Shawn's thread: #LegalStatus

[anotherbrick]

And stock suspension.

[anotherbrick]

Also, those injectors look * much larger *

[chaloux]

Sweet man. Pitter patter get at'r!

[DE80q]

Head is ready, manifold is brazed, just need to machiine the head mating surface. I now understand why these crack so often. There is over .025" difference between the runners.

[anotherbrick]

This makes me scared for the civic. Time to throw this girl back together!

[anotherbrick]

[vt10vt]

Slow day at work and a lot of shit I'd rather clear from my mind so I started doing a little fuel pump research

Initially I was looking at Walbro 255lphs, the inline high pressure version (GSL392) with a sidecar surge tank set in the engine bay kind of like this: http://www.evodynamics.com/evodysutaex.html The stats I've found on the GSL392 show @3bar it can flow ~200lph @~13v which means that @30psi peak torque I'd be limited 600cc worth of injector, but Radium Engineering rates the same pump @520chp, and Evo guys say about the same, although I'm sure they take a lot less fuel to get there.

I might just suck it up and do a Walbro 400, but I think I'd stick with the gas version since I'm not sure of E85 availibility to me in the future and the 255's seem fine on E85 anyway. What do you guys think? Just pony up for the 400 or see what a 255 can do? I can't log fuel pressure so thinking it might just be worth it to go 400

EDIT: also effff me ^^^^^

[DE80q]

I wish you would have told me that you were planning to remove those. Would have made my life a little easier

Glad to see you got it out though.

[vt10vt]

I don't ever reuse exhaust manifold hardware, definitely took a couple hours to get it out. Tried center drilling it, hammering a triple square into it, ez outs, another extractor tool, ended up just drilling it big enough to get the 8x1.5mm tap I luckily had around to catch the first thread and the rest was fairly easy.

After looking at overall price, the Walbro 400lph was the obvious choice, and I got the E85 version so it flows that much more and from my research it will handle 93/E85 changes much better than the gas pump. Found it on Ebay for $137 shipped so I placed that order today, WOHOO!!

[DE80q]

Makes sense on not reusing the hardware.

Just wondering, are you sure you need a surge tank? I havent really done any resarch on them, so not really sure what the purpose of them are.

[vt10vt]

Makes sense on not reusing the hardware.

Just wondering, are you sure you need a surge tank? I havent really done any resarch on them, so not really sure what the purpose of them are.

It turns the original fuel pump into a feed pump and let's you reroute the return line to the tank as well. This prevents fuel starvation issues and lets the pump on the surge tank flow greater amounts by minimizing the vaccum that pump operates under.

But I just went with the walbro 400 in tank unit, for a few bucks more than a 255 I can have a ton more flow and not have to worry about building a surge tank, extra lines etc. I was looking at building a double pumper setup like Nick is doing with the 400's but with 255's but again, more time and effort than a single 400 in tank which should be just fine for me for a while.

[vt10vt]

Okay, so to review what's happening with this...



'New' motor showed up looking like this


Which necessitated building a motor from scratch out of the two I had. What it ended up being is my old valves in the 'new' head which was gasket matched by Dave (DE80Q) with my original MC1 cam, my old rods with a combination of pistons from the two motors, and new rings/rod bearings/valve stem seals. Budget was the name of the game, I've never built a motor befor so I was kind of learning as I went Hoping I put it back together right

After getting pressure washed by some crazy machine Dave gasket matched the exhaust ports of the 'new' head and I then resurfaced it backyard style on a big piece of glass I got for free with some 320 grit sand paper on a fairly flat concrete floor



Dave also milled the exhaust manifold on a machine, apparently it had .025" rock to it so very glad I got this done







Crappy pic of some sweet ass ports

[vt10vt]

Then it was reassembly time!

Lapping valves in, bottom=before, top =after I hand lapped (without a drill) which took quite a while but I feel like you can go way too far way too easy with a drill. I practiced lapping and honing with junk valves on my old head and 'new' block before I started on the real things. Very happy to have spares around.



New stem seals and mostly my old valve train



Cleaned the CRAP out of everything going into this motor, here's the OEM pistons ready to roll, OEM Goetze rings.



Cleaned the oil squirters with a combination of parts washer, braklean and compressed air







Super sketchy heater that made all this possible in the timeframe it went together. 2 screws hold the burners to a piece of wood, which is tied to the tank. I didn't leave the shed for long periods of time with it running





As mentioned above, this was a little bit of a PITA







I'm still very much a skeptic, but I had it from my fuel rail package so I added the intake manifold and clearanced both manifolds for it to clear. Here it is with my Siemens Deka 830's



The car gods (or maybe a halogen wedged in the rafters) looking down on the 20v about ready to go in. Note the top of the pic



And since we had crazy warm weather this weekend I took the oppertunity to run my new harness, remove the last of the factory stuff that was in the bay that I didn't need, and gave it another wash, because you can't put a new motor in a dirty bay.



So I was still behind schedule, but it was looking like I was going to at least have it running and broken in before I left for VT for christmas, but then I decided to try and change the pilot bearing, and it turned into a nightmare. The race is still stuck in the crank, I tried the soap trick, a 3/8" NPT tap, got the bearing to destroy out and now I'm gonna need to dremel the race out. VERY frustrating, spent way too long on it so I kind of bagged the car for today so I can get other stuff more in order for my trip.

