Just Another Plain-Jane Build Thread.

[B5RiceEater]

This project is siiick bro, can't wait til it's all done, keep up on the good work

[Dan[FN]6262]

Yo, what are you doing with your ADR intake manifold?

[chris164935]

That manifold looks pretty nice.

Could you shoot 1 more picture looking up one of the runners towards the plenum?

Anything for my 2 fans. Lol.

The money shot: AEB intake manifold gasket lined up with the manifold. And yes, I know that the gasket is not on right, I just lined it up real quick to show off the port job.

[Don R]

CNC Porting FTW!

Looks like a stout setup

[v dub'n]

Sweet build!! you Sir have some good taste in parts!!

[jaychen]

What's happened to this thing?

Updates?

[chris164935]

What's happened to this thing?

Updates?

See Post #1 for most recent update.

[jaychen]

Schhhwwweeeet.

You won't be having any trouble with fuel from now on

[spindoctor]

My daily driver 1.8t felt like it was being left out and wanted some attention. Anyway, now that that is all sorted out, I am trying to get this project back on track.
Currently, I am in talks with Pete at IE to get ahold of some Mahle Motorsports main and rod bearings as well as some JE FSR pistons. Other than that, a while back I picked up an 044 pump. Then, I got a GREAT deal on this a couple weeks ago:


So, now all I need are some fuel lines to the rail, a FPR, and an AWIC setup. Finally, it's just a matter of having time/space to put everything back into the car.

Just went through your thread. Interesting build.

One of your post, you mentioned the JE pistons have a tendency to crack(hairline) around the wrist pin area and you're gonna use CP pistons.

Now, you're looking JE's FSR. Have they fixed that problem?

[chris164935]

Deal on the CP Pistons fell through; that, coupled with my older builds not having that good of a tune and the new design of the FSR pistons, I decided to go with JE pistons again. I don't think we'll be having any problems this go-round though. Live and learn.

[chris164935]

Earlier I posted about the FSI main caps. As it turns out, the lack of thrust washers for the #3 cap actually make these a worse option than using the 06A main caps. Apparently, crank walk is somewhat of a problem with the 06F motors at high HP levels. Sucks. Anyway, back to it again...

See Post #1 for most recent update.

[chris164935]

See Post #1 for most recent update.

[Grip99]

Awesome build. This thing is gonna be sick

[un1ko]

Cool build! Can't wait to see it done.

[un1ko]

Did you ever finish this build?

[jaychen]

Updates?

[chris164935]

Just updated the first post with all pictures, new routes, etc.

It seems like every time I go to work on this thing, a new part comes out that I want or something happens and I cannot focus any attention on it. But, I have been tinkering with it off and on again. Got an IE billet crank gear, Vi-PEC i88 stand alone system, and we have started working on getting the camshafts properly timed. My best friend and I get a couple hours each week to work on it. Recently picked up an engine hoist, so once the camshafts are timed, we'll pull the transmission and install everything at once.

[chris164935]

Well, I started a pretty fun process the other day: checking the gaps between the cam lobes and solid lifter buckets.
So, the exhaust side was fairly simple; I knew it would be. I suppose that is why I did it first, to make it seem like I was making decent progress. Unfortunately, the intake side is not so easy. The tight spaces make it QUITE HARD to get stacked feeler gauges in there. The fix isn't too hard, assuming someone makes offset feeler gauges with a width smaller than the set I am currently using (they are 12.7mm wide, if anyone wants to check that against their set).

[chris164935]

Ordered some wiring supplies to start on the harness and also finished the measurements for the lash caps. Ordered those today as well and I am hoping they will arrive before Thanksgiving next week.

[BaseDrifter]

Awesome build, can't wait to see it running. What are your awhp goals?

[viceprp]

This car is going to sing. You got a sick build going on here. With the fuel system he gas, I would say race gas or E85 will be used. I'm going to guess 500whp on the conservative side and if pushed, 650+awhp. All depends on tune/fuel. This will be an awesome ride.

[chris164935]

Over 500AWHP is the goal. Turbo, motor, fueling, and engine management are all capable of making 700 or more HP, so we will see. I'm hoping tax money will give me enough to finish the intercooler system and have it running by February of next year.

