B4Q 80-AEB; TD04HL-15T-> Test run video

[alxdgr8]

What did those poly bushings for the inner tie rod come from? Want to replace mine but it doesn't look like anyone makes any.

[ringbearer]

Powerflex?

[ChrisAudi80]

What did those poly bushings for the inner tie rod come from? Want to replace mine but it doesn't look like anyone makes any.

Oh, they were some PU parts locally made laying around my mechanic's shop. They were close, but had to be machined to be made to fit.

Not Powerflex.

I'm not 100% satisfied with them because the sleeve is not the same diameter as stock, but works for now.
It would be better to use the old steel sleeves and pour PU around them.

[ChrisAudi80]

Been a long time since updates and plenty of things have happened.

In June, spent a bunch on new EBC rotors and EBC Red Stuff pads all around. Sure makes a difference, but not major. Unless working the brakes hard. They bite harder when warmed up. Got the stock calipers painted red.

Also got some more bushings from AK MS. Front and rear ARB and snub mount.

The fuel tank has been redone. It's actually bolted to the chassis now and has a rollover valve on the vent! Redid the pump set up in the tank and relay wiring. Still not totally happy with it.

All rubber lines have been replaced with AN-6 PTFE hoses and I got a great deal on a Fuelab regulator and billet fuel rail from speedingG60.
All installed now with a 100psi fuel pressure sensor. I have also installed a post-turbo pressure sensor and put the EGT sensor in the same place to use as post-turbo temp sensor. Works great. In full boost, outlet temps can hit up to 180c, IM IAT shows 52c or so.

The stock PCV system has been completely eliminated and got the block breather adapter from IE that connects to an AN-10 push-on going to the catch can.

Coming up is the turbo swap. Bought a SAAB TD04HL-15T, no shaft play. Got a cast EM with T25 flange. Should be good for 300 crank. It'll run out of injector at 3 bar base pressure, but might squeeze by if going to 4 bar which corresponds to 727cc.

Learning more about tuning. The tune is getting better, IMO. No idea where I am on the Dunning-Kruger curve.

However, the clutch now slips. It has 50,000kms of abuse on it so I guess that is OK life span. Will get it redone when the turbo swap is being done.

[ChrisAudi80]

Clutch swap and turbo swap in progress. Did a bunch of work this past week.

The rebuilt clutch and pressure plate assembly arrived Friday late, so don't have any pictures of that now, but I do have some of the old clutch plate. As you can see, it was done and left a bunch of shit inside the bellhousing.

The TD04HL-15T is fitted on the EM. The stock oil feed line bolts up, but the hardline had to be shortened 70mm and rotated about 45 degrees.
Coolant feed was relatively easy too. Used a banjo fitting I had laying around for that. Connects right up to the stock hose. Oil and water return is up next week.
One of the AC lines to the dryer was in the way of the oil drain and way too close to the turbine and down pipe. That has been modded too.
You can see what it was like.

Replaced the valve cover gasket as it was leaking.

Pics

[ChrisAudi80]

Today was a big day.

Had the car towed to the exhaust shop. Down pipe was modded to the new turbo and wrapped it. Have a 2.5" V-bad at the bottom now.
Also had them make the compressor to IC pipe and the intake pipe. Plenty of pie cuts.
I will put some kind of air box around it. Eventually.

The shop is a bit rough and not all the welds are pretty, but it works.

Also, pictures.

[ringbearer]

Sweet! Love the pics, no OSHA out your way

[pilihp2]

Welding barefoot with no gloves. ho man. that's hilarious.

[DE80q]

Welding barefoot with no gloves. ho man. that's hilarious.

Hey wait... He has flip flops on!

[ChrisAudi80]

You wouldn't believe some of the other shit I see in this country. Dudes welding with just sunglasses on.

Anyway, the clutch needs needed a lot more bleeding. It is still hard to get it into gear. The AC system needs a charge.
Really looking forward to driving and tuning this.

If I got this right, the turbo should be good for 300 crank.

[ChrisAudi80]

Went for a long drive today. About 300km or so.

This thing is LOUD! First thought the stock 710n was done, but then went for a boost leak test. Should have done that sooner.
Found three leaks. Fixed that.

The stock DV was fine, but still lots of whooshy sound. Very noise, much wow. An open pod filter is quite noisy.

Will see if I can make a decent vid to post up. The tune is coming along nicely. Only have it up to 170kpa at this time.
It does need more throttle input now to make boost, but it is quite controllable with throttle.

Smiles for miles

[ChrisAudi80]

Tuning boost control.

Target 180kpa, spikes a little to 192kpa. Sure is a different car now...

Anyone have advise for working with the circled part? I have read the boost control guide many times.
I think I get it, but need a few pointers.

[ChrisAudi80]

A little test run...

https://youtu.be/loehvMo0miE