Page 7 of 26

Posted: Fri Feb 16, 2007 12:03 pm
by jretal
per page 4 ;)

Jretal wrote:There were really no documented photos of this, so I figured I'd give it a whirl so those of you that DO go for this mod know what you're looking for. I drilled a 3/8" hole all the way through, but ran 2 pilot holes first. Basically worked it up to the 3/8" bit... then tapped the hole

Posted: Sat Feb 17, 2007 3:13 pm
by sam80quattro
:tard: lol must have missed that bit :-D

Posted: Mon Feb 19, 2007 9:21 pm
by jretal
well it's been a VERY busy weekend, and unfortunately not as successful as I wanted it to be :( But I've taken a few steps forward and also another step or two backward :wtf: piss me off. More on that towards the end.

Spent some quality time with the car friday though today. First things to handle was to get the exhaust all clamped down and secured.

Unfortunately, when I tightened down all the clamps to the exhaust, it cause everything to start binding... me = :frustrated: :frustrated: :curses:

So I ended up cutting a bunch of "reliefs" into the piping to take the pressure off the downpipe as well as to keep it from binding over the rear axle. after much :curses: and welding, I was able to get it to fit... also, I ended up "massaging" the tranny tunnel a little bit to make extra room ;)

you can see where I did the massaging by the marker marks in this pic:

Image

after I got the exhaust all positioned where it needed to be, I started to fab up the custom dual 3" tips for the end. The donor car originally came with a set of tips I liked very much, but unfortunately they were way to long to fit the car and looked like utter $hit due to rust and what not

Image

thankfully though, after a little quality time with the wire brush wheel on my drill they shined up REAL nice 8) I was rather impressed by how nicely they cleaned up actually. I'm gonna toss a coat of high temp clearcoat on them to hopefully help maintain the shine. we'll see.

After tossing on the bumper I got to measuring to figure out how long the tips needed to be so that they didn't stick out retardly far from the bumper...

here are the tips after a good deal of cutting, fitting, welding, and filling, etc to get them to look nice and not have any holes around the tips:

Image

here is the whole "tip assembly" that goes from the muffler... turned out pretty good if I do say so myself 8)

Image

and installed on the car:

Image

pic is a lil hazy from all the smoke from finishing weld it to the muffler. unfortunately, it seems it's starting to sag a little bit from the rubber muffler mounts stretching under the weight, so I might have to make some adjustments to the mounts down the road, but for now this will do just fine :)

Next on the plate was to get the intercooler all plumbed up. Big thanks to Jesper (zepmoreau here on MG) for hooking me up with the 2.5" AL tubing!!! Also to Rich (Bing on TDIF, not sure of his handle here if he's on here) for shipping it out to me for Jesper. Though I didn't think I needed all of it, I came damn close to using all 4 feet of the stuff :o

Here it is all mocked up:

Image

Image

in order to help the hose make it around the oil pan, I ended up flattening it out a little bit with the trust 'ol hammer :) Not much of a dent, but it did the trick to let me tuck it up and be completely covered by the bumper (once I put it back on that is ;))

I picked up the couplers from www.siliconeintakes.com. This guy by far had the best prices that I could find on all fittings, and had a HUGE supply of different reducers, etc etc etc. His shipping was a lil high in my book (charged me $20 to ship the box when in reality it cost him $10 :wtf:) but had great service. He also hooked me up with a deal, so basically that $20 of shipping was free... so guess I can't complain that much. I actually need to put in one last order for a few more odds and ends (either a 45* hose or a hump hose to make the angle to the throttle body and a 2" to 2.5" 90* elbow to make up from the turbo output to the intercooler).

