eS2 evolution

[PRY4SNO]

You won't be able to put enough heat into the subframe to warp it, as the edges are really thin.

When I did mine, I used a pulse setting to keep the heat down. Prepped first by using a buffing wheel across the seams and above/below about two or three inches. Then, I laid a small bead, about an inch long. Moved the frame 90 degrees to the next side and laid down another small bead. Moved again, small bead. By the time I'd get back to the first bead it had cooled down and I just tied in another inch and moved to the second bead. Repeat until the seams are as sealed as possible (while leaving some spots for drainage). Then I cleaned up the edges with an abrasive wheel so it looked tidy and finally buffed the spatter clean.

[FFF]

You won't be able to put enough heat into the subframe to warp it, as the edges are really thin.

When I did mine, I used a pulse setting to keep the heat down. Prepped first by using a buffing wheel across the seams and above/below about two or three inches. Then, I laid a small bead, about an inch long. Moved the frame 90 degrees to the next side and laid down another small bead. Moved again, small bead. By the time I'd get back to the first bead it had cooled down and I just tied in another inch and moved to the second bead. Repeat until the seams are as sealed as possible (while leaving some spots for drainage). Then I cleaned up the edges with an abrasive wheel so it looked tidy and finally buffed the spatter clean.

Thanks, that’s kind of what I was thinking, hadn’t thought about the pulse setup... but I’ll do some testing.


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[jbrentd]

Love the attention to detail. Hopefully my engine bay will look that go soon.

Keep up the good work!

[FFF]

Love the attention to detail. Hopefully my engine bay will look that go soon.

Keep up the good work!

Thanks very much!!


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[FFF]

Everything pulled apart....







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[FFF]

Bad ass .. you’re not leaving anything untouched

Well, you know, while your in there...


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[PRY4SNO]

Bad ass .. you’re not leaving anything untouched

Well, you know, while your in there...


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What kind of paint/coating are you using after welding?

[FFF]

Bad ass .. you’re not leaving anything untouched

Well, you know, while your in there...


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What kind of paint/coating are you using after welding?

I am just planning on using POR 15.


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[PRY4SNO]

That the route I took as well.

I've heard that it adheres better if there's some surface rust, any truth to that?

[FFF]

I’ve always had good results with “slightly” rusted surfaces, the POR 15 tech documents suggest, rusted, seasoned or sand blasted metal for best adhesion - they also have a metal prep that I have used on brand new steel... so for the subframes and all of the suspension components I just use a scotch brite pad, then a quick wipe with lacquer thinner for a final clean...


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[FFF]

Ended up re doing my seam welding, didn’t like the first result, struggled with getting enough heat... much better round 2.





Pressed control arm bushings out...








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[FFF]

Summers over so back to work... rear subframe and suspension refurbishing.





While that’s drying started on mock-up for fuel regulator and filter.










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[PRY4SNO]

Ummm... more info on that filter, please! Where are you mounting it, what's the service interval, etc etc.

[FFF]

Ummm... more info on that filter, please! Where are you mounting it, what's the service interval, etc etc.

It’s the new Injector Dynamics filter, I also added the option for pressure and temperature sensing. Meets the Bosch filter spec which most filters don’t. 87% @ 5 microns. It’s got delta P pressure indicator so you can see when to change the filter.

It’s nice.

It’s the ID750
750 litres / hr with 1.1 psi pressure drop or 1000 litres / hr with 1.9 psi drop. Max pressure is 145 psi.

I’ll have a pre filter before my surge tanks, then this one followed by the regulator.

So the system is 044 in tank feeding 2 - 1 litre surge tanks with 044’s in them, return line back to surge tanks and then overflow back to main tank.

I’m planning on putting it on the firewall but need to get my strut bar from work to figure out exactly where...






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[FFF]

Also working on a bracket and mounting for my ECU...






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[FFF]

Moving stuff around in the garage... once the rear suspension in in I plan on dropping engine and transmission in so I can start pulling wire , fuel lines etc...

So when I pull stuff out, I have to unwrap and have another look...

Porting by FRP.







I have one of Issam’s throttle bodies here somewhere. In a box.




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[PRY4SNO]

Well done... that's a pretty badass filter and supply solution. I've started to reassess what I have/where I'm going with my build that way after having had a CR TDI for the last couple years. I'm about maxxed out on stock-ish set up and a DW300 right now, so when I go to upgrade the fueling, looks like I'll take a page out of your playbook here.

Manifolds look alright, those done by hand? Thought Mr. Gerner did CNC porting nowadays...

What's the community/manufacturer support like with that standalone ECU?

[FFF]

Well done... that's a pretty badass filter and supply solution. I've started to reassess what I have/where I'm going with my build that way after having had a CR TDI for the last couple years. I'm about maxxed out on stock-ish set up and a DW300 right now, so when I go to upgrade the fueling, looks like I'll take a page out of your playbook here.

Manifolds look alright, those done by hand? Thought Mr. Gerner did CNC porting nowadays...

What's the community/manufacturer support like with that standalone ECU?

The filter is higher end but solves a lot of potential problems and I really liked the dual sensor

Jeff does heads with CNC but he did the port matching by hand - the pictures don’t do it justice, it’s very nice work. The Wagner is very nice, he said he didn’t have to take much off.

Nothing in Calgary but Lightspeed in Red Deer is a dealer and worked with Emtron during development so they know the ECU very well. Emtron doesn’t do a great job promoting their stuff but from all of my research it is very good. I liked the features / cost when compared to other high end ECU’s.




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[Afterthought]

Those filter /FPR look and sound awesome.

Not much room on the firewall is there in these cars !!
I wish I would have gone with the red Audi coils in hindsight in my car to free up space .

[FFF]

Those filter /FPR look and sound awesome.

Not much room on the firewall is there in these cars !!
I wish I would have gone with the red Audi coils in hindsight in my car to free up space .

Agreed, I plan on switching to them purely for that reason.


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[Afterthought]

Did that intake come supplied with a throttle cable?
My intake manifold I think uses the same cable as what you'd use but I had to crimp a new end on it due to the pedal end being a hook. I think the B3 is the same but I can't remember

[FFF]

Needs a new cable, I purchased it from Audi Tradition before they decided to stop servicing customers... part number #893721555R


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[FFF]

So before reinstalling rear suspension etc I gave another scrub. When I pressure washed last time there was to much in the way to really clean it. The POR15 degreaser works very well.







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[FFF]

Starting to bolt the rear suspension on, rear diff should go in shortly but working on it still (upgrade to 108mm output flanges.





Also did a protective clear coat for a bunch of stuff that will be outside...






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[PRY4SNO]

Hey if it's not too much trouble can you post a few pics during the flange swap process and some notes? Haven't seen much on that over the years and it's on the to do list.

Your car's undercarriage gleams. When are you serving dinner?