed 1.5 grams shaved in some spots. I searched around and found a machine shop a lot more professional for the type of work I do, better mind set also. My full rotating assembly is now with in .10 of a gram between each cylinder... so I'll be plastigauging the next couple days then final install.



I've also started to gather some dry sump parts... got my pump, made a pan, and rounded some other small stuff together (lines). I'll get more pics soon. ARE was at the PRI show and we got some great info from them. They carry sump kits for a # of engines.



I've also been brain storming a bit more on development of the swing arm with a co-worker for the divided turbine. The idea is using oil pressure... we got further into thinking about it and found it would be an excellent source of energy always on tap. Its always availabe in greater volume/force than the pressure needed to move the flapper when the car is spooling. This methode could work out to have more control via a solenoid and a table in the SEM. My co-worker Tommy forwarded me this item that got the ball rolling. Pretty easy to setup after a pivot arm is made to keep the slave cyl away from heat.



If any one has a log of their oil pressure that would be great.

quick collector snaps

[solowb5]

I heart you Jay

[Anthony]

OK so by the request of a number of AZ'ers, this thread has been cleaned up and reopened. Lets keep it professional, informative, and on track.

[Toyotatech]

Thank you Anthony.

[blkb6a4]

anyupdates on numbers from the TT yet or any fun tidbits on your turboflapinator(I think I like that name....I claim rights to it if you want to use it it will cost you one full BAT engine build )

[Don Supreme]

Yes, I am happy this thread was unlocked!!!

[bernB5]

OK so by the request of a number of AZ'ers, this thread has been cleaned up and reopened. Lets keep it professional, informative, and on track.

Thank you Anthony.. It's nice to have a democracy; I always feel that sending letters does nothing, but I gave it a shot.

Happy New Year, almost, to everyone and let's get this back on topic

[dougyfresh]

Jay, nice welds. Your stuff is hand-welded? I can't remember.

What activates that wildwood 'slave cylinder'? Is there an electronic signal seeing as that schematic has an in and out for the oil. I should go refresh my memory on hydraulics.

[sean1.8t]

YEA!!! it's re-opened

[thopp00]

That is such a good idea for the oil pressure!!! and so simple great idea!

Mad props

[California Jay]

Hey guys , thanks for the enthusiasm and compliments.
Been traveling the last couple days seeing family, home in two.

All my items right now are hand welded in the pics above and in my sig.

The slave cylinder will be controlled via a solenoid. Much like v-tec works in a Honda. Most of your main stream SEM's allow for a relay or solenoid activation in their aux control tables.. I've got a few DEI CO2 solenoids that I could use.

Oil will flow up from the oil block to solenoid to slave then dump. But I'm unsure how it will work upon deceleration. Either the flapper will flutter and relax fast enough from exhaust, or I will need to have it reverse force... Still some stuff to figure out.