AEB 254267 My build thread

[Rodgman15]

Said fuck it to painting the trans, that shit is for girls if it ain't adding power or providing extra mechanical features.



Slave cylinder is now fitted with a stainless line and 3AN fittings.

Motor and trans are resting in the chassis, gotta bolt up the axles, rear prop shaft, and trans mounts and put the front clip back on, then she's good to fire. Gonna run shit dino oil through it until the oil temp is warm, then drain and refill with Brad Penn break in oil, and proceed to try and blow it up .



Hopefully I get some cool videos out of the deal.


Ordered my manifold diy kit through Treadstone, cast stainless 304, so the old engine is going to be my fitment guinea pig for my Holset. Also have an aeromotive afpr and fuel pressure gauge on the way, as well as a set of Bosch 1000cc injectors on the way, so hopefully next week I'll have everything short of an line and fittings (which I can get here in town).



Walbro 450, bosch wideband, and manual tensioner tool showed up today as well. Making progress!

[A1 A2 German]

Or sandblast it, a $20 gun and 20 mins.

Do it do it, show me that fresh aluminum!

[Rodgman15]

Sorry boss already installed lol. If this wasn't my daily and I had a few more days with my borrowed pickup I'd do more, but the situation is just that.

[Avant Nate]

But wait, you can't see the transmission in that picture...or ever.

[A1 A2 German]

You should pull it and consider polishing it.

[Rodgman15]

First start, complete success! Sea foam had nothing on how bad this thing smoked lol. Let the oil and coolant get good and hot, shut er down, good as gold. No leaks no noises, much better than expected.

Tomorrow I'm pulling it all apart because I'll never be able to sleep knowing the trans isn't painted

[A1 A2 German]

Thank God, so nickle plating it is, good call!

[Rodgman15]

Pulled the trans and it's being sent to Abu Dhabi for 24k gold plating, or something like that .

All joking aside, A1 A2 German I used a few of your diy threads on this bad boy, stainless clutch lines and under manifold coolant pipe, so thank you! Gotta give credit where it's due!


I think I welded the under manifold pipe a bit goofy, so I may try to make another that fits a little better.

[demonmk2]

Are you getting it dyno'd when your finished?

[Rodgman15]

Oh absolutely! That's ultimately the last step, as the local dyno tuner here does tons of tuning. I'm hoping he's willing to take on Maestro, pretty sure he's never dabbled with it but it seems like other stand alone systems so should be no issue. After everything is said and done I'll let him put it up on the all wheeler and perfect the tuning according to the dyno.

I'll be getting my exhaust manifold kit from Treadstone next week, and I'm guessing I've got about 40 hours minimum of cutting and welding to fab that up. Once that's done, the Holset and fuel components go in, then it's on to tuning!

[A1 A2 German]

Thank God! I'll sleep fantastic tonight, mo betta then ever!


I believe I mentioned in the Metal Slave thread if you use a ~4' line it gives you the leeway to drop the trans with out removing the slave if ever in those situations. You can use a shorter line, yet will have to pop off the line or remove the slave if you drop the trans. The difference is ~$10 so better to go with the longer line for those who are planing down the road.

[Rodgman15]

Well this is like the fourth time doing a slave and my bay is gutted enough they're easy to do, so the 2 foot line is plenty.



It's party time!

[Rodgman15]

Have about 150 hard miles on the new engine, everything is holding together well. Taking a trip about an hour north back home, so i'll be taking back roads and absolutely beating the life out of it.



Awaiting an email back from eurodyne to get maestro going. Excited to check this out, even with limited aeb support, should hopefully still do everything I want it to.





Got a few other miscellaneous parts, 12an oil drain for the turbo, t31 outlet to vband adapter, and my injectors. Had that cheap fuel rail sitting around so I stuffed em in there to see how it would look. I'm going to make brackets for that rail, but I'm thinking I'm going to end up buying a different one, depending on whether it leaks or not, we'll see.

I really hope the exhaust manifold kit shows up today so I can start welding that together, it's going to be totally trick. Polishing every piece before it gets tig welded. Stoked!

[nynoah]

I really hope the exhaust manifold kit shows up today so I can start welding that together, it's going to be totally trick. Polishing every piece before it gets tig welded. Stoked!

Fuel rail leaks = fire = no fun

[Rodgman15]

Ya that's kinda what i'm thinking. I don't mess with that fire shit lol. From what i've read on AZ it's been hit and miss for people with cheap fuel rails, but like nynoah said, fire=no fun, so i'd rather hit than miss.