And here is the setup for the BOV installation:

Image

for fitment reasons I'm putting this thing within 8" of the TB. Supposedly this isn't the most ideal place for a BOV, but I also have a BPV I might be tossing in if the BOV is too loud for my tastes... so I figured I'd design it for the BPV and if I end up keeping the BOV I can cut it out and move it to before the intercooler.

next on the list was to get the fuel lines all run and hooked up. The original fuel line had a straight -6AN fitting on it, so I picked up a 90* one from good 'ol fleebay for a price and tossed it in there. This was the first time I've ever messed with these fittings... and it was a ROYAL PITA to get it to slip in there... but I figured it out after a bit:

Image

So once the fuel was set up, IC was routed... it was time to get the aftermarket oil cooler installed :)

The Donor car had the oil cooler mounted on the radiator, so I figured I'd do the same since the lines were PLENTY long enough to make it across. I used the clips and holes for the A/C condensor to mount the one side of the oil cooler:

Image

and then fabricated a mount to go to the other side of the radiator and tie it in nice and tight:

Image

After a lil TLC from the grinder and then a quick coat of paint, it was all done and looking real 8)

NExt on the list was to finally secure my positive post as welll as my coil pack. After looking around, I was able to figure out an easy place to put the coil. I didn't really have the patience to build a fancy rack in all honesty, and for just 1 coil... this made sense. I simply drilled a hole into the fire wall, then took an oversized sleeve and put it between the coil and the firewall... ending result:

Image

works perfecly, and the coil wire to the distributor fits JUUUUST right :woowoo:

Once that was done, it was time to tackle the cone filter and get that all tucked in... after some minor cutting to the 3" 45* bend I had left over from the exhaust, I was able to get the Bigmouth cone filter I had laying around from my A4 installed:

Image

because the cone filter sits so close the the exhaust mani, i figured it'd be a good idea to toss in a heat shield. Thanks to work once again, I was able to score a big piece of 16 gauge AL sheet metal... and after some measuring, cutting, and bending (both with the hammer and my knee) I was able to come up with this (miller approved of course :-P):

Image

And installed:

Image

I had a little bit of the rubber gasket that goes on the timing belt cover left over, so I figured I'd dress up the edge a little bit and put that there. Also, this helped save me from cutting myself on the edge... cuz I know I'd be stupid enough to do that one day ;) Shield is held on by one bolt that was used to hold down the original CIS airbox.

from this point, I then buttoned up the laaast of the coolant stuff... got the afterrun pump plumbed up and mounted :)

Image

Once that was done, I did something I hadn't done on this car for over 6 months... I closed the hood :o!!!! I needed to make sure that my IAT and plug would clear the hood because it looked REALLLLLY tight. Much to my surprised, it cleared just fine... BUT just to be 100% sure it'd never hit incase the motor movement was bigger than the existing gap... I cut a little relief in the frame of the hood...

Image

This brought me up to today... and today was suppose to be THE DAY! I wanted to get the car started... but alas, the stars were not aligned :( :bullshits:

after a little time on the inside to get the center console installed once again and get everything else buttoned up... it was time for the 'ol girl to get rolled out of the garage and into the bright sunny day :-P

Image

The tasks to get accomplished were as followed:

1) fill the car with coolant. one would think this would be a nice and simple task... but alas, my welding job of the coolant pipe to incorporated the afterrun pump wasn't as good as I thought it was :frustrated: Yup, you guessed it... it leaked like a siv! So after a lot of cursing and swearing, and some grinding and welding... and pressure testing this time, I was able to get all the holes patched up.

2) fire up the ECU and get it updated with the appropriate configuration. Simple task again... but alas, not so easy. I turned the key... and nothing. No power to the new fuse panel.... AT all... but I was getting power to the battery post :wtf: I pull down the panel and check out my relay... it was getting power :wtf: but with the key turned, the trigger wire for the relay wsan't getting power... yet, the 15 block on the ignition switch WAS getting power :wtf: again. So after doing a few continuity tests, I noticed the new wire I ran didn't connect... and after poking around I found that SOMEHOW the wire got tangled up in the steering column... and broke in two :bashtard:. Once I found that, I clipped the wire and got it all connected again... and low and behold... it worked!!!

3) Turn the car over w/o the distributor hooked up or the fuel pump relay installed. yet again, simple task (noticing a pattern yet????)... what happened? nothing. click click click... dammit. battery was dead. had 12 volts, but guess the amps were way down. So I hooked up the A4 to the battery in the trunk and ... :woowoo: it turned over!

