The Project Pad

Marc you didn't max your stock pump out though? Last time we talked about it I thought you said on the dyno your A/F was fine and the injectors were at about 60%.

newt wrote:Better safe than sorry, the stock pumps are known to start falling off under higher boost or rail pressures.

For sure!! It's always good to have reserve especially since I've seen these pumps loose volume just while getting hot!

Alright, finally finished an update to the oil cooler setup I had put on the car. First, a recap... I had posted a separate topic about my initial oil cooler setup, here's a copy of that post:

So my //Shaggin' Wagon has been overheating on the track... I decided to try adding a bigger oil cooler before Watkins Glen coming up on the 10th.

I ordered all the bits I needed from summit racing. The total came to around $220 shipped for:

2x18mm -> -10 adapter fittings

4x90degree -10 AN hose fittings

2x1/2NPT to -10 adapters (for the oil cooler)

10' -10 hose (Aeroquip, summit brand was out of stock :x )

1xB&M oil cooler, 8"x12" bar and plate

I would be totally done with the job right now buuuut, I didn't have as much oil as I thought I did :(

So I'll have to see if I can find any auto parts stores open on the 4th. I was hoping to fill up with mobil 1 15w50 but couldn't find any :?

Anyway, :pics:
I installed the oil cooler where the factory intercooler used to be, and installed a vent in the fender liner to improve airflow:











anyway, we'll see how she does at teh Glen!

So at Watkins Glen last year I was still having overheat issues. Not as bad but the oil temps were still getting too hot for my tastes. Robert Caro convinced me that ducting and possibly a fan were necessary to better utilize the oil cooler.

So I set to work adapting a factory intercooler duct to work with the oil cooler. As I was fabricating the bracket for the whole assembly I thought it was sort of funny that it came out looking like some kind of creature when detached from the fan/oil cooler :-P



The assembly about ready to go on the car:



installed:



I still have to wire up the fan to a switch but I'm pretty happy with how everything came out.

In other news the replacement brake servo has solved my no-assist problem (thanks Haydn!). Good to have brakes at the Glen...

looks nice marc, fits in there beautifully

Looking forward to seeing how it works!!

a4kquattro wrote:In other news the replacement brake servo has solved my no-assist problem (thanks Haydn!). Good to have brakes at the Glen...

Yeah, lets hope that this time around a caliper doesn't decide to blow a seal on you like last year, forcing you to use a "surgical" clamp to get you home. :wink:

Alright, so a little post-glen update. No overheat issues at all, but part of that probably had to do with making very little power :(

After the first run on the first day I had a pretty significant exhaust leak between the turbo and manifold that got worse and worse throughout the day into Thursday. By the end of Thursday it was easy to see that almost the whole gasket was completely gone making boost pretty much non-existent.

So I'm not confident that just replacing the gasket is the right thing to do. I verified that the nuts were all tight so the gasket did not blow out due to lack of clamping force. In talking with a few folks it seems that gaskets like to blow out at that location all the time. I've been told that one option is to have both surfaces (turbo hotside inlet and manifold outlet) machined perfectly flat and then run without a gasket. Thoughts? I'm thinking I might go this route.

a4kquattro wrote: I've been told that one option is to have both surfaces (turbo hotside inlet and manifold outlet) machined perfectly flat and then run without a gasket. Thoughts? I'm thinking I might go this route.

That option works...I've also seen some guys use a hi-temp paint and clamp them together without gaskets...seems to work on a few Porsche 996tt cars that I've watched on the dyno. I'm just the messanger, though... :wink:

wow, all the way back to page 3 in the projects forum, time for an update

So looking further into my gasket issues I noticed that the turbine inlet doesn't fully match the gasket profile of the factory KKK gasket (the marker denotes where the gasket is exposed to the interior of the turbine inlet):



So my thought is that elevated track temperatures eventually burn up the gasket from the inside out. I never had any issues at all on the street, only at the track did I have problems with blowing up gaskets. To address this issue I (and by I, I mean Fred Soucey, my mega-pro welding instructor ) welded some filler material into the corners of the turbine inlet



and milled the flange flat, so now the gasket has a full surface to sit on.



here's the adapter we made up to mill the hot side on the bridgeport.. it bolts where the center section sits and then gets bolted to a right angle adapter to sit correctly on the bridgeport:



We'll see how it goes as I just put the turbo back on the car last night

Just got my 4 bar updated ECU back :thanks:, so its time for more dyno time soon :woowoo:

:woowoo: looks great as usual marc

Furthering my addiction to v-bands, I replaced the three bolt flange on the bottom of the wastegate. Downpipe removal now takes 2 minutes



