Just Another Plain-Jane Build Thread.

[ray4624]

that thing is quite the show piece.

[chris164935]

It was about $1400 with the downpipe and new turbine housing. Can't wait to have it in person. Should be shipping out tomorrow, hopefully.

[ray4624]

damn that isnt bad at all. Especially for something with a lifetime warranty,

[chris164935]

Quick update: Almost finished adjusting the lash on the intake valves and then we can time and install the motor. Also, the new exhaust manifold and downpipe should be here tomorrow.

[chris164935]

Unboxing...


...

New V-Band exhaust housing (.82 AR) and clamps.

3" Downpipe.

Tubular manifold. It's way smaller than I thought it would be. My hand covers about half of it!

6266.

Mocking up the TiAL wastegate and the V-Band exhaust housing.


Now, it's back to playing the waiting game. Ordered an ARP stainless studs kit for bolting up the exhaust manifold to the head but it was backordered. Of course, as I tried to cancel the order, they tell me that a distributor overseas (?) is sending me a kit...

[ray4624]

Oh man I'm jealous. Gunna be a beast!


Sent from my iPhone using Tapatalk

[viceprp]

Damn, I can't wait to see this thing run.

[chris164935]

Test fitting the new turbo manifold. Man, the new V-Band turbine housing it crazy light! My turbo's old T3 housing weighs about as much as the whole turbo with the new V-Band housing.
Hoping to get this thing installed into the engine bay next weekend. Once it's in, we'll be able to torque the crank gear and put together the timing belt setup. Then, it's just finishing the wiring harness and fuel/vac lines... And figuring out the intercooler plumbing.

[wtfscarnon]

Nice, same mani and downpipe :)

[chris164935]

So, I finally got an engine crane and we still weren't able to get hardly any work done...

Cleaned up the engine bay some more.


Got the engine hooked up to the crane and a few odds and ends torqued onto the motor. Decided to take a break. That's my best friend Karl in the picture. Best engine builder I know.


Installed the FX725 steel flywheel.


Installed the FX725 clutch disks and pressure plate.


This is where we got stuck. My FX725 kit did not come with a clutch alignment tool (or I lost it...) so I had to use the old alignment tool I got back in like 2005 that came with my SPEC clutch kit. Unfortunately, it was just too brittle or too weak but we could not get both of the clutch disks to line up and subsequently get the clutches lined up with the input shaft. The disks lined up enough that you could push the tool in with a little bit of force (and it would scrape a **** hair sized chunk of plastic off of the tool), but it was off enough that the metal input shaft would not go past the first disk. The motor was literally about a 1/2" from being seated to the transmission. We tried several times removing the pressure plate and disks, but for whatever reason (shitty alignment tool most likely), when torquing down the pressure plate the second disk would turn and get out of alignment. I'm gonna have to contact Clutchmasters or find another decent alignment tool on Monday.
So close! Yet, so far away...

[Seerlah]

Is it in yet?

















That's what she said

[chris164935]

Took me about 2 hours, but I finally got it!


Unfortunately, life stuff interrupted my progress. But, hopefully, I'll be able to get some more done later tonight. I want to try and get a lot of the wiring done.

[Seerlah]

I really want to ditch my entire setup, engine and turbo setup, and start over. When I start making decent money, I will. So, maybe two years from now. Seeing builds like this leave me with so many regrets.

[chris164935]

Some days, I wish I would have stuck with my original build. Just not being able to drive this thing kills me at times. I haven't been able to drive it in over 7 years. And, with new parts coming out all the time, it gets tough, budget wise, to get it finished since I'm constantly having to go, "Well, I've already done this and that, why skimp now?"

[B5 Quattro]

Hang in there Big guy !

[chris164935]

Slowly chipping away at getting her put back together. Got the turbo manifold installed tonight. Also, I've been working a lot on the wiring harness. Finished the coolant temp sensor, wideband sensor, ethanol content sensor, oil pressure sensor, crank trigger sensor, and most of the injector harness. Still need to figure out what injectors I want to run so that I can then install the proper plugs on the injector harness. Gotta fix the MAP sensor and air temp sensor wiring though. Did those when I was half-asleep and made the wiring too short. Anyway, I think it looks pretty decent. It's no MIL-spec though.