4) prime the fuel system... this is where the major headaches came, and I still reek of gasoline because of it. I think I wired somehing incorrectly for the fuel pump relay... and I say this because, when I turn the key I get... well, NOTHING! :frustrated: When I took the car off the road, the fuel pump relay worked fine, so it's gotta be the wiring I'm guessing. I figured though, in order to test the system I might as well just hotwire it and see if the pump works. So i jumped the terminals and the bump flys into action... followed by a hissing noise coming from the engine bay... followed by fuel spraying past the injector seats on the fuel rail and alllll down the side of the motor and onto the ground :o :o. SHYYYYAAAT!

So I quickly pull the jumper and look in amazement as to what just happened. I wiggled the rail and twisted the injectors to see if I could get them to seat better. I also removed the tabs that held it to the head... still flowing a lot of fuel out of the seats. SO i figured that the orings were shot and needed to get replaced. I pull off the throttle body and get the fuel rail out, then reconnect everything w/o really touching anything... low and behold... it didn't leak a drop! :wtf: Feeling brave, I decide to put the fuel rail BACK into the car, but not bolt the brackets to the head and not install the throttle body... and wouldn't ya know it... not a single drip! I started to attach the brackets, and fuel started to drip past the injectors... dammit! So I leave those be, and then try to install the throttle body again... it was tight against the fuel rail... and unfortunately, it's TOO tight against the fuel rail :( :frustrated: Unfortunately, that little bit of interference (due to the thicker silicone coupler I'm using instead of the MM hose) is enough to upset the seats on the fuel rail... which leaves me as I am right now.

I have accepted the fact that I"m going to have to pull the IM and put a spacer inbetween the head and the IM to make enough room for the stupid fuel rail to clear that damn teardropped throttle body (damn you MC1/2 throttle bodies!!!!). Not exactly sure where to get those, so I'm in the process of shopping around. I'm a little bit annoyed to say the least, but do realize that this is part and parcel of the course unfortunately. Hopefully I'll be able to source the spacer I need this week and get the remainder of the parts and get this thing on the road in the next two weeks, but we'll see. If any of ya can provide a good place (will be sending 034 a message as well) as to where to find one of these spacers, that would be awesome. I'm blanking on the name right now, but it begins with a "P" I know that much :-P

On a brighter note though, I was at least able to clean my garage... this is what happens when you have a car sit in there for 6+ months w/o ever coming out:

Image

spent a lil time in there reorganizing stuff so I can walk around w/o tripping and swept up the floors before PUSHING the damn car back into the garage...

so that's where she sits right now. Garage unfortunately is REEKING of gasoline from all the stuff I spilled on the motor. I will be sure to hose down the motor with a lil bit of water before starting it officially so I don't have any fires in the engine bay... that owuld be the LAST damn thing I need at this point ;)

well hope ya enjoyed the show as always... more to come! the light at the end of the tunnel is. almost. there.

Posted: Mon Feb 19, 2007 9:38 pm
by AudiSport4000
BTDT with gas leaks upon trying to fire the motor. Having the fuel pump on and cycle the fuel is an interesting way to check for leaks. You will always have headaches like this. If you didnt and things went TOO smooth it wouldnt be any fun, right? :)

Hopefully you can get the car fired up soon, Im really anxious to see how it works out, this project thread has a ton of helpful pictures, I love it.

Heh, upon starting up the 4ktq for the first time (with incorrect FP relay) my friends were like "DUDE, theres fuel everywhere, YOU SUCK!" Gotta love the great motivation they gave me :).

But really, great work. I wish I coulda spent more time hooking up goodies (afterrun pump one of them). Hopefully soon.

Keep us posted with kickass pictures! 8)

Posted: Tue Feb 20, 2007 11:25 am
by jretal
ha, yeah... fun, that's it ;)

gotta work on sourcing the spacer for the intake manifold then I'll start cracking at it again. Kinda bummed that I have to take the damn IM off again, but what have you... part and parcel of the course as I said before. This will let me get at my EGT sensor a little easier though so I can put washers in there and space it up a little bit so it's not sticking so far into the chamber.

I'm glad my one friend WASN'T there when the fuel started spewing everywhere... I didn't need his ball busting at that moment in time ;)

Posted: Tue Feb 20, 2007 11:49 am
by SEStone
Keep tryin' Justin, you'll get there! What turbo is that by the way? Nice work with the intake routing...do you think there will be any issues with ground clearance/ground damage with it?

