The Project Pad

audifreakjim wrote:Amen to that. I run 034 rear tie rods. I think AK offers them now? The only special part is the tapered bolt for the knuckle side. If you can machine your own, they are easy to make

I believe Aaron (G-60) told me Issam figured it out, maybe made a few sets

Afterthought wrote:I was thinking of your car too. Are yours 17” ? I’m hoping these wheels will look ok on the b3. I’ve test fit and they clear front and rear . 17x8 ET32
Yours look great .

As far as the tie rod the boot was torn and thinking I would replace with new I damaged the treads a little , my stupid mistake as I didn’t know they were unobtanium . I bet the threads can be fixed .

Yes, 17s. I like the ride on 17s.
Nut on tie rods are different thread, real fine, compared to other nuts used on VAG products.

Greg W.

I haven’t worked on this at all sadly due to other things in life that have taken priority . But I haven’t forgotten about it .

I acquired some Por 15 brand caliper repainting kit , I know it’s not recommended to repaint calipers but I’m going to have to give it a try as mine are mismatched .

I’ll have to figure out soon what suspension to get . I was thinking of going the KW route .

I also started acquiring all the parts needed to swap to black interior since I never have liked platinum . I have almost a full interior , have a line on a black dash , just some trim parts here and there that are missing .

I’ve spent a good bit of time on the exhaust header . I didn’t really like the first one I made and I’ve wanted to revise the design and make it radial flow as Jim and others have said that’s the best .
I’ve had a few attempts at it now and I still can’t get it perfect . I can’t get radial flow no problem but equal length seems to be out of the question . So I tried to use as many 45 deg bends as possible and where I need a 90 I used long radius bends where able. The exception is the runner for #3 which is shorter but has some tight radius bend.
Tonight I screwed around and this is the best I can come up with yet.
I could try it again but If I do I would change the collector and experiment with that .

amazing !!!

Seriously awesome stuff in here.

I ordered some aluminum so I can drill the pattern into some heat sink/purge blocks and weld the manifolds together , then hopefully I can stop getting distracted and work on some other parts of the car . I just enjoy practicing welding and it makes me procrastinate on the things I don’t enjoy as much .

It would be nice if I could put the proper flanges on the 01E (I have them just need to put them in) , swap the driveshaft, figure out the front axle situation and finish the brakes . Once I have the axles in then I could do the rest of the exhaust , for now it’s only a down pipe

Nice work on that header. Gonna be a work of art when you get it finished.

I’ve got the b5 A4 rear diff parts in my
Possession . I’d heard from Jimolde that maybe I need to shorten these a few mm. So I removed what was in the 01E to check difference .
01E

01E vs the new used ones .




There are a few differences in dimension. But they do fit right in as is .
So now I guess the next step is to take a look at the axles I have laying around and see what I can use . I think I have all 4 from a b3 or all 4 from a 4000 at my disposal .

Looking great

Where did you get the header flange?

Cheers

I have heard both ways with the output shafts. I shortened the ones I have to match the 01E shafts so I k ew there would be no problem. Fair warning though, they are hardened, and take small cuts. I almost threw one out of a lathe. Don't forget to shorten the bolts too.

DE80q wrote:I have heard both ways with the output shafts. I shortened the ones I have to match the 01E shafts so I k ew there would be no problem. Fair warning though, they are hardened, and take small cuts. I almost threw one out of a lathe. Don't forget to shorten the bolts too.

I can see exactly what you’re saying ... so when comparing how they seat in the trans, the difference is about 3-4mm .
To me it looks like it will still seal no matter what , But if I get it fully seated that will help my axle fitment .

So here’s the difference .
Original 01E piece


B5 rear diff cup


Now I looked and the 4000 axles are useless as the spline is too small on the outer CV .
The b3 axles , drivers side fits perfect with no changes to anything .


Passenger side the axle is a little long .


With everything fully seated . I still have a few MM to go . My ball joint is adjusted all the way in, so I didn’t touch that yet- I think that I could easily make up the difference there , however . I think I will have a go at shortening the piece first and get things as close as possible before adjusting the ball joint and try and get it centered. So that’s good news , I can use my stock axles I guess.

highlander69 wrote:Looking great

Where did you get the header flange?

Cheers

The header flange is from a place here in WA that just started making a couple of billet parts for the 07k. The flange is first but I hear they are working on more. They also make the collector cutting fixture, which works realllly good.

