My "Oh what the hell...I post a build thread" thread

[M-Hood]

Cam gear not set right for the cams?

[stunner247]

Wjat does the timing look like when the power cuts?

18.5 degrees. looks good the whole way

Cam gear not set right for the cams?

Maybe...I have the cam gear 2 degrees advanced to shift my power band in a little sooner cause it was very laggy under 5k rpm.

I have had this problem though for a few months. When I went to the track a few months ago I was tell my friends that it felt like the power dropped off around 6000 rpm then came back in just after. I had the Schrick cams and stock manifold on at that time so I think it is a pre-existing issue not relating to the current mods.

[stunner247]

Better yet....

Here's one of the first runs I had when it was doing it (only vid that I got that day) . If you listen to it closely you can here to pitch change in 3rd at the 1.37sec mark then come back in...same thing that happened on the dyno.


Log from that run (blue bar shows approx when it happened)

[M-Hood]

So it only happens in 3rd gear? Boost doesn't look to be dropping when it happens.

[stunner247]

1st and 2nd go by to quick so I notice it in third and the dyno was in third. I imagine I would feel it in 4th but 6500 in 4th is bookin for the roads around here.

Yeah boost doesn't drop... in fact nothing drops out except power.

I'm going to redo my crankcase breather system and see what that does. Might be over pressurizing the engine causing compression to drop out under load...only idea I have at this time

[M-Hood]

At that power level the power just seems to be peaking really early seeing 82mph with the B5 01E is about 5800 and dropping after that which is well before the hesitation at 6500 rpm.


To me it seems like a flow restriction issue seeing the power doesn't come back on till after it has dropped down far enough. Were you able to get the raw dyno file and have a dyno sheet with the torque included?

[stunner247]

Yeah Mike I thought about flow restriction also. I will have to go back over everything and see if I can find any weak links. That being said, other then the manifold I haven't really changed anything in my intake and air charge system since I took it to the dyno last year.

For some reason Dan did not include the torque graphs...I will see if I can get them. From what I remember, the torque graph was smooth and peaking about 1000rpm before the power curve came in.

Here are all 6 runs overlaid. First 3 were at waistgate pressure (about 13psi at the intake man). 4th was 18 psi, 5th was 20 psi, 6th was 22 psi

[stunner247]

Wow it's been a while since I've been on here lol.

So after my last post I parked the car to concentrate on some other projects...2 years later I finally have started messing with the car again so I decided to post some updates. The engine was making some strange sounds and I never figured out what was going on with my power issues. Did a compression check and found cyl 1 and 4 to be pretty damn low so I decided to pull the motor and check everything.

It was in a sad state from sitting outside for so long



Cleaned her up, got her inside and started disassembly







Found some problems right off the bat. Passenger side motor mount was destroyed...no idea how long in was like that but it looks like a while




A little later I found the exhaust manifold was cracked badly. I imagine this was not helping the power delivery. The crack went about 60% of the way around the turbo flange.





Started pulling the rest of the motor apart. Still look pretty clean after 6 years





Pulled the head and found some more problems...valves had hit the pistons. I was kind of expecting this but hoping that I was wrong. When I installed the IE cams originally, I had the exhaust cam a tooth off on the chain side when I first started the motor. Had it running for a few seconds before I realized something was wrong but I guess that was enough.



Also found a lot of blow by in cyl 1 and 4



Pulled the main caps and found #3 bearing to be in bad shape. No damage to the crank thankfully, guess I caught it just in time. All of the other bearings looked fine though

#3

[stunner247]

Big thanks to Fullrace for the warranty on the exhaust manifold. they built me an entirely new one for free and split the cost of ceramic coating so I was out $45





Also got a new set of JE FSR pistons and new supertech valves from Integrated. I decided to put over sized valves in it while I have everything apart and bump the bore up from 82.5 to 83mm. Head and block are at the machine shop right now

[spindoctor]

Looks good Gunner..

Just wondering, do you still have a/c? I saw your intake setup when it had the MAF. I assume it's the same minus the MAF or you've changed it completely?



Danny

[stunner247]

Thanks man. Yeah Im still running AC and the intake is similar to how it was with the maf. I will be changing multiple parts of my set up while I have the engine out so I might change th eintake set up also. I will keep everyone posted

[stunner247]

Pulled the head apart for machine shop fun




New 1mm oversized valves, seals, decked and cleaned

[spindoctor]

Tidy indeed Gunnar.

I'll have a chat with you on Facebook soon about your setup. I'm half way into my 1.9L EFR build.

[stunner247]

Some more updates....Slow going but making progress

Went in with a friend on a new torque plate from Techtonics



Back from the machine shop, ready for paint and assembly





Main studs back in and new Mahle race bearings



Gapped all the rings and assembled the pistons...kind of a pain in the a$$ on the FSR's



...And back together



Also been messing around with the engine bay. I have a lot of respect for people that do body work but have decided it sucks!




Primed and ready for some paint

[stunner247]

Got a hair up my ass and decided to relocate the ABS pump to the cowl area. Almost done

Cut up the factory bracket and welded it to the battery tray







Made a bunch of brake lines

[NeedingAnAudi]

Might I recommend pulling the abs harness back into the interior and the routing it up through the ecu box? That's what I did and I feel it's a little cleaner looking.