Sam

Posted: Tue Feb 20, 2007 12:02 pm
by jretal
thanks sam! I'm def not in any low spirits for sure... my folks were actually laughing hysterically at me (just because I was laughing too) when I told them how fuel when spraying everywhere and were amazed in how positive I was about it :) And of course, my mom had to needle me about "you didn't REALLY think it was going to work the first time, did you?" haha.

Turbo is a GT 2871 w/ 034 coolant and oil lines.

As for the routing of the intercooler stuff... it is all even with or w/in a half inch of the bottom of the subframe/oil pan... so I don't really forsee any real issues with it hitting the ground unless I take a speed bump stupid fast... same with the exhaust. I tried my hardest to keep everything tucked up high. Not as much a concern right now with it on stock ride height/suspension... but once I drop it, I don't want to be scraping over every bump in the road if ya know what i mean :)

Posted: Tue Feb 20, 2007 12:26 pm
by death 4kqt
but once I drop it, I don't want to be scraping over every bump in the road if ya know what i mean

my 4k scapes a lot. I have cheep intrax lowering springs and i think they are lower than most others. Not sure on what you're thinking for springs but if for whatever reason you are looking at intrax (im guessing you are not) i would not recommend them. It handles a bit better than stock but its to low and soft. Just my $.02

Posted: Tue Feb 20, 2007 12:59 pm
by jretal
thanks for the tip. I'm planning on going complete coil-over setup on this thing as it'll be a track whore down the road :) Probably gonna shoot for 400lb'ers on all 4 corners 8)

Posted: Tue Feb 20, 2007 1:06 pm
by death 4kqt
Probably gonna shoot for 400lb'ers on all 4 corners

most excellent!

Posted: Sun Feb 25, 2007 9:40 pm
by jretal
well time for a quick and dirty update...

So the reason for the fuel leak was because of the interference b/n the throttle body flange, silicone coupler and teh fuel rail... so the way to fix that? eliminate the coupler near the fuel rail...

The concept was to convert that stupid teardrop TB into a 2.5" straight pipe...

here's the mocked up:

Image

I mocked up the TB on the car and angled the pipe so that it clears the fuel line and the fuel rail, then I'll take a 45* silicone adaptor and tap it into the line from the intercooler.

Since I don't have a tig welder, I had to find a local guy. Luckily, there is a 75 yr old guy that could basically tig weld aluminum (regardless of thickness) in his sleep! This dude was way old school, and a real nice guy. Charged me $35, to weld the BOV bung, TB, and reweld the hard vac line together that goes to teh wastegate. somehow i managed to break it apart, so he got it back together for me.

Here's what the TB looked like after getting welded:

Image

and the welds up close:

Image

here's teh BOV flange all welded up:

Image

weld on this thing was like dimes laid out... simply beautiful welds

here is teh TB installed with the fuel line attached and fuel rail installed:

Image

and my new found clearance:

Image

now unfortunately, the dude got the TB a little too hot when welding it up, and meslted the platic bushings that held the springs together and forced the throttle butterfly plate shut. After a bit of cleaning up, I got the TB to work cleanly, but it gets a little tighter towards WOT than I like. I'm going to leave it be for now, but if it starts to worry me I'll probably be forced to pull the damn thing apart and clean up and replace the bushings and what not... but we'll see.

So at this point, everything works like it's suppose to EXCEPT the fuel pump relay. There seems to have been a mix up on the capabilites of what the Ib can do, and I thought I could get the Ib to run the FPR through the GPO2... but apparently the Ib doesn't ahve that capability... oops :-P So I have to undo the wiring that I did and revert it back to how it was stock. Hopefully I'll get some time to do that tomorrw, so we'll see I guess.

That's about it for now... hopefully I can turn over the car this week and get it fired up! :woowoo: we'll see how sucessful I am though by friday ;)

Posted: Sun Feb 25, 2007 9:49 pm
by SteveAngry
Looking good.

I'm a little concerned about that AN fuel fitting going over the TB.

You're supposed to tighten them to about a fingernails width . I can still see some of the threads.

I'd hate to see something happen and the line pop off.