[RedDefiance]

awesome build

[chris164935]

awesome build

Thanks! She's slowly coming together. Unfortunately, not much else to report on the build right now.

[chris164935]

Probably could have had all of this stuff done in one day, but I have the Chinese disease: Dragon Ass...
Anyway, got the turbo manifold, turbo, and downpipe installed. Tight fit.





So far, it looks like the big pains will be getting the O2 sensor in (it's very tight near the valve cover), setting up the boost/vac lines for the wastegate, and getting the oil drain line installed. The compressor housing is also going to have to be clocked so that the boost pipe will be on the outside of the frame rail.

[chris164935]

Another quick update. I picked up some Fuel Injector Clinic 1000cc injectors last week. I decided on these injectors for several reasons. After extensive research, I've found a lot of positive reviews on them. Every set of injectors is flow matched and comes with a spec sheet that has all the information I need for tuning with these things (dead times, etc.). I have read a lot of decent things about the Genesis II injectors but the lack of flow matching and specs on the Genesis II's is what swayed me to the Fuel Injector Clinic injectors. That, and a site I've ordered parts from before had them on sale + an extra promotional code for 10% off.
Anyway, I've finished about 90% of the wiring. Just have to wire up the gas pedal, the MAP sensor, the fuel pressure sensor, and figure out if I want to run the knock sensors or not (and then wire them up). I also played with the Vi-PEC a little more as well. Tested the functionality of everything wired up and so far so good! Injectors work, the oil pressure sensor works and the 2D table for it spot on, and both temperature sensors (coolant and air intake) work. The throttle body also clicks and moves for a second before an error code disables it (the error code is for the gas pedal). Very exciting stuff!
Some quick pictures:
The finished harness (well, the parts that can easily be seen).

The new injectors. These things are about the same size as the stock injectors.

Testing out the wiring. That's the injectors pulsing.
http://vid49.photobucket.com/albums/...psf29fmktx.mp4
Other things that are working properly

I'm hoping to pick up some exhaust wrap and more fueling stuff within the next couple weeks.

[Seerlah]

So........... *crickets*

[chris164935]

I got nothing. November/December took away all my budget, unfortunately. But, I'll be able to get all the parts I need for the fuel lines come February (if my wife doesn't keep spending all my money ). For now, all I've been able to accomplish is getting the crank bolt properly torqued. I also ordered brand new bolts for the cam caps. Once those arrive, we will finish up timing the cams.

I'm also currently on the hunt for an S4 front bumper, so if anyone knows someone selling one or if you're selling one yourself, get at me!

[chris164935]

Got a few more updates for you guys. I purchased some thermal wrap for the downpipe the other day and got the downpipe wrapped up today.


I also received my Fuelab FPR. This one is the mini version. It's so tiny and cute!


And, finally, I have ordered all the other parts I need to complete the fuel system (-AN lines and fittings and an IE fuel rail). I'm hoping I get everything by the weekend so I can do some work on that (I don't think the fuel rail will show up in time though).

Oh, and tomorrow, I plan to have the camshafts and engine timed up. It's getting close!

[viceprp]

I'm selling my surge tank, 044 Inline, -8 feed, -6 return, filter, custom fuel rail and FPR for $400 + shipping. All AN fittings & all.

Have well over $800 invested in it with less than 1000 miles on all of it.

[chris164935]

I'm selling my surge tank, 044 Inline, -8 feed, -6 return, filter, custom fuel rail and FPR for $400 + shipping. All AN fittings & all.

Have well over $800 invested in it with less than 1000 miles on all of it.

I've already got a dual 044 surge tank setup. Thanks though.

[chris164935]

Still coming along...


I'm picking up an S4 front bumper next week.

[Seerlah]

Is this going to be daily driven? Plan on hooking the heater core into the plumbing? Or no, simply because Florida?

