Sebastian's '93 UrS4 SMURFETTE85 - Motor Burning Oil

[chaloux]

Disconnect the n75 and run spring pressure (or set dc to 0). It's more than enough for break in and will keep you safe just in case. That's also awesome on ie's part, makes it easy to support them like the other vendors here.

[S4Pirate]

Was making pretty good progress. Got the new core mount all welded up, pulled the head off, and picking up the new one from the machine shop tmrw (friday).

As the head is sitting on the workbench with the turbo attached, I took a closer look and sure enough looks like something small made it past the filter. Put a decent bend in one fin, slight tweak to another, and a nick in the blade edge of another.

So...is this turbo junk now? Can I still run 15lbs through it during the breakin? Should I not even bolt it back up? Kinda bummed to find this but always seems to be something so I was just waiting to see what it would be this time. Maybe it's time to go billet...does this still count as a core Hank?

[Hank]

Yes, we can billet that. Send it in.

Hank

[chaloux]

Yes, we can billet that. Send it in.

Hank

AWW YEEEAAAAHHHHH!

[EDIGREG]

That sucks. You could run it without any ill effects besides less air volume and efficiency.

BUT if it were me, I'd upgrade to billet

[S4Pirate]

Yes, we can billet that. Send it in.

Hank

<Oprah voice> Everybody look under their seats! You get a billet! And you get a billet </voice>

Cool - will talk to you soon!

[S4Pirate]

That sucks. You could run it without any ill effects besides less air volume and efficiency.

BUT if it were me, I'd upgrade to billet

You? Upgrade?

At least I can break the motor in. I suppose I could use a spare k24 but I don't have a solid tune for it.

[EDIGREG]

<Oprah voice> Everybody look under their seats! You get a billet! And you get a billet </voice>

[chaloux]

BUT if it were me, I'd upgrade to billet

Yeah dude, just ask yourself, "what would ed do?"

sage advice

[EDIGREG]

hahah agreed

[S4Pirate]

Got a chance to get the cylinders honed tonight (thanks to Marc for letting me borrow his flex hone).

Turbo will be on its way to Hank tomorrow and hopefully a new set of rods will be here in the next week or so (slight mixup with what I ordered but doesn't make a huge difference at this point since the turbo is headed west anyway).









Going to finish up the intercooler tomorrow (just need to tweak a pipe or 2) and that's about all I can do until I get the rods in so I can start buttoning everything back up. Stock rod bearings looked in great shape - hoping the mains are the same as I'm not changing those.

Time for a or

[S4Pirate]

The snail is officially en route to IMS

Big thanks to Hank for a quick turnaround time

Can't wait to get this billet goodness in 2 weeks!

[chaloux]

UPDAAAAAAAAAAATE

[S4Pirate]

Will do a write up this week! God damn sharks...

[Hank]

Been a busy week for you! That is a lot of progress from needing rods to having a successful dyno pull. Good work.

[Audilard]

Will do a write up this week! God damn sharks...

[chaloux]

Man I'm living vicariously through you!


on my stinking phone!

[4v6]

Looking good but just a note of caution on the honing.

Flex hones are the bees knees i dont use anything else, initially getting it sized at the machine shop they use stones i always apply a flex hone afterwards, its pretty much impossible to cock it up and its unbeatable, however you absolutely must be thorough when cleaning the bores afterwards.

Best way is to use a nylon toilet brush in a drill and hot water with detergent and a rust inhibitor such as Jizer, dont use solvents it wont work as well.
Then dry it all off and scrub the bores with clean lint free paper towels, using white ones helps you see whhats coming out the honing pattern drenched with auto trans fluid.
Youd be amazed how much crud will come out the bores using ATF even after you think its clean, just do each one in turn and when the bores are clean the towels will be clean(apart from all the atf on it..).

If you dont do that the rings will get torn to bits by the crud entrained in the honing and itll never bed in, ittl just burn oil a lot though!

Couple of photos of one i did earlier to show what i mean about the bore state after cleaning.

[S4Pirate]

Thanks - we spent a good amount of time cleaning up the cylinder walls as you mentioned.

I'll do a leak down test after 1000 miles. But it's making good power so I believe all is well.

Hank - it was a very busy week. I literally worked myself sick...have a full on cold to the nth degree.

As for driving impressions - it spools stupid early. I'll have a more thorough update in a few days as I'm off most of the week.

Only have a couple small things left to do, including finishing the exhaust cutout and building a bumper.

For now - I'm just trying to avoid da .

[urs6ville]

I can feel an E85 tune in my near future..... the only difference on your setup is the polished/ported/oversize head right? No milled out hot side or anything?

If the head is the only difference it would be interesting to see what the difference would be.

Did you spin yourself a base E85 tune so you could get up to Marc's place? Or just manage on the pump tune?

Feel better man, not surprised you got sick.. you had a looooong haul getting from engine in pieces to tuned.

[urs6ville]

Or just manage on the pump tune?

heh.. nevermind, just started reading about E85 characteristics... yea, AFR/etc all different, so no, no pump gas tune... duh

[S4Pirate]

I can feel an E85 tune in my near future..... the only difference on your setup is the polished/ported/oversize head right? No milled out hot side or anything?

If the head is the only difference it would be interesting to see what the difference would be.

Did you spin yourself a base E85 tune so you could get up to Marc's place? Or just manage on the pump tune?

Feel better man, not surprised you got sick.. you had a looooong haul getting from engine in pieces to tuned.

ported/polished/oversized valves and also ported intake manifold

we did a base tune on e85 for wills car which ended up being basically just right for my setup as well to get decent mileage up to marc's

thanks - feeling a little better today. hopefully good to drink some beers on thursday

[S4Pirate]

I'll probably post this in iterations as the fear of losing what I've typed crests my mental high mark.

Here's where we ended up hardware wise:
-ported and polished head with oversized valves
-ported intake manifold
-DMF rods
-Coated rod bearings
-Freshly honed block and new rings

I think the only other piece of changed hardware not in my original post would be the turbo. Obviously if you've read this far you saw the bent find on my original RS2 turbo so it got sent to Hank to get dat billet.

Huge tHanks (get it?) to Hank for getting me a billet turbo back 2 weeks from the day I shipped it. Went well out of his way for me and even called my cell to make sure it would get here in time. (sorry I had to message you back but I was stuck in a meeting when I got you voicemail)

We headed up to EFI Express on 6/29...the motor only started to go back together about a week before. It was a huge clusterfuck time wise but big thanks to Will for helping out the last 2 days to make sure we could make it to Marc's in time. I got about 7 hours of sleep between Thursday through Saturday. Did I mention the car didn't start for the first time until Friday night? As in...the night before we headed to NH?

Motor was broken in on pump gas. Then we wrapped up an E85 base tune somewhere around 2:30 am Saturday morning. I woke up about 3 hours later to hit the road to NH. Truth be told, this is exactly what I was trying to avoid but a series of unexpected events pushed us right up to the zerohour.

There was absolutely no way we weren't headed to Marc's on 6/29. I wasn't waiting another month for his dyno to come back to him so that was the main driving motivation throughout the last week. I had to completely re-plumb the new core's piping as well.

---Save As ---> PostNowBeforeILoseIt.txt ---

[S4Pirate]

This is a photo from 6/28 sometime after midnight...departure hour: T-6hours...



Here was another piece of motivation. I had been saving this in my camera roll for over 3 months:



Some arrival photos stolen from JC:

[chaloux]

I like where this is headed...

on my stinking phone!