Next up, replace passenger side lower control arm before my trip to canada for F1 and Mosport next weekend. Discovered it was blown while crawling under the car to play with the downpipe. Guess that explains the occasional shaking I get under braking :-P

a4kquattro wrote:Furthering my addiction to v-bands, I replaced the three bolt flange on the bottom of the wastegate. Downpipe removal now takes 2 minutes



Next up, replace passenger side lower control arm before my trip to canada for F1 and Mosport next weekend. Discovered it was blown while crawling under the car to play with the downpipe. Guess that explains the occasional shaking I get under braking :-P

Nice V Band, nice Carbon plug cover too

timmmy wrote:

a4kquattro wrote:Furthering my addiction to v-bands, I replaced the three bolt flange on the bottom of the wastegate. Downpipe removal now takes 2 minutes



Next up, replace passenger side lower control arm before my trip to canada for F1 and Mosport next weekend. Discovered it was blown while crawling under the car to play with the downpipe. Guess that explains the occasional shaking I get under braking :-P

Nice V Band, nice Carbon plug cover too

Yeah, other than the extra heat it'll hold in on the coils! :wink:

New Track wheels curtosey of 034 :thanks:


Arrived just in time for the COMSCC mosport track event. Wheels are Rota Torque 17X8 shod with 255/40/17 Toyo RA1s. I would have shaved them if I had time, oh well, these tires still kick ass even with full tread.

you will soon wear them down to slicks

Nice wheel/tire combo Marc!

:stupid:

"courtest of 034" ??

are you guys selling wheels now, too??


*cue quick witty response from Javad along the lines of "we'll sell you anything you need, for a price"* :wink:

I got a call today from the guy I sold my 90q20v to, apparently the car was having clutch slave issues. So I loaded up the wagon with tools to pressure bleed the clutch figure it was possibly air in the lines but also packed a spare clutch slave I found in the basement just in case. He's local so it was only a 2 minute drive.

I get out on the main road go to shift into 3rd and I hear a *SNAP* and my clutch pedal goes to the floor :curses: :curses:

I coast the car into the town hall parking lot, take a peek and the goddamn pedal snapped at the tab that connects to the clutch slave rod :x

So Keith arranged a ride to come pick me up and we worked on the slave on his car for a bit. Basic symptom was that the pedal would just stay on the floor when pressed, but could be picked up by hand. so I start bleeding it, really nasty fluid coming out of the bleed line. So I bleed it till it comes out clean, but then notice that brake fluid is now leaking from the bottom of the transmission housing. Goddamn seal on the slave was completely blown out, the piston was just pissing fluid straight into the tranny. Didn't quite finish the install on the new slave because it was getting fvcking cold out, will help him out again tomorrow.

Anybody got a spare clutch pedal assembly for an S6 (what else fits?) :bashtard:

That sucks, and is real weird too! I would think even A6 pedals fit. See with Weldon, he must have a bunc as I doubt he sold much of those...

My clutch slave blew out on the track 2 yrs ago...I thought it was clutch master and had a spare, swapped that out, kept bleeding the clutch but fluid kept pissing out....I was done for the day as no spare clutch slave:(

a4kquattro wrote:I got a call today from the guy I sold my 90q20v to, apparently the car was having clutch slave issues. So I loaded up the wagon with tools to pressure bleed the clutch figure it was possibly air in the lines but also packed a spare clutch slave I found in the basement just in case. He's local so it was only a 2 minute drive.

I get out on the main road go to shift into 3rd and I hear a *SNAP* and my clutch pedal goes to the floor :curses: :curses:

I coast the car into the town hall parking lot, take a peek and the goddamn pedal snapped at the tab that connects to the clutch slave rod :x

So Keith arranged a ride to come pick me up and we worked on the slave on his car for a bit. Basic symptom was that the pedal would just stay on the floor when pressed, but could be picked up by hand. so I start bleeding it, really nasty fluid coming out of the bleed line. So I bleed it till it comes out clean, but then notice that brake fluid is now leaking from the bottom of the transmission housing. Goddamn seal on the slave was completely blown out, the piston was just pissing fluid straight into the tranny. Didn't quite finish the install on the new slave because it was getting fvcking cold out, will help him out again tomorrow.

Anybody got a spare clutch pedal assembly for an S6 (what else fits?) :bashtard:

DOH DOH DOH DOH DOH

I think I have one Mark, I know I had one and I am hoping I did not just chuck it out...

I can probably check tonight

H

cool! let me know. I was going to call AAA to get the car home but since it was only like two miles I made it home in first gear I know, I know.. I'm a wuus for not speed-shifting.

a4kquattro wrote:I got a call today from the guy I sold my 90q20v to, apparently the car was having clutch slave issues. So I loaded up the wagon with tools to pressure bleed the clutch figure ............