Steve

Posted: Sun Feb 25, 2007 10:26 pm
by jretal
oh really? I can torque it down more if need be... I wasn't sure how far i could crank down on it so I stopped there cuz it was REALLY tight... i might do that later in the week before firing it up.

Posted: Sun Feb 25, 2007 10:33 pm
by SteveAngry
Jretal wrote:oh really? I can torque it down more if need be... I wasn't sure how far i could crank down on it so I stopped there cuz it was REALLY tight... i might do that later in the week before firing it up.


Cool.

BTW are you lubing the threads on the fittings? You should be. IIRC it's a 30w oil.

Steve

Posted: Sun Feb 25, 2007 10:40 pm
by jretal
no, i didn't... i put a lil bit on the tip to help get it to slide into the hose, but that's about it... guess I might be taking it all the way out and redoing it ;) hard part was getting that stupid red collar over the braided line anyway, so this won't be too bad.

thanks for the tips steve, appreciate it!

Posted: Sun Mar 04, 2007 9:00 pm
by jretal
It's ALIVE BABY!!!!! :woowoo: :-D :-D :-D

Spent some time this week/weekend getting the the old girl up and ready for some action!

On wed of last week, I had two goals... get the fuel line fixed (thanks for pointing that out Steve, it was way off spec), and get her cranking over on her own power and fired it up.

To get the fuel lines right, I just pulled everything apart again and made sure that the hose was seated properly in the fitting...

Image

and then threaded it back together after dipping it in a lil Straight 30 oil.

Image

ONce that was done, I got her cranking over on her own power... and cranking, and cranking... and... sizzle... seize... snap... damn, burned up the starter motor :bashtard: :frustrated:

In addition to frying the starter, my fuel pump relay still wasn't firing right. I found that the Ib couldn't run it like I thought it could, so I wired it back to what I had before and grounded the wire... and it STILL wouldn't fire up the FPR :frustrated: After playing around with it, I realized that the problem was I wasn't wired to the trigger on the FPR... I wired it like a normal relay. So instead of using the standard FPR, I tossed in a regular relay and it works PERFECTLY! Might try to rewire it a little later on so it runs off a regular FPR, but for now.. it works and I'm happy.

Back to the starter issue... After looking it over, I wasn't sure if I had ample amounts of grounds on the car, so I ran a new ground strap from the starter to the motor mount

Image

wasn't too difficult, but took a lil time to get up and running.

From this point, my buddy decided the 4000 needed a system!!!! Yup, this track car is gonna have a lil bump :o Deal is, my buddy had a real pimp setup in his pickup... alpine head unit, 2 12" subs, whole 9 yards... and he's giving it all to me in exchange for my deck building/landscaping skillz ;)

here's my buddy wiring in the radio:

Image

and here's the HU all installed. you can also see the Zentronix WB screen setup, as well as my custom 3 gauge pod in the middle vent... complete with the plexi to disguise it

Image

and everything alllll lit up:

Image

And this brings us to today... Keith A. (lil keith to some of you) had some free time today and was kind enough to come out and help me get this puppy up and running. He was able to help me to get the FPR running right (after showing me how it works :wtf:) and then get the 'ol girl to fire up!

Originally, I couldn't get the car to fully fire... i could hear it stumbling, but not fire up. It was getting gas and spark, so I figured it was a distributor issue. I'm not too up with cars with distributors, so this is where Keith came into play.

here is the car ready to get fired up once again:

Image

and Keith and my buddy looking things over

Image

after a few twists of the distributor... SHE ROARED TO LIVE!!! :woowoo: I was giddy, not gonna lie to you.... and it ran REAL smooth. No lifter knock, no ticking, nada! Had good oil pressure and was ready to go.

So after a few tweaks and making sure everything was ready... I geared it up to break in the motor and seat the rings. I had to install a filter onto the TB since I wasn't running the turbo for the first break in... so this is how she looked:

Image

and this is just as keith and i were about to leave:

Image

so you think the cops would mind me driving around like this? :-P :wtf:
.......


well they did actually... lol. Jim G, you'll love this :P

So we went to a low traffic back road to do the 3rd gear pulls and coasts to get the motor broken in. We were on our last few runs up and down the street (hitting 65 to 70 mph in a 35 mind you... so I was def a bit hopeful I wouldn't run into johnny law). Well as I was coasting down on one of the last runs... sure as luck would have it, I passed a cop! I was only going 30-40, so speed wasn't an issue... but the car itself kinda attracted attention.