[chris164935]

Is this going to be daily driven? Plan on hooking the heater core into the plumbing? Or no, simply because Florida?

I might take it out on the weekends for daily driving commutes (mainly, if I'm heading to work, as the roadway is pretty open on the weekends). But, mostly the car will be for track days and other activities.

As for the heater core, I am not sure what I am going to do yet. The heater core was not hooked up when I originally purchased the car. The guy selling it claimed the heater core was busted. I might pour some water into it to see what will happen... If it really is busted, then I won't hook it up or replace it. The car is in really great shape and I'd hate to mess anything up taking the entire dash out. Good news is that the car does have heated seats, so I can live without the heater core if need be.

[Seerlah]

You still have electronics down there. I would pressure test it at maybe 5-7psi with air and see if it holds. Dumb design by Audi. They wisened up with the b6 design.

[chris164935]

Yeah, it's my greatest nightmare.

Anyway, I finished up the wiring for the electronic throttle body and gas pedal today. Played around with the settings for it in Vi-PEC until the calibration tests were perfect. Now, I can do this:

The throttle body is an 80mm Hemi unit.
I know it doesn't seem like much, but it is a really good feeling when something you diagrammed out, worked on, and built comes together and works beautifully. Did I ever mention how much of a pain the ass wiring a motor is?

[chris164935]

Posting some new updates. I modified, flushed, and cleaned up the power steering system. I wired up a new fuel pressure sensor for the stand-alone. I also finished all the wastegate vac/boost lines. Got the fuel lines done up as well. I also ordered a Fuelab fuel filter that I plan to install on the feed line to the surge tank in the engine bay. I'm also planning to remove the stock filter and feed/return lines from the rear of the car and just use rubber fuel lines that will go from the hard lines under the car to the tank itself (my OEM lines are cut up and getting new ones would be too much hassle, plus too much $$). I also wired up my MAP sensor but while testing it, discovered that the thing is toast. So, I have to order another one (this time I'm ordering from a dealer, not 2nd hand).

Anyway, some pictures.
Here are the wastegate lines installed.


The fuel lines for the surge tank. The far back fuel line I plan to cut the hard line down and install the fuel filter there between the hard line and the surge tank.


Also, it was time to move on from my daily driver B5. She was old and starting to have A LOT more problems than I cared to fix. So, we went looking for a Golf R. Unfortunately, the dealer we went to sold their last Golf R the day before we showed up. Test drove a GTI with the performance package. It was fun, but the price tag was too much... For a VW. We hopped next door to the Audi dealer and picked up this bad boy. 2016 Audi A3 Premium 2.0T Quattro. Ibis White. It came equipped with the Winter of Audi package which included 19" wheels, the Sline body "kit", heated seats, black optic package, and a couple other little knickknacks. This car is a BLAST to drive with the quattro system. The added power over my B5 make if feel incredible. I thought I might miss the manual transmission, but the Stronic is amazing. It shifts so fast and so smooth. The Sport mode is fun. I will say though, that it isn't as quick yet to respond when I want to go in certain situations. For example, if a car is in front of me going slow and it finally merges over out of my way and the road is clear, I get down on the gas but it takes longer and more gas pedal for the Stronic to respond and downshift. Now, when it does finally respond: Holy shit! Anyway, here's a picture (sorry for it being a bit dirty, it was washed yesterday but the pollen in Florida right now is ridiculous).

[Seerlah]

You have two b5s? Of course if stock, or close to, the a3 will embarrass it. Hahaha

Do the newer A3s have Quattro? I believe the older generations ran haldex, while still rocking the quattro badge.