The flange is really nice and much nicer than the other one I had used. Added bonus is the ID of the 1.25" tubing is a perfect match to the flange, so once its welded up I will have to barely any porting are polishing at all to have a perfect transition from flange to pipe. Its not the cheapest but its the nicest flange you could get .
https://www.lpsfab.com/product/vw-2-5l- ... 1-1-4-pipe

Ok so I got those shortened . I took off 0.125” and then shortened the bolts the same amount . Used a lathe with a steady rest and as mentioned above they are super hardened - well the inside is soft metal but the outside is hard. took off about 0.02 at a time, and low rpm (50) . After shortening I used a set of diamond files to clean the ends up and it works great.







Also made another EFR Indy specific flange to match this .








So what’s next is , get the cork CV gaskets in the mail, install axles . Finish manifold , downpipe, and remaining exhaust . I priced out 3.5” and had all the parts in the cart but at the end of the day I decided to use metal I already have and go 3”.



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awesome thanks.

Keep up the great work. I'm looking forward to seeing this done.

Great motivation for me to get back at it

I'm going to build my next manifold using this collector.

Looks good in my opinion.

https://www.race3.ca/fabrication-components

It looks good and probably great quality , but I didn’t use it for mine due to the size. It looks to be 1.75” so it’s made so that you would sleeve 1.5” pipe into it , like so .


I wanted to do 1.25 as it’s supposed to have the best characteristics for this size engine /turbo, as in spool faster but not limiting to power .
I also I wanted to try different merge angles and see what was the best middle ground between low angle and still being able to weld it .

Now with that said if you want to make 1.5” header you should be able to sleeve it in just fine and it might be even easier to weld .
I did make one of those larger dia. Headers just to do it, and it fits in the engine bay just fine and looks beefy as hell. Quite a bit bigger but not a problem with this much space .




Also if you want A smaller collector let me know and I could cut you one since I now have the cutting jig.

For any folks who have done the later 01E swap... I’ve got a question about the slave cylinder, didn’t get any lines with the transmission . I have a plastic slave cylinder , haven’t seen one like this yet .
I’m assuming I need the factory part , can’t just adapt to some standard flared fitting ?

Slave cylinder looks like this .

USP makes a phenomenal master -> slave cylinder and its reasonably priced as well. More so than it would be to source an older, OEM, almost bursting hose.

Hmm ok . Thanks . That sounds like a perfect solution

what year is that 01e you have? I did a TDI 01e out of an allroad in my 90 and I think i just used the stock 90 slave cylinder.

dana wrote:what year is that 01e you have? I did a TDI 01e out of an allroad in my 90 and I think i just used the stock 90 slave cylinder.

It’s from a 2003 A4 3.0 V6
That’s a good idea. When I get a chance today or tomorrow I will measure the OD of the slave and compare .

Ok bad news and bad news .

Bad news #1 : I haven’t had any time to work on anything .

Bad news #2: The stupid cork CV axle gaskets don’t fit . They are about 88 or 90mm m too small .




So, after looking into it again using 7Zap I'm not finding any gasket but I'm seeing a tube of sealant that looks like it runs about 100$ from Audi. So Im guessing ill either be cutting cork gaskets out with an exacto knife or using some sealant.


Bad news #3 : The brake calipers don’t fit over the rotors. This is the largest MC4 mechanical parking brake caliper I can find. So I want to make it work .
Rotor dia measures 22mm.
Distance between the pads is about 20.6mm
The pads are super thin, 6.9 mm each.

So I guess I have 3 options at least,
1- Sand the pads down somehow 1mm each
2-turn 2mm off the rotors
3- fixture this in the mill and mill this circled area where the back of the pad goes.
I may have an idea , when I get a day off I’ll look at it

Afterthought wrote:

dana wrote:what year is that 01e you have? I did a TDI 01e out of an allroad in my 90 and I think i just used the stock 90 slave cylinder.

It’s from a 2003 A4 3.0 V6
That’s a good idea. When I get a chance today or tomorrow I will measure the OD of the slave and compare .

Like Dana I used the stock metal slave on my b3 audi with an fyf 01e conversion also from the v6 a4.

Ok sounds good , thank you. This gives me plenty of options to find a good setup.


So maybe it’s time for me to figure this out , I keep going back and forth .
What is going to get me a better setup...

The KW suspension or the 2bennett special ?
The KW , I don’t know anything about the spring rates or quality .
the 2B is easy to make work too , I can put in whatever spring rates I want and have single or double adjustable koni dampers .

Regarding the spring rates I don’t know what I should be looking for , but I would probably go stiffer than what’s in my UrQuattro . I have 340 front 440 rear springs in that (might be backwards I don’t know)