The Project Pad

audidub wrote:i got a set of g60's in the scrap pile, they are kinda rusty but if you want them their yours

how are the pistons? do they move freely?

I literally threw away 3 sets of G60's recently, sorry Tim. I tried giving them away but nobody wanted them, and they were in good shape too. Not that this helps you at all.

my2000apb wrote:ive also had thoughts of b3 c-arms, knuckles etc, to widen it all out and it should work fine

This is what I've decided to do.

I figure it will be a lot easier down the road to replace axles if needed, since I won't be swapping outer CV's too.

And if I ever decided I didn't like my Volks, I'm a couple steps closer to 5-lug.

Haven't done anything to check axle lengths yet though.

timmmy wrote:I literally threw away 3 sets of G60's recently, sorry Tim. I tried giving them away but nobody wanted them, and they were in good shape too. Not that this helps you at all.

ah dang, well timing is everything, they are common enough

may or may not need em based on the spacer fitment test thats about to go down

WRC wrote:

my2000apb wrote:ive also had thoughts of b3 c-arms, knuckles etc, to widen it all out and it should work fine

This is what I've decided to do.

I figure it will be a lot easier down the road to replace axles if needed, since I won't be swapping outer CV's too.

And if I ever decided I didn't like my Volks, I'm a couple steps closer to 5-lug.

Haven't done anything to check axle lengths yet though.

well if you run the cast arms up front with proper knuckles, balljoints etc, and b3 fronts *should* drop right in

youre supposed to shorten both cup splines by 3mm, i have done one and not the other yet, as the b3 front w 4kq outer doesnt work on 4kq passenger side of the car, its too long even with the balljoint at max camber. so i may run an unshortened cup to help take up space for the shorter 4kq pass axle

its looking like im going to be running a b3 front axle w 4kq outer cv and 100mm 4kq trans output cup thats been shortened 3mm on the drivers side

an a 4kq passenger axle on the pass side with a 13mm spacer and with either the 3mm shorter cup or stock length cup

more to come once fitment session is done

my2000apb wrote:well if you run the cast arms up front with proper knuckles, balljoints etc, and b3 fronts *should* drop right in

I'm going to use the stamped control arms I have with a 2-bolt 80 ball joint. I don't see that it would make a difference, cast versus stamped.

youre supposed to shorten both cup splines by 3mm, i have done one and not the other yet, as the b3 front w 4kq outer doesnt work on 4kq passenger side of the car, its too long even with the balljoint at max camber. so i may run an unshortened cup to help take up space for the shorter 4kq pass axle

I've already shortened both output splines by 3mm. I figure if I left them long they might not seat/seal properly.

its looking like im going to be running a b3 front axle w 4kq outer cv and 100mm 4kq trans output cup thats been shortened 3mm on the drivers side

an a 4kq passenger axle on the pass side with a 13mm spacer and with either the 3mm shorter cup or stock length cup

more to come once fitment session is done

By how much is the hybrid axle too long by. It could be that the CV isn't fully on the B3 shaft. That's probably not it, just a random thought.

so are the b2/b3 stamped arms the same? jsut a longer balljoint for b3?


the cv is def seated on the axle, plenty of brass hammer on that one

my2000apb wrote:so are the b2/b3 stamped arms the same? jsut a longer balljoint for b3?

I'm pretty sure b2's and b3's stamped arms are identical, just different balljoint diameter.

WRC wrote:

my2000apb wrote:so are the b2/b3 stamped arms the same? jsut a longer balljoint for b3?

I'm pretty sure b2's and b3's stamped arms are identical, just different balljoint diameter.

cool so after looking at it, the b3 rears look jsut liek burlier 4kq fronts with a bigger diameter

going to try that tonight

update

so i could only screw around with this damn axle issue for so long.
i got sick of it, i had two motor and trans swaps going on at the ame time and i needed a car, the 7a was in a ready to go but the 01e axle issues, and other small stuff the car needed it seemed liek it was going to be a hundred bucks in parts every week haha

so the motor is out and gone
trans and linkage and mounts etc are going to my friend shortly and being used to pay off cq vr labor

the motor got traded to a guy from plattsburgh,( who should be signing up here soon) for a 175k 100q w/ NF, pearl on black leather

so car is going out back for a while

eventually itll get the 16v/aba turbo setup but for now im happy to have one project and a beater car and money coming in

we've been working on the 16vT/aba swap again, motor is in and mounted, manifold progress has been made

update coming

Update

So I cant seem to find all the pictures on my computer, but I will get more up as soon as I find them. Engine mount arms are nearly done, they need some bosses welded on them and an add’l piece of plate on one. Theres a few pics of them but many more to come.