[chris164935]

Yeah, I believe they are still haldex systems. I don't know why they went with a transverse setup in the A3/S3. I had 2 B5s. Not sure if you remember (or knew), but my first big turbo car was a FWD silver B5. After messing with that for a long time, I decided to go a completely different route. Bought the red A4 with quattro and swapped the motors putting the silver B5 back to almost stock. I've been daily driving that since (about 8 years now). I love the new car though. And yes, it would destroy the stock B5. Lol. I just have to get used to a 100% working car again. With the silver B5, I had to do certain things to keep it from breaking. Easy turning so the axle wouldn't explode. Pulling on the driver door carefully so the panel wouldn't rip off. Also, it is night and day difference between the stock B5 brakes and the brakes on the A3. I thought my B5's brakes were pretty good. The A3's brakes blow t he B5's away. It has convinced to me save up for a big brake kit for my project B5.

[Seerlah]

I have st40s if interested. APR discontinued BBK. New pads, new lines, and basically brand new discs. Also new bleeder screws. Little project didn't complete. Want to strip paint completely, where I'm currently at with the project.

[SlowGolf]

Sub'd for updates

[chris164935]

I have a lot of updates, but I'm waiting until this weekend to go all out and share them all with you guys!

[chris164935]

Alright, so here are the updates!

A few weeks ago, I had finally gotten around to getting the camshafts timed. Everything thing was great. I made paint marks on the camshafts to make sure the next time I needed to install them, I could easily line them up. Got the cam chain and tensioner installed. Got the crankshaft to TDC and installed the timing belt. Everything was going great. Turned the crankshaft slowly by hand and it was a cake walk! Everything was pretty much perfect. No metal hitting metal sounds; no resistance from turning the motor; I could feel compression building and coming out of the spark plug holes. Then, by the 4th or 5th full rotation I heard a "Ting! Clank! Clank!" My heart sunk and I about died. After sulking for a few minutes, I decide to just dive in and figure out what the fuck had just happened. I pull the camshafts out and one of the lifters on the exhaust side nearly popped out of its bore. I pull that lifter and find my brand new valve like this:



These valves have never been used in a running motor before; they had zero hours/miles on them (as far as I know) except for the times I needed to rotate the exhaust camshaft to measure the gap between the lobes and the lifters for lash clearance. Emailed Supertech about the problem and the guy was just as confused as I was. He asks me to send him my valves so he can inspect them. By the end of it, none of us could figure out what caused it. My friend and I believe it might have been just a manufacturing defect, but the guy at Supertech says he has never seen anything like it before. Anyway, I worked out a deal with him for some of their new Sodium-filled Inconel exhaust valves. I also ordered new valve keepers and retainers because I had found out that Supertech had improved a lot of their products since the time when I purchased a lot of their stuff (I want to say I bought my valvetrain from them back in like 2008 or 2009). They also have markings on all of their stuff now for authenticity and for production purposes.
Newer style retainers (old one is on the left).


New exhaust valves (one of them at least, I had already inserted the rest into the head before I realized I should take some pictures).



So, that has been the biggest hold up to the project, but the motor is pretty much back on track now.
I ordered one of UroTuning's aluminum head coolant flanges. A very nice piece. I was definitely surprised by the quality for the price. I also picked up some TT caliper carriers, larger brake rotors to match, and rebuilt my calipers (and painted them black).




New metal slave cylinder installed with SS braided line.

Missing the head.

New valves, retainers, and keepers installed and waiting for me to get a torque wrench to install the head again.


So, once I get the head installed back on the block, the next step will be to measure the clearance between the camshaft lobes and the lifters to figure out the proper clearance needed for new lash caps. After that, it should be as simple as aligning the markings again and then trying once more to turn the motor by hand and hope nothing breaks for no reason.

Lastly, I would like to take a moment to mention how awesome the guys over at Supertech really are. They went above and beyond to help me with the valve issue and were quick to respond to my inquiries and requests. They worked with me and gave me a great deal on a new set of parts that they really didn't have to. I highly recommend you use their products just because of the great customer service.

[chris164935]

Another update.
New wheels showed up today. They are 17"x7.5" Alzor wheels. They look similar to the Audi Twist wheels that came in some titanium packages (at least, I think they look similar anyway). Can't wait to get some tires on them.

[Seerlah]

Trying to actually drive it this year? lol

[chris164935]

God, I hope so! The sooner I get it running the sooner I don't have to spend anymore money on it (right away). Lol.