On a positive note, Eurodyne has lived up to their reputation of awesome customer service and got back to me right away this morning. Going to set Maestro up after work and see what kind of mess I can make.

[redline380]

I have an 034 rail and have had no problems with the rail itself. However, I have burst a fuel line, ripped an injector oring and had the bolt that was holding the rail down strip out. Both times provided decent size fuel leaks.

After the first problem, I put an extinguisher in my car. Im not going to be the guy that watches their car burn to the ground

[Rodgman15]

I have an 034 rail and have had no problems with the rail itself. However, I have burst a fuel line, ripped an injector oring and had the bolt that was holding the rail down strip out. Both times provided decent size fuel leaks.

After the first problem, I put an extinguisher in my car. Im not going to be the guy that watches their car burn to the ground

Shit, i've already got an extinguisher in my car lol

[Rodgman15]

So, i'm absolutely stuck with Maestro. I was able to read the ECU and send that info over to Eurodyne, I got my credits and downloaded a base map, but i'm unable to write to the ECU no matter what I do. They were very helpful last night trying to diagnose the issue, but I never did find the gremlin. They were talking about the K and L line being screwed up, and I did lots of reading about that, Ross-Tech has a good write up about "the aftermarket radio problem". Unfortunately, none of that applied to me, nor did pulling fuses help. My question to you gurus is: if the ECU already had a tune on it, would that make in unable to flash? I honestly have no clue what tune it could be, nothing on the case or the inside of the ECU. Thing is i've never had an issue hooking a scanner up to it, hell I have a bluetooth scanner that lives in the OBD port to clear my Evap CELs. Any insight anyone can provide would be much appreciated, I suppose my next shot should be getting a stock ECU and trying that. Anyone got a spare stock AEB 5-speed ECU on the cheap? lol

[redline380]

Stock ecu could be physically chipped. I'd take that apart and check

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[Rodgman15]

So if in fact it is chipped (which i'm pretty sure it is), would that make it so that it couldn't be flashed?

[Wet0willy01]

i saw the brake light is on, does the ABS light also flash? if so Unplug your ABS module and try to communicate with the ECU.

[Rodgman15]

Abs light does not flash and works properly, parking brake was set. Removed the fuse last night, I'll try the whole module tonight.

If I turn the ignition on the check engine light doesn't come on with the dongle plugged in, but if I plug the dongle in after the ignition is on (and start the flash in 5 seconds according to eurodyne) the check engine light stays on.

I'll have to pull the ecu apart and get a pic, I have no clue what a chipped one/stock one look like.

[Wrath And Tears]

If you have a boost gauge and are boosting past 7/8 PSI you have a tune on that ecu and it can't be flashed.

[Rodgman15]

Ok perfect, I thought I has read that somewhere but needed a definite answer. I'll find myself a cheap stock ecu.

[Wrath And Tears]

Yeah, when the tune involves them resoldering on a chip to the ECU, then it can't be flashed. I'm not exactly sure why, I did my fair share of modding xboxes and stuff and it was always easy to flash the mod chip, but cars seem to be stuck in ancient times as far as computers and computing power goes.

I assume the modders "lock" the chip they solder in. Or it differs just enough from the stock chip that the flash won't take.

Edit: For example data travels through modern cars at a max speed of .5Mbps..... what year is this? (Might not be 100% accurate, this is second hand information from a BMW class my coworker and boss have taken, so I might be remembering it wrong. I get to take it next month. Even if I'm wrong the speeds are incredibly slow)

[Rodgman15]

Sure sure that makes sense, good info!

From what I understand 557n and 557p ecus are interchangeable correct?

[redline380]

Sure sure that makes sense, good info!

From what I understand 557n and 557p ecus are interchangeable correct?

Ones better than the other for some reason I can't remember, but yeah I do believe they are interchangeable.

I would take apart your ecu just to make sure it is chipped first.

If you indeed need one, just hit up car-part.com. I looked and it doesn't seem like there are any in your area. If really needed, I could grab one around S. Cloud (there is one in Royalton) or down in the cities somewhere. You should ask if they will ship it though because many yards will.

[Rodgman15]

Ah yes, Royalton. Funny story, I went there to pickup a rear door (which was smashed to shit on my car), but I had to stop in Staples to rock a piss. As I was coming back outside to my car, some hillbilly fuck in a Chevy pickup hit my door on the other side, and drove off. Unfortunately for him I got his plates, and got just shy of $1000 for "damages and repairs". We partied.

I'll hit up Rick's and see if he's willing to ship one my way, otherwise eBay has some really cheap ones, i'll just wait a few days for shipping. If not, i'll let you know and I can paypal you a stack of cash.