So this is sort of a parts bin kinda car. I have a 304ss 20vt weldel log manifold that we cut up for flanges ( head and turbo/wg) to make a nice header out of. I am utilizing a k24 for now and the oem audi wg. I think the k24 into a 2.0L 16v should be good fun for a winter thrasher.

So I had the 304ss 20v exhaust flange that is now 16v size ahha. The k24 turbo flange is from the same cut up manifold. I got the oem audi wg flange from Marc @ EFIexpress along with the smaller 16ga ss elbows to integrate it back into the downpipe.

I need to thank Ryan @ Higbee Fab. for getting this manifold mocked, tacked and all seam welded up while I was away for three weeks, in his spare time.

Attachment ( 28527 ) : 4cyl quattro together.jpg


Attachment ( 28528 ) : 4cylo1e in car.jpg


Attachment ( 28529 ) : 4cylo1e in car2.jpg


Attachment ( 28530 ) : 4cylo1e in car3.jpg


Attachment ( 28532 ) : ex mani collector welded2.jpg


Attachment ( 28533 ) : ex mani 2 and 3 tacked.jpg

exhaust manifold, all tacked up and ready for seam welding

audi oem wastegate is also finished, ya i could have bought a used tial 38 for a hundred and fifty bucks, but its a part binner haha i had all this stuff already.

Attachment ( 28537 ) : ex mani all tacked2.jpg


Attachment ( 28538 ) : ex mani all tacked 3.jpg


Attachment ( 28539 ) : ex mani finished in car.jpg


Attachment ( 28541 ) : k24 with collector and dp.jpg

Update

So I need that thank Ryan again for the 16v manifold, it’s a piece he had lying around the garage for years, we had to modify the rear portion/cap for the plenum as it was too close to the vacuum booster. I’m not sure what throttle body I will be running because im not sure on engine mgt yet ( debate to come). So it will remain 90% complete til that debate is solved.

Also I had some spare dash8 Ross machine fuel rail so we drilled that to 16v spacing and popped in some mockup injectors. We just need to tap the ends for ½” NPT and I can get started on the fuel plumbing.


the aba oil filter housing doesnt fit too well with a longitudinal swap so i acquired an AEB oil filter housing and it fits much better.
heres the difference.
ill get some better pics but tie rod clearanceis better than the pics show

AND lastly the motor with its intake manifold and fuel rail in place all mounted up,
soon to come , more mount arm pics and exmani installed with everything else

Attachment ( 28547 ) : IM end cap.jpg


Attachment ( 28548 ) : IM end cap2.jpg


Attachment ( 28549 ) : aba vs aeb oil filter hosuign.jpg


Attachment ( 28550 ) : aba vs aeb oil filter housing2.jpg


Attachment ( 28551 ) : oil filter housing aeb installed.jpg


Attachment ( 28552 ) : 16vaba in car.jpg


Attachment ( 28553 ) : motor and im fuel rail in car.jpg

a few more pics i found on my phone

k24 on tube header. I am intrigued...

That's going to be a sweet 4k

A nice light weight solution for power and fun.

Cheers

Craig

some good progress there!

pilihp2 wrote:k24 on tube header. I am intrigued...

yeah its k flange for now, theres always people dumping kkk/gt hybrids and i can always put a t3 flange or anythign else on as well. the k24 is a great lil turbo for a 4cyl 16v 2.0L, it feels bigger there than on a 2.2 5cyl

Rocco16V wrote:some good progress there!

thanks

Highlander wrote:That's going to be a sweet 4k

A nice light weight solution for power and fun.

i think it should be a ton of fun, the red 3b car was great but so clean i couldnt even really drive it hard, and then only a season or two at that, now i can have a ski trip / rally/snow all year allweather fun car, thats how a 4kq was meant to be enjoyed

mini update, i got a hold of some g60's from a 20v 90q, now i jsut need to source some 90q 20v knuckles or get rid of these and run b5 stuff

also looking at ordering one of these
http://www.cxracing.com/mm5/merchant.mv ... _Code=RADI just need to check my tolerances once im home and its time to order it up!

i need a daily!!

the oem 4kq radiator doesn fit by about 1/2" damnit!!!! :curses:
so i guess ill figure out a way to cool it
the radiator is about 14.5" x 16.5" and is 2.25" thick should do nicely

i have a small order from 034 coming, a oil cooler sandwich adapter, a few 14mm metric flare to 6an adapters, and some npt to an adapters for the oil cooler as well.

ryan and myself built up a cool catch can from an a/c drier, its pretty trick , pics to come when im home thursday

and i have a cxracing oil cooler coming as well.

major update and pics by the weekend!!!


oh yeah and what to do about engine management? hmm may jsut have to vems it, by the time i buy a oem wiring harness and an ecu and a chip its damn near the price of vems, and would be inflexible, so im thinking vems it is!!!!!!!!

