2.0L20v90Q...white wheels it is!!

[Zerb]

ex studs were slathered in anti sieze prior to install. wouldnt want those fuckers practically welding themselves to the head, lol.

and i know, its been way tooooo long. my buddy who pretty much made the entire manifold/did all the welding, wanted to make it all seem like it was one piece like, almost cast i guess. thats why he ground all the welds down and polished them out.

[Zerb]

motor is IN. finally.

[speeding-g60]

bullshittin.... you got those pix from some website in Poland..... i seen that car before.

the BLING gold stuff gives it away

sending modded detent tomorrow. to the addy i have on file. which is parents-in-law?

and you may not want to, but i am now running top belt cover-less anymore. gives me the opportunity to keep an eyeball on the tensioner nut. but i like the stock look for certain.

[O2VW1.8T]

looking good, cant wait to get mine in.

[Zerb]

Ok, so ive been doing alot of everything....i tend to jump all around at this part in time of the project.

friend of mine made 662whp on his t3 6765 .82a/r (pretty much balls on exact setup as mine) on a quick dyno tune, which is impressive, but i was personally hoping for more. he decided to go to a t4 housing, .91 to be exact. after he got it on, i saw some vids, he told me the spool was still ridiculous for a 67mm turbo, so i hopped on the t4 bandwagon. and thus where i sit as of now.

brake booster is in, rough brake line running just to make sure i have enough line here. made a little bracket for the aftermarket adjustable proportioning valve for the rear brakes.



had a pipe thread fitting welded to the booster for the vac line that feeds it. ALLLLLLLL vac/boost lines are push to connect tubing, 18 wheeler air brake tubing to be exact. pain in the nutters to get all the fittings correct, especially that 1/16th NPT on the aeromotive fpr, but in the end its worth it to have no, hopefully, boost/vac leaks. and an easy assemble/disassemble setup




saw a thread on here the other day about dash material and flocking. hadnt a freaking clue as to what it was, but it sure looked sweet. made some calls the next day at work to one of our distributors and had the stuff in a few days to flock the dashboard. not the toughest thing in the world at all to be honest, messy though. didnt come out perfect perfect, but for a first time attempt im satisfied, it sure feels cool.





figured out my manual serp belt tensioner setup and got the parts today, thanks to mcmaster carr. should work out pretty well, just gotta get some belts in the size range that i need tomorrow and ill make sure that all works out nicely. didnt use the stock mounting hole for the alternator, drilled a hole about 1/2 inch behind it and then ground down the opposite side where the bolt comes out to get a nut in there, needed to do that to get the room for the tensioner setup to be far enough back that i could tension it out once a belt got on there. needed a spacer bushing so i ended up finding a nice assortment of door hinge pin bushings this afternoon at work and one happened to work out pretty much perfectly.



last but not least, the new tubular manifold with a t4 flange, which will have the t4 .81 6765 on it and a turbosmart 50mm pro gate attached to it (somehow)

[Quattro v1.0]

Did you buy one of the flocking kits or did you make one of those home built setups? Im really interested in trying this on a project of mine. Do share the steps you took with us ;o]

[Zerb]

i bought one of the 'mini flockers', pretty much tube inside of a tube with some holes punched out on one end. i cleaned the dash with a towel and some simple green, filled the flocker up. applied the flocking paste that came with the flock, and went to town. it wouldve been easier with two people, cause in the end my arms felt like falling off. but its really quite simple. i was just told to make sure i didnt do it by 'areas' ya know? i just moved it around and got it everywhere covering the entire dash liberally. only SO much of the stuff will stick anyway so you cant really apply too much. it didnt come out perfect like i said, but for the 15 minutes i spent on it, its close enough for government work,

[Quattro v1.0]

Yea, looks like a great first try. I'd be happy with it. Do you have a link where you bought the kit and material from?

[Zerb]

i actually bought the kit through a distributor i deal with at work, local napa store. but you can get the stuff from here..

http://www.donjer.com/

[pitts]

what do you feel the durability of the flock is? Does it feel like it will rub off very easily?

[Zerb]

it doesnt feel like it will come off easily no. but then again its only been on there for two days, lol

[Zerb]

manifold runners are all tacked up, my friend is going to hate me for giving him this to weld, lol.
going to hopefully get the flange on tomorrow and get the turbo on there and see where i gotta cut the fender for he downpipe, going to try and plop the wastegate on top and dump it right into the downpipe too. time will tell.

[Hank]

Looks good. You should be proud!

[Zerb]

been doing some work here.

power steering rez mounted up. figuring out lines now. instead of welding the clamp the the bar i ended up putting a strap over it and then riveting it to the bar so that i can adjust the clamp to my liking.




tacked the turbo flange on the mani as well and got the hole in the inner fender done-ish. how im going to run a 4 inch intake pipe and a 3 inch ic pipe in that area is still a mystery for me, lol




bay

[speeding-g60]

the hole thru the inner fender is much too tight. give it a 4.5" minimum.... heat and expansion, it will move things around a bit. trust me.

[Zerb]

oh thats not the final hole for sure. its just there to locate the pipe so i can make sure im making the 'downpipe' right.

[O2VW1.8T]

Im soooo doing that when i get my ish running or thru the hood we will see. Looking good man.

[Zerb]

mocked up the downpipe yesterday and handed my buddy the turbo housing so i could get the vband welded to it so that i could finalize the downpipe this evening. just got a text with this in it....


so hopefully tonight ill be able to finish up the downpipe and fender hole and then figure out how im going to mount that thing to the body. WANTED to dump the external wastegate into the downpipe but im not too sure that will happen with the space i have, i dont want it to look hookey NOR do i want to have a 90 degree elbow dumping into the donwpipe cause im sure that wouldnt be good for exhaust flow.

[loxxrider]

eh, no point in rerouting wg if there is no muffler anyway lol

IMO at least

this thing is looking awesome btw.

[Zerb]

I was gonna try and get a 4 inch vibrant race muffler in there to TRY and quiet it down a bit, but idk.

[SilverCQ]

DUDE, i just read through this and got caught up. its lookin great. awesome work!

[speeding-g60]

looks familiar..... LOL. (i know i know)

so, you ARE going to want some extension out of the fender. mine barely sits out and i wish it had about 3/4" or so.....

[Zerb]

really? explain the reason for the extension, just curious. only other example ive found with a large turbo 4 banger and a fender exit exhaust is the s200 from hell that t1 built a few years back. and he had the exhaust pretty much flush cut with the fender.

video of said car...

Link to video

[speeding-g60]

you will see when you get that black sooty exhaust crap running down your door

and the typical moisture that runs down the side of the car on warmup.

plus, with your usage of the car, you will know it by the amount of exhaust present inside the car from the front door seal, or leak thereof. at least with it stubbed out some it has most chance of being away from the car.

[Zerb]

Hey you say make it further out....i make it further out, lol.

I'll have to make sure that particular door seal is top notch too.

I'm interested to see how the vinyl holds up here. I may cut the hole larger by alot and rivet on a ss panel or something of the sorts there with the hole in it.