[redline380]

Ah yes, Royalton. Funny story, I went there to pickup a rear door (which was smashed to shit on my car), but I had to stop in Staples to rock a piss. As I was coming back outside to my car, some hillbilly fuck in a Chevy pickup hit my door on the other side, and drove off. Unfortunately for him I got his plates, and got just shy of $1000 for "damages and repairs". We partied.

I'll hit up Rick's and see if he's willing to ship one my way, otherwise eBay has some really cheap ones, i'll just wait a few days for shipping. If not, i'll let you know and I can paypal you a stack of cash.

Rick's is only a few miles up the road from me and I got nothing going on tomorrow. Let me know.

[Rodgman15]

Well, so far I have about 600 miles on the new engine, and the brand new oem audi coolant flange leaks, imagine that. Should have an aluminum one on the way in a few days. If I decide to go through with the whole process I'll post pics up, but I'm thinking I may just make an aluminum flange that eliminates the o-ring. We'll see.

For anyone interested, I beat the ever living shit out of my engine from mile 1 and will continue to do so until 1000 miles when I switch over to full synthetic. I've been driving it like I stole it, as that's how we've always done with our dirt track cars. There's no doubt in my mind that's the way it needs to be done.



Found a 557P ecu on ebay for $25 so I couldn't pass that deal up. I'm going to give maestro another try tonight to see if that fixes my issues, being mine is chipped / flashed whatever you wanna call it. Wish me luck!

[Avant Nate]

What tune are you using to break in your engine? The flashed one? I'm pretty close to completion on my rebuilt engine, and figuring out how I'm going to break it in.

[Rodgman15]

Ya, I had a flashed ecu that ran about 15-16 psi, I kept the boost at about 7 for the first hundred miles or so. Lots of boost, lots of vacuum, repeat, then repeat again. After the first 100 I cranked it up and it's been running like a raped ape.

[Rodgman15]

Starting in on this bastard. Lots of cutting to be done. Luckily I was able to get my hands on an ice kit courtesy of a hot rod shop in town, so that'll take all the guess work out of the fabrication!







Had this sexy bitch in the shop last night too, bad o2s fucking it up.

[Avant Nate]

Those are very cool! Where can you get them? I was just thinking about starting a thread in Tech about ideal placement of the turbo, whether parallel to the head or angled downward like the full race, height and what not. Have you thought about doing the manifold in twin scroll?

[Rodgman15]

Ya, it's a pretty awesome setup, expensive as shit though.
http://www.icengineworks.com

I think I'm going to try placing it a bit back more and slightly angled for better downpipe/tip placement due to the size of the turbo.

[Rodgman15]

Have you thought about doing the manifold in twin scroll?

Totally missed this part. I'm not going to pretend to know everything about turbos. Air goes in, magic happens, tires melt lol. The original HX35 12cm exhaust housing IS in fact a twin scroll, but I've got a different housing from Tim's Turbos that ISN'T a twin scroll. As far I know there's no reason for a twin scroll manifold if the turbo can't take advantage of it, but someone please correct me if i'm wrong.

[redline380]

Totally missed this part. I'm not going to pretend to know everything about turbos. Air goes in, magic happens, tires melt lol. The original HX35 12cm exhaust housing IS in fact a twin scroll, but I've got a different housing from Tim's Turbos that ISN'T a twin scroll. As far I know there's no reason for a twin scroll manifold if the turbo can't take advantage of it, but someone please correct me if i'm wrong.

Yes, you would need a twin scroll housing to take advantage of it. But twin scroll would be worth the extra effort IMO. The only thing that sucks is you would have to fit two wastegates in there and that is tough to do on a b5.

[Rodgman15]

That was the understanding that I had. I saw that VRMM fella on here modified a wastegate tube into twin scroll to get away with just having 1 wastegate. Obviously i'm no scientist so I don't know if that's something a guy can get away with or not. Seems to be working for him!

[Rodgman15]

Manifold day at the shop! Finally getting some decent weather is a big motivator!

Generic picture of AEB manifold:



Still needs a bit here and there:



Came up with a rough idea for my exhaust manifold. Need to make sure I know what wastegate I'll be going with so everything is oriented correctly.







No clue if anything will clear lol

[Avant Nate]

I can get you rail measurements etc. tomorrow, I just pulled my manifold, turbo, etc. Gotta love emissions.

The waste gate position is weird, I would test both turbo and wastegate fitment before anything else. Where you planning routing back into exhaust or open dump?