Why not run a fwd 4cyl 4k rad? Should still be plenty of room for a front mount. Or you could stick the IC where the 4kq rad is, that'd be pretty easy

can the fwd 4k radiator come all metal?w/o plastic tanks?

its cheap and easy enough to buy a new radiator and slim fan and have all sorts of spare room

i love the 16v i almost put one in my coupe

Major update time!!!!

Ok so I’ve been away working on the road most of the winter, but what little time I was home I got some stuff done, and then in the last month I’ve gotten a ton of things done as I’m finally working/staying/living in the same general area. Back to the car

The decision was made to go VEMS, after considering a chip tune, and having to buy the ecu and wiring anyway, it only made financial sense, after buying a chip tune or two and then still having no flexibility. The VEMS setup will allow me much more control over the engine, and no more buying chip tunes.

I also got my self one of the VEMS WB02 and EGT gauge and sensor kits, I got my EGT bung welded onto my exhaust manifold, now to run and install this as well.


So much progress has been made I’m not even sure where to start. Ok so the intake manifold has been completed. We tapered off the rear portion to give the brake booster and brake lines a bit more room around the engine. We then built a feed tube from the tb to the plenum. I am using a stock i5 20vT throttle body as I had one around, and can easily setup my VEMS for whatever tb I choose to use.

I also made a mounting area for fpr on the back of the plenum where it will be mounted via 6mm isolators. Also put a few vacuum bungs on there, just have to do the IAT sensor bung and a bung for the vacuum booster/brake and it’ll be totally finished.

I was going to go with a used fpr as it is a bit of a budget project (atleast compared to the vr6t cq) but alas fuel is something you don’t mess around with, so I just sucked it up and went with a new aeromotive fpr. I also pulled the trigger on some used, but freshly flow matched siemens 60 lb’ers. Yes they are way large for the k24, but I should be able to get them to idle alright for a bit. The key here is I’m building most of the car to be ready for a larger turbo asap. It’ll be on VEMS already and have a strong clutch and big IC and an o1e, so there isn’t much in the way of a big turbo setup other than the snail itself.

I’ve been keeping an eye out for a gt28/71 as that’s what I really want, but may get a holset hx30 as they are quite a bit less expensive, and I could have a pair of fwd vw engines into Quattro cars both boosted by holset, which would be sweet noise heaven.

I’ve also been able to build all the fuel lines for the car ( in the engine bay anyway), so it’s currently OEM lines (not rusty at all, weird) to the firewall and then adapted to -6an earl’s pro-lite from there on.

Attachment ( 30246 ) : Im tb feed.jpg


Attachment ( 30247 ) : intake mani almost done.jpg


Attachment ( 30248 ) : IM tb cable pulley.jpg


Attachment ( 30249 ) : IM fpr mounted and vacuum ports.jpg


Attachment ( 30250 ) : fpr mount and vac port detail.jpg


Attachment ( 30251 ) : fuel rail and plumbing.jpg


Attachment ( 30252 ) : fuel rail mounts.jpg

UPDATE!!!!
Ok got more done @ ryan’s, and its really coming together., the car is finally coming back to my garage, and its ON!!!!!! Crunchtime is here!!!

IAT 1.8t sensor receiver welded on

10an SS male fitting welded to k24 oil drain

02 sensor welded onto DP also EGT bung

also not sure if I had pics of WG replumbed into DP but here they are

fuel rail mounts were welded and bolts recessed into rail

we also got a chance to fabricate and weldon the valve cover breather, there isn’t a ton of clearance for a 90 degree hose end so we ran the vent across the valve cover ad out the side so we can use a cheaper and better fitting straight hose end to the catch can.

We also tacked on some vband flanges and the 3” > 2.25” transition tacked on as well, the catback exhaust will fall right together, once I get a little bit of time for it.

Attachment ( 30260 ) : IAT reciever welded in.jpg


Attachment ( 30261 ) : k24 10an oil drain.jpg


Attachment ( 30262 ) : k24 10an oil drain2.jpg


Attachment ( 30263 ) : 02 sensor ready to zap.jpg


Attachment ( 30264 ) : dp o2 sensor welded on.jpg


Attachment ( 30265 ) : egt bung welded on.jpg


Attachment ( 30266 ) : more dp.jpg


Attachment ( 30267 ) : 3 inch to 2.25 taper.jpg


Attachment ( 30268 ) : recessed fuel rail bolt.jpg


Attachment ( 30269 ) : fuel rail mounts welded.jpg


Attachment ( 30270 ) : fuel rail mounts welded2.jpg


Attachment ( 30271 ) : fuel rail mounts welded3.jpg


Attachment ( 30272 ) : vc vent 10an.jpg


Attachment ( 30273 ) : vc vent 10an2.jpg