If I didn't have as much car related stuff to do on my trip I would be cancelling my trip home so I could work on this, but I need to get some parts for a friend, and pick up an exhaust for Dave, try and find myself some parts in the junkyard where pre B4 Audi's actually exist etc.

Thanks for reading along, hope you enjoy the progress updates!

[loxxrider]

Nice work.

Only one thing... looks like some scoring on that cylinder wall. Am I just seeing things?

[vt10vt]

Nice work.

Only one thing... looks like some scoring on that cylinder wall. Am I just seeing things?

Thanks..

Yup guess I should have posted a different pic. No way around it the new block was complete shit. It's not as deep or bad as it looks in that pic, it shouldn't be a huge problem. I'm sure it's not going to help compression, but it's not going to be the end of the world.

Not sure if you saw, but I resurfaced the head with a piece of glass... I don't really have any money to spend on this, sometimes you gotta work with what you've got.

[chaloux]

Not sure if you saw, but I resurfaced the head with a piece of glass...

Lol. Yeah I noticed the scoring too. Whatever, just a 20vt right? :p

Kidding side, nice work dude. That's some motivation! I'm trying to figure out how to get a bigger hotside with no money. So far I've got nothing, lol. The things you are pointing out as sketchy are just the things many of us don't mention in our threads.

[vt10vt]

I can only say that this was 100% the worst part of this whole process thus far.

[vt10vt]

Not sure if you saw, but I resurfaced the head with a piece of glass...

Lol. Yeah I noticed the scoring too. Whatever, just a 20vt right? :p

Kidding side, nice work dude. That's some motivation! I'm trying to figure out how to get a bigger hotside with no money. So far I've got nothing, lol. The things you are pointing out as sketchy are just the things many of us don't mention in our threads.

I'm a firm believer it's only as sketchy as the amount of effort and research time you put into doing the best with your given resources. 320 grit is fairly fine as far as people go for this process, and I worked figure-8's from all four sides of the head for even amounts of time. Scoring may drop compression a couple points, but I'll test it after break in to see for sure.

You're running a .63 hot side right? You should check out the numbers the DSM guys are putting down on the .55 BEP housings with HX35's in them. People seem to put the K26 #6 around a .43. Holset exhaust wheels "flow really well in small housings," and HX35 guys are throwing down 500+whp on the .55 hot sides and running in the 10's.

But you already have a super sweet garrett, and of that, I am jealous

EDIT K26=.43 my bad, brain fart

[chaloux]

Absolutely! I more mean things like the heater setup and whatever other home grown solutions you used. Or maybe I shouldn't speak for everyone else, but dad and i certainly do!

Yeah it all depends on the turbo. The 76 compressor is a slight mismatch with the 30r turbine, but a .63 really limits boost because of backpressure and egt. It just makes the mismatch worse.

[chaloux]

Whoops double post

[DE80q]

Glad to see things I have been working on are actually beng used. Looks like you are pretty much ready to drop that baby in there now. Wish I could have been able to come down and give you a hand. Things have been just crazy around here, and havent really been able to do much of anyting.

Looks good, thanks for picking that up for me while your up there.

[vt10vt]

Absolutely! I more mean things like the heater setup and whatever other home grown solutions you used. Or maybe I shouldn't speak for everyone else, but dad and i certainly do!

Yeah it all depends on the turbo. The 76 compressor is a slight mismatch with the 30r turbine, but a .63 really limits boost because of backpressure and egt. It just makes the mismatch worse.

I didn't realize the mismatch was the main reason you were reaching the det limitations of the .63 but that makes sense. Glad to see you finally found an .82 housing and local even!

I came back to Maryland today, finished up a 1200 mile trip to VT and back for Christmas

Came home to one of my presents to myself



Note Heady Topper, this stuff is great!

Hope everyone had a good vacation, thanks for reading along!

[vt10vt]

Getting closer..



Blue loctite, good to go



This is the clutch disc out of the MC1 I bought that was all locked up. BRAND NEW which is sweet because I had another almost new one I bought that got damaged in shipping. So it's my original flywheel, parts motor (5ktq MC1) clutch disc, and the flywheel from the damaged clutch kit I bought. This whole thing is quite a mutt.

[DE80q]

WOOT! im glad to see it has made it back between the rails. Sorry I couldnt make it down there to help out.

[vt10vt]

WOOT! im glad to see it has made it back between the rails. Sorry I couldnt make it down there to help out.

Help would have been awesome but I'm getting pretty good at throwing this motor around by myself!

Slowly making headway, got up kind of late this morning and had some other stuff to do before I let myself back at the Audi but I made a fair bit of progress. All the engine bolts are in (only had 3 in yesterday) and the starter is in. Oil feed and drain for the turbo are hooked up, and I cut out another restrictor plate for the holset feed. I run a piece of sheet metal sandwitched between two gaskets that necks the OEM feed down a little bit. I originally put one in when I was having oiling issues, thinking it was the turbo blowing out the seals, but it was actually the oil rings in cyl #3 falling apart. It didn't hurt anything and seemed to help with my cruise and idle oil pressures a bit, so I'm going to continue to run it.

I got the radiator in and most all of the cooling system buttoned up. The clutch feels perfect so seems my hybrid disc/PP is fine. I need to splice the injector harness into the new main harness, wrap that, wrap a couple pieces of the factory harness, and then get everything in it's final location but as it sits in the pics all the wires are run and plugged in. You can see the injector wiring hanging out on the VC but besides that it has cleaned up a lot from the rat's nest it was for a while









Thanks for reading along!