This is what the desk where I'm doing some of the wiring harness work currently looks like.


And here's the harness itself. I'm going to run it under the dash. The ECU will mount to the bolster and I'll run the USB cable for tuning out the side near the radio.

[viceprp]

What's the plan far as fueling?

[chris164935]

If you look in the second picture, you'll see my IE surge tank with dual 044 pumps. I'm going to use the stock pump to feed that. I have some 1600cc Bosch injectors right now, but I'm thinking I might sell them and move to the Genesis II 2000cc injectors. I've heard/seen a lot of good things about the Genesis II injectors.

[chris164935]

Started making some progress with getting the Vi-PEC i88 wired into the car. First thing was to get everything stranded out and fed through the firewall.

Got a lot of extra inputs left over.

And, the start of the relays harness. I have to wire up a total of 4 relays to the ECU. The ECU power relay will be mounted in the stock ECU plenum and the E-throttle relay will be mounted next to it. Under the dash, I will be partly rewiring the stock fuel pump relay. The stock fuel pump relay will now power the twin 044 pumps because the relay is rated for about 40A and the twin 044 pumps will draw at least 30A. I will be installing a new relay under the dash in one of the open slots to run the stock in-tank fuel pump.

[chris164935]

A quick update:

[spindoctor]

Nice!!

[B5 Quattro]

Wow.
Keep it coming.��

[chris164935]

Wow.
Keep it coming.��

Slowly, but surely. Lol.

Waiting for a few parts to come in...

[chris164935]

Should have the new exhaust manifold and matching downpipe some time this week. Until then, not much progress to report on the mechanical side. As for electronics, I've been able to make some progress with getting the fuel pumps going. The twin 044 pumps are run from the stock fuel pump relay since it is capable of handling up to 40A. Combined, the 044 pumps require about 30A. I used the stock fuel pump's fuse location and ran the power wire from there to the pumps (and swapped the fuse for a 35A one). I installed a second relay under the dash in one of the open spots for the stock fuel pump. I ran the power wire from that to an unused spot on the fuse panel and then connected the stock power wire for the stock fuel pump to that same spot (with a stock 20A fuse).
Anyway, here's a teaser video I put together of the 044 pumps running for a quick second (mainly did this to test the wiring as well as the functionality of the ECU and to play around with new GoPro camera). Also, it's the car's first step toward actually sounding like a race car.


EDIT: The sound in this video clip does not do the 044 pumps justice.

[chris164935]

After 10 long weeks, finally, an update!

[un1ko]

After 10 long weeks, finally, an update!

Love the manifold!! Are you fabricating it?

[Seerlah]

Plan to brace it?

[chris164935]

I wish! Unfortunately, I don't have the skills. This is the manifold JDL Auto Design makes for our cars. I'm switching to a Precision V-band setup.

I'd like to make a brace for it, but I'll have to wait until it arrives to figure out how to set it up.

[Seerlah]

Not sure how much you are paying for that, but poopie is making me one. He offered it in posts prior (not this thread).

[chris164935]

They were having a sale, so the price wasn't too bad. Once this thing comes in (with its matching downpipe and new V-Band turbine housing for my 6266), then I will be able to move forward again with the build. It will just be installing the engine into the car, finishing up the wiring harness, and getting the intake plumbing done and she will be ready to run again.

[un1ko]

I wish! Unfortunately, I don't have the skills. This is the manifold JDL Auto Design makes for our cars. I'm switching to a Precision V-band setup.

I'd like to make a brace for it, but I'll have to wait until it arrives to figure out how to set it up.

Oh wow I just checked the website and it's $764.. That's cheap compared to Full Racing.

Not sure how much you are paying for that, but poopie is making me one. He offered it in posts prior (not this thread).

Good to know. Once I'm ready I'll contact him to see how much he sells them for.

[ray4624]

1500 for a t4 divided manifold, downpipe and dump tubes....want

[chris164935]

And... It's done!

[Seerlah]

Purdy! How much total, if you don't mind me asking? You can pm me if you don't want to post it.