The Project Pad

DE80q wrote:Those are the same rotors I have. If you have the small bearing knuckles, you will still have to space the caliper back to center it on the rotor.

do you have the rotors for the euro spec 90 sedan or the coupe quattro rotors? 90 sedan 276mm rotors have a different offset, maybe that is the issue requiring the backspacing? The part number I used is 893 615 301 for the lower offset rotors.
http://www.worldimpex.com/parts/brembo- ... 28102.html

I used this info, we will see if it was 100% correct when I bolt everything together. Test fit looks right. http://www.20v.org/brakeupg.htm#G60

I don't remember the part# I used, but they were listed by brembo for the 1991 90q 20v sedan. They have a much lower ofset than the CQ and B4 rotors I had lieing around.

hmm, sounds like the same rotors that I used. Very noticeable difference in offset from the coupe rotors I have. I guess the larger knuckle has a different offset at the caliper mounting tabs.

I think the difference I have it useig the 80q front hubs with the 75mm bearing. I believe they have a lower offset than the 90q 20v with the 82mm bearings.

bolted rotors and carriers on and it all fits without spacers. Success.

That must be the difference between the 75mm knuckle, and the 82mm knuckle. I'm glad it was just a bolt on affair for you.

Wow great move forward again, can't wait to see the final result, congrats for this amazing job Dana !

Dana when will you be driving it?

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I want to get a drive over the mountain in the snow this year. That would be totally possible if I hadn't gotten the bigger turbo, but I still think it will be possible. I am 99% ready to drop in the 01e, then I can do the fab work to fit the new turbo and build an exhaust...then wiring, then a bit of body work, then its done.

It is back on all 4 wheels right this moment for the first time in years. Every bushing, bearing, ball joint etc is new. I will need to replace the poly subframe bushings with Tacos updated bushings, but I think i can do them with subframes in.

My only hard deadline coming up is carlisle in may. I got to get this thing done since I am in the early stages of planning a tear down and rebuild of my house. Got to get this done before that or I will never get it done.

6 speed 01e is in, fully mounted, shifting and has axles!
I used:
-b4 90 fwd axles that fit the TDI trans tripod joints
-second hand set of hanks first generation rs2 replica mounts
-made some spacers for the mount on the passenger side from some old inner control arm bushing sleaves
-made up a lower downpipe hanger bracket to hang from the passenger side mount
-cut down the 01a trans bolts to work with hanks mounts
-stock 90 20v outer knuckles
-276mm g60 rotors
-g60s from a coupe quattro
-early b5 s4 linkage. I had to actually lengthen mine about 1.25 inches. I redid this several times because I really didnt like how it shifted. At first I made a short shifter using the mk1 vw shifter, but I just didnt like the reverse lockout action. I ended up using the slightly worn factory shifter flipped (so reverse lockout is correct with 01e pattern) I cut the end off the original linkage with 1.25" extra and mated that to the b5 s4 linkage. Shifts as well an an 01e can now. Damn things are notchy.
-b5 s4 shift knob
-audi 4000 driveshaft. (not yet installed, assuming this will fit)

No pics of it installed, but I am glad to have that hurdle cleared.

Downpipe hanger bracket

more salvaging from this old winch mount plate. This thing is all over my car. Many brackets including motor mounts were made from this thing.






had this random hanger that came on the TDI trans, didnt work for my application, so I scavenged it too.


you can see the spacers made from the control arm sleeves, perfect for this


mounts all painted up


hanger

Nice work Dana! I love the reclaimed pieces you use. Will be awesome to see this thing at Carlisle.

6-speed going in












k03 turbo removed, and ready for holset


TDI cluster! Will have to put my mph speedo into this cluster


its officially a 6 speed now!

Very nice as always, glad you got a real turbo so I won't be so embarrassed cruising to Carlisle alongside it

vt10vt wrote:Very nice as always, glad you got a real turbo so I won't be so embarrassed cruising to Carlisle alongside it

Are you planning to do that? Would be nice to see you again too!

vt10vt wrote:Very nice as always, glad you got a real turbo so I won't be so embarrassed cruising to Carlisle alongside it

yes!

Yeah now we can go get street racing tickets in the TDI!!

I mean... Failure to obey a traffic sign

not sure we can make such a spectacle as last time with a lowly TDI. Maybe i can get a ticket for rolling coal? That seems like something that might now be illicit in PA.

As of last night, my car now has a full and complete drivetrain in it for the first time in a VERY long time. This is pretty exciting. The chassis restoration portion of this project got out of control. It has been super fun and rewarding though. No stone left unturned.....and this car needed EVERY stone turned over. It looked nice, but it was a raging pyle of crap.

big ol injectors!

This thread needs videos!

RACE 520's?! I approve! They've worked out fantastically for me! Nice work!

PRA4WX wrote:RACE 520's?! I approve! They've worked out fantastically for me! Nice work!

they seem like a good choice, plenty of fuel for any amount of reasonable mods without getting crazy (read waaay to expensive). Trying to get someone to write a tune for this car is like pulling teeth. Its pissing me off so bad, Ive tried all the major tuners. Kerma was a straight dickhead, malone stopped responding, jeff at rocketchip was encouraging and liked the project but said the AHU cant take over 150hp (which i do NOT believe, and he never got back to me after talking on the phone), mike at TDtuning said he could and would do it, but takes 2 months to get back to me. I think MR Tuning in Quebec is going to do it, but still waiting to hear if hes burned the chips yet.

Makes me really annoyed that there isnt a decent and affordable self tuning option for these.

PRY4SNO wrote:This thread needs videos!

here you go! here it is running like a champ!
[youtube]https://www.youtube.com/watch?v=Ov-Wt5XNfX8[/youtube]

Holy fuck seriously? That's ridiculous. Shoulda used an ALH

dana wrote:here you go! here it is running like a champ!
[youtube]http://www.youtube.com/watch?v=Ov-Wt5XNfX8[/youtube]

Tapatalk friendly link

chaloux wrote:Holy fuck seriously? That's ridiculous. Shoulda used an ALH

This is what I had, so thats what i used. Internally it has the same pistons and rods as an alh. Same size valves. Should have same potential as an ALH. Worst case scenario I will convert it to run an ALH ecu, either way the tuners are dicks to someone who wants to think outside the box. Their bread and butter is canned tunes, which makes sense.

The TDI crowd is mostly pretty damn lame with a few exceptions. Im used to the old audi crowd who has the "try it and see if it works" attitude. The TDI forums attitude is "do it by the exact formula or IT WONT WORK AT ALL"

I've built enough shit to know pretty well what will and wont work. I also know how to read a turbo map. I just need to be able to do my own tuning, then no issue.