The Project Pad

I like the look. Will be a beast, especially with boost.

40v4kq wrote:Cool. I didn't know he has an S4. He brings his audi's to my friends shop for service so I wonder if he still has it, I should have heard about it or seen it by now.

Marshall ended up selling it...

Holy smokes I need to get off my ass

Lovely project so far. Did you end up re-welding the core support in or go with a fastened solution for later R&R?

dubsmith - I dont remember the et on the wheels, I want to say it was 30? Next time I have a wheel off I'll get the ET for you.*EDIT* Wheels are 16x7.5 with an ET of 35.
ringbearer - Sorry to hear that. It's nice to know where a loved one is once you've sold it.
Nedry - We intalled four thread-serts into each frame horn so the core is a bolt on affair for easy R&R.

Ok. it's time for another update and this one will get you up to speed on what state the car is currently in.

Next came the cooling system which still isn't completed but we did manage to get a radiator in and get all the hoses made and attached. The radiator is a single pass alluminum unit from summit racing. It's the biggest one we could make fit in front of the motor which makes room for a fam almost non-existant but we will get that sorted out later. We had to cut the in and out off the radiator and weld them back on where we needed them and also cut the next off where a cap goes on and just welded in a plug. I"m using the factory coolant resivoir.


This is how close the end of the hub for the orignal fan comes to the radiator. We ended up cutting the nose of it off so it would have some clearance.


We used rubber mounts that are for a 4 cylinder 4k to hold the radiator in a the top with some simple brackets, and we made some brackets that run down the sides for the bottom mounts.







The biggest hurdle with the cooling system is the cross over tube on the back of the heads that the heater hoses connect to. It took a lot of welding and pressure testing to get it right. Whatever it's made out of sure doesnt like to be welded and we were constantly pressure testing and reweldeing it. We also made a pipe to connect the crossover to the radiator. With the radiator in we decided to reverse the intake again to it's original position because there simply was not enough room for an intake system in front of the motor.





Once the car had it's suspension and brakes, and radiator done and was pushed outside to await my return to oregon the engine looked like this. I had gone through the factory harness and ohms checked every wire and labeled them all to verify they all had continuity and that they matched the factory diagram so there wouldn't be any confusion when wiring in the VEMS.



Then it was time to wire it up. Some boring pics for ya.

OK, to continue the update for tonight.

Originally I wanted to go with guages froma 5K in the 4K cluster but instead I went for something a little more unique.



It's a Digi-Dash from an 87' coupe GT. I had my choice of red or orange and I think i'm going with the orange, just seem to like it alittle better and Derek already has a red one in his 4kq, Had to swap over both harnesses from the cgt, one inside the car and one in the engine bay to make it all plug and play.

It works!


Guess what else is working?









And what happened at about noon today.The moment I've been waiting over 3 years for.....


Link to video

awesome

:woowoo:

congrats on the first start! i love the cluster. love it.

Dude... I can't wait to see this in person!!!! Sounds like such a beast!

Very very nice - congrats guys!!

At which point did you abandon front mount TB?

Thanks guys. More videos to come.

a_CQ wrote:Very very nice - congrats guys!!

At which point did you abandon front mount TB?

Thanks Peter. We decided to abondon it once we had the radiator in and found that there was no reasonable way to route and intake setup to the throttle body. It would have required cutting out the radiator support more than I was confortable with. Plus it would have had to have been all flattened just to fit between the tb and the radiator. I"ll go make a video to show the new intake setup.

turn up your speakers more


Link to video

You're dang right that's good and proper sounding!

Peter(and anyone who cares), here is the airbox setup. Its a video...no more pics, all video from now on...unless i'm feelin lazy.


Link to video

I approve. :-)

No velocity stack for intake tube to TB?

Loving the build!

Good work guys! Now onto the fun part, the tuning

Chris - I wasn't aware that they were used in factory intakes since I dont have the factory setup, but now one may make its way in there :wink:

Marc - Thanks, and THANKS for all your help. I dont know if you could tell over the phone but things were getting quite frustrating and you helped big time with keeping us going. I even learned a few diagnosis techniques in the process. Now we know that audi didnt put any marks on these motors to indicate TDC, only marks to put the motor in a "safer" position for replacing the t belt and pulling cams/heads, which would have been nice to know about a year ago. oh well, thats how it goes sometimes. Thanks again for the unbeatable customer service, you will be getting some more business from me, and possibly others too

glad to help. I'm already wondering when I'll be getting a phone call about how to enable boost control

How about a twin K24-7400 set up?
That would be one hard hitting torque monster.

MUHAHAHAHA

LOL. Boost is still a little ways off for now, and with the semi-lack of space this motor creates in the 4k I'm thinking it will probably be a single turbo. I know next to nothing about turbos, but probably something like a gt30r? I dont think this motor will take too much boost because of its higher compression. Fast spool would be the name of the game.

Some compression lowering gaskets could take care of that. Is it 11 to 1?
And if no space, maybe pioneer a remote mount set up?

But you are right, enjoy the car NA. The motor sounds real healthy and snappy.

Well done!! I had a hunch it was 180 out when I got a call at 11pm!!!

E85 to the rescue for those high compression engines!!! If the rod limit holds up for the v8 as well, that is 75whp x 8 cylinders for a cool 600whp!!! That is basically a pair of gt28s not working hard at all!!

Compression is 11:1 and I dont know if there are comp dropping gaskets available....1.8t gaskets? Remote mount is an idea but I'm not going to put much thought into the whole turbo idea until the car has been enjoyed NA for a while. I still have a lot to learn with the VEMS and ofcourse the car isnt driving just yet.
Sorry about he late call Hank. I blame Derek for that one E85 would be a good solution for the high comp. I"m gonna have to start saving my pennies for a turbo setup. Heres a quick list of things to do before the car can be taken for a test drive....

1.Button up cooling system: heater valve(got a new one today), cooling fan.
2.Finish wiring: mostly sensors...temp, oil pressure, speed, tach, and headlights.
3.Finish exhaust: down pipes only tacked and no bung for WB02.
4.shifter: either urs4 shifter or modify original.
5. bleed brakes.
6. insurance.
Thats about all thats left. Could have it done a a few days if all goes well.

I was up welding. Not a big deal at all. I have been there with the late night stumps and was more than happy to give my shots in the dark! Good plan with NA for a while. 300hp will keep a smile on your face for atleast 4 months!!