I looked in my rear view and saw his brake lights go on, and I could see he was looking for a place to pully a u-turn. I decided to just pull into a parking lot and wait for him, cuz I knew he was coming. Less than a min later, he pulled in, and I was out of the car waiting for him... lol.

me: hey officer, how are you today? Am I in trouble here?

officer: Hey there, no, no trouble... I wanted to make sure you were OK cuz, well... the front of the car is in pieces and I wanted to be sure you didn't get in an accident or anything.

I laughed and told him what I was doing and why the car looked the way it did. I invited him to check it out, and he got out and looked it over, laughing his ass off. I asked him if I could get a pic of him with a thumbs up by the car, but he respectfully declined :P

So once he left, we made a few more runs and headed home. This is when we ran into a decent issue... seems teh alternator isn't charging the way it's suppose to... grrr. When i tried to lower the windows, the thing basically started to stall out... lol. Turns out (via the 034 software), the alternator was only putting out like 7 volts :frustrated: :wtf: So after retightening the belt, it still wasn't working right... so looks like I'm gonna pick up a new voltage regulator and then go from there and see if I need to replace the alternator or what.

Then came the next problem.... we got a bleeder!!!!!

Image

so being the dumba$$ I am, I tried to force a hose over the nipple on this after run pump... and wouldn't ya know it, it broke :frustrated: So I JB welded the hell out of it... but apparently, the JB wweld was no match for the heat of the coolant... so it pretty much ate the glue and started spraying everywhere...

after a few minutes, it finally stopped... and this was the aftermath:

Image

Plan right now is to just put in a copper elbow and completely bypass the afterrun pump. If I find one for really cheap/free I'll toss it back in there, but until then... I'm not too concerned about it.

So that's where she sits! I didn't video tape anything running unfortunately because I was too excited that it finally started 8) I'll get video soon enough though. Car is amazingly "quiet" for having a 3" exhaust w/ only a cat and muffler... that xlerator muffler def helps keep the sound down. I had no resonation at all in the car and it has a nice deep burble to it while idling.

That's it from now... I'm still REALLY pumped with how it turned out... 8 months in the making, it's finally ready to rock! I need to order 2 new silicone fittings this week maybe, then I can start assembling everything FOR GOOD! Also need to plumb the breather hosing up so I'm not running an open breather. It was fine for the breakin, but that's def a no go for me for regular driving.

Turbo sounded amazing spooling up and I can't WAIT to get this thing driving. 10 miles down, 990 to go till we start seeing some big boooost 8)

Posted: Sun Mar 04, 2007 9:05 pm
by SEStone
NICE JUSTIN!

Did you pull a Jeff Redig and get 3rd degree chemical burns on your arm when the coolant thing let go?

Sam

Posted: Sun Mar 04, 2007 9:14 pm
by AudiSport4000
CONGRATS!!!!

The feeling of the car roaring to life is super great, especially if its your first time doing a swap. I remember it all too well, as does Katman, he was there!

Just wait until you start driving it more and stuff, you will be amazed, I know I am, and I still run crummy CIS.

Very nice work Justin, now go drink some beer!

Posted: Sun Mar 04, 2007 9:17 pm
by TurboCGT
Very nice... now put some more miles on it and get boosting :woowoo:

Posted: Sun Mar 04, 2007 9:38 pm
by jretal
thanks guys! Thankfully, no Sam, no 3rd degree burns. I saw it steaming away and told Keith to shut the motor off. It literally JUST started doing that after we had it sitting in the driveway, so that was a gift honestly. I later put on a thick rubber glove and opened up the reservoir to relieve the rest of the pressure so it stopped hissing and such. I tried to tighten down the clamp, but it made it worse... haha.

Probably won't get much more done on teh beast till after my trip to paris for class on friday... but I'll def be stoked to get back and get this puppy fully road worthy!!