Here you can see the hole and grommet in my ecu box.
10 by Alexander Krieter, on Flickr

[stunner247]

Cool, thanks for the idea. I have it routed through the heater core hose grommet right now but your way might work better

[stunner247]

Brake lines done



Engine bay painting done enough

[nynoah]

Love you car. Looks amazing. I wish I could find a B5 S4 bumper for mine.

[stunner247]

Thanks man. I'll keep my eyes out for one

[stunner247]

Engine is back in



Went away from the twin disk and went to a more traditional FX400. The twin disk was just to annoying to drive

[stunner247]

Some updates

Sent the intake manifold, throttle body and compressor housing out for polishing. Came out pretty good I think. Been hand polishing the other parts and ShineSealed everything.







Made some heat shielding




Started running turbo lines

[stunner247]

Been doing some fabricating

[spindoctor]

Coolant pipe looks damn good Gunnar. I hope to get mine started this week. Just sorting out little things that add up lol

[stunner247]

I hope it goes well too Danny! Been watching your build on the facebooks and it looks good. Hoping to have mine running in a week or two.

[stunner247]

Also been doing wiring...welcome to my hell

[spindoctor]

OK that is hell indeed lol.


Im looking at running a haltech elite 1500 or Link Fury after my tune's dialed in. flex fuel is something I really wanna have than anything else. Hopefully tomorrow its up and running ! :)

[stunner247]

Nice. look forward to seeing what your car can do after tuning. The wiring i'm doing is just to try to get the car through emissions lol. I'm working on having the stock ecm see everything but let the VEMS control the engine. This way i can get it to pass OBD testing without taking the standalone completely out. In theory it should work but I won't know for sure until I get it running

[stunner247]

Its running finally!!! (No the intake is not going to look like that)

[stunner247]

Back together and on the road. now for some tuning

[czum09]

I was laughing hard at that intake! Nice build, gotta love Fullrace.

[stunner247]

Thanks a lot. Feels good to have it back on the road after 3 years. Ended up getting first place at H20i which made it all the sweeter

[Seerlah]

Looking good. Makes me realise how much I need to address looks in engine bay. I really dont go to shows, so never rushed to get it done (I have all part, but it is a project never really wanted to get into for certain reasons (ie redo fuel lines in braided lines...just to spend the rest of day tending to one annoying leak that you end up cursing at like it can hear you, and leads to why my sig says what it does). But seeing your bay is an incentive.

Also update how it is at h2o. Didn't go last year because of hurricane, but year before that turned me off due to the traffic and extra shit thanks social media. Wanted to do go-cart racing before Audi gtg that year, and took us like 40 minutes to pass only a frew streets. Go cart spot on southside bridge off island. Stayed more up top to stay away from theives and shenanigans (heads up: it is up here where you see alot of stop light drag races. really good one that year with an e30 that took everyone off the lauch by like 1-2 cars. great launch). Took north bridge off to take scenic route to do some go carting. At this time, no longer time to get a couple rounds of go carting. Others stayed for carting, while I go back over bridge to island. Basically turned me off to h2o. Need info of it will be same this year to decide to attend future ones or not.

[stunner247]

Thanks man, I'm looking forward to seeing how your bay turns out. I never intended on making a show car and still dont consider it that either.I always wanted to have a bad ass street car that I could take to shows if I wanted then maybe hit the drag strip after lol. I concentrated on making everything functional and able to be worked on if need be. I just wanted it to be clean and look the way i wanted. I kept looking at it over the years and found my self thinking "i could do that better". I just took the opportunity to do everything while the engine was out and ended up being very happy and proud of how it came out.

As for H20... Its still a sh#t show however having the show the weekend after sunfest now instead of the same weekend helps. Traffic was bad on Saturday but better then past years. The rest of the time wasn't that bad. You could actually get around in a reasonable amount of time. We stay down at the bottom between 10th and 12th most years which is away from the real crazy stuff. I go down there now to meet up with friends I never see and have a good time. I stay away from the antics for the most part. I had a good time this year and the kart tracks that I saw weren't very packed at all. I would recommend giving it another shot

[stunner247]

So I have around 1k miles finally. I turned the boost up and went to do some logs when I found that the pressure would not go above 14psi. After some diagnosis I found that the CAT had blown apart internally and was lodged further down the exhaust causing a huge restriction. I ended up deleting the CAT temporarily and found that it has probably been partially blocked for some time because the car is WAY faster then its ever been now!

[stunner247]

Here is the first pull at 20 psi after addressing the CAT situation. Had to add a bunch of fuel to the top end of the map after this pull...as you can see the AFR gets way too lean at higher RPM. Its Amazing how higher flow demands more fuel LOL .

[jaychen]

Shit yeah. Been a few years since I checked in here. Nice work dude. Car finally romping like it should.

[stunner247]

Thanks a lot. I'm really excited

[stunner247]

Finnally got her on the dyno again with much better results. 431 awhp and 352 awtq @25psi on 93oct pump. Still needs some tuning. It was hitting some strange rev limit at 7500rpm even though nothing is set to that but oh well...making progress



(torque graph not included on print out because of rpm pickup problems)

[stunner247]

Also started doing some updating to the interior