The 90Q (07k?)

[varia]

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

[90quattrocoupe]

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.

[Afterthought]

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 .

[Afterthought]

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 .

[varia]

amazing !!!

[vt10vt]

Seriously awesome stuff in here.

[Afterthought]

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

[jbrentd]

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

[Afterthought]

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 .

[highlander69]

Looking great

Where did you get the header flange?

Cheers

[DE80q]

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.

[Afterthought]

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.

[Afterthought]

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-07k-stainless-steel-exhaust-flange-1-1-4-pipe

[Afterthought]

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”.



Sent from my iPhone using Tapatalk

[highlander69]

awesome thanks.

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

Great motivation for me to get back at it

[highlander69]

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

Looks good in my opinion.

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

[Afterthought]

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.

[Afterthought]

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 .

[jolio1994]

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.

[Afterthought]

Hmm ok . Thanks . That sounds like a perfect solution

[dana]

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.

[Afterthought]

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 .

[Afterthought]

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

[Lucky]

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.

[Afterthought]

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)