Posted: Sun Mar 04, 2007 10:04 pm
by GTIVR62801
Congratulations Justin! Glad to see all went well and that I haven't lost my touch in building engines! 8)

Posted: Sun Mar 04, 2007 10:42 pm
by SteveAngry
Congrats on getting it started!

Steve

Posted: Mon Mar 05, 2007 6:41 am
by jretal
GTIVR62801 wrote:Congratulations Justin! Glad to see all went well and that I haven't lost my touch in building engines! 8)



def didn't buddy. in all honestly, I was kinda expecting the car to smoke more on startup too... but didn't let out a single plume of blue smoke from mile oil burning... was def VERY happy to see that :)

Posted: Thu Mar 29, 2007 6:45 am
by jretal
Welp, figured I'd toss an update on here since it's been a few weeks. I've put a total of 25 miles on the new motor without the turbo hooked up. Need to do another 25 miles or so and then I can change the oil and hook up the turbo :woowoo"

To date, I had been having a real issue with my alternator. I got a spare one from a 90 from Keith (karthurq here on MG). Unfortunately, that alt had a different mounting scheme than the 4000, so instead of waiting to get the right bracket, I just swapped the regulators around. That didn't do a thing and alt still wasn't chargine. So I got fed up and pulled it from the car and brought both alternators to autozone. Before testing them, I swapped the regulators back to their prospective alternators. Wouldn't you know it, the 4000 alternator worked perfectly when tested :wtf: Guess the swapping around and jostling of the alternator knocked something loose or back in whack? who knows, but it works. I figured, since I had it there, I'd also test the one Keith gave me. As soon as the guy started up the tester, sparks went flying and he jumped back a foot or so. Needless to say, that alternator failed :-P But I got one good one out of the deal, and after REinstalling it again in the car, it works without a flaw! :woowoo:

So now that the car was charging itself once again, it was time to do some more road testing! I tossed the front bumper on once again (so I didn't attract so much attention to myself, as well as giving me full blinker capability again), and got the 'ol girl fired up and did a lil rough tuning on her so it wasn't running so rich... but ended up richening it up some more so it didn't lean out when doing part throttle runs.

So I went out last night and put 10-15 more miles on the car, and had a lil bit of a hiccup :bashtard: I REALLY NEED TO FIX MY GAS GAUGE!!! Yeah, I ran out of gas 'bout 2 miles from my house :frustrated:

I could feel the car not running right after driving aroudn a bit, and as I looked at my fuel pressure gauge in the car, it was slowly dropping (generally around 40-50psi). Also, the afr was going through the roof and it was running really lean, with EGTs running really high for just tooling around and not going WOT. I start nursing it home, and the unmentionable happened... it died in the middle of the road :frustrated:. Good thing my hazzards work! Thankfully I was near a parking lot and was able to push the car into the lot (as people in the diner where I parked the car stared at me since it had no front passenger's side light and a big cone filter sticking out of the grill area).

Thinking things over, I went to the trunk and peeled back the foam liner and gave a knock on the tank. Yeah, sounded like an empty 55 gallon drum (bollocks!). So I called up my friend and had her come pick me up and take me to my house so I could get my gas tank for the lawn mower to refuel the beast. TOpped that off and tossed it in the car (I was 2 mi max from my house). The 'ol girl fired RIGHT up again! I slapped myself repeatedly in the forehead and drove straight to the gas station. 17+ gallons later and $47 (dear lord!!!) it was full and ready for action.

At that point, it was around 1030-1045, so I drove straight home and parked her for the night... but it looks like I've worked out the running gremilins. I need to put 25 more miles on the car and then can start hooking up the turbo stuff. I got the remainder of the silicone hose fittings I needed to hook everything up... so hopefully this weekend, it'll be up and running!! Then, hopefully with Keith's help, I can get this puppy tuned and start using it again :woowoo:

Unfortunately, I am having issues with my driver's side parking lights though :( I have to look into more of my wiring/rewiring to make sure I didn't botch anything up, but I'll tackle that this weekend. Overall I'm pretty stoked at the moment! Feels good to drive the 'ol girl around again.

Sorry, no pix this time around... was too lazy to download the ones from last night...

Posted: Thu Mar 29, 2007 6:59 am
by NoNonsense
It's going to be awesome when you hook up the boost lines and really get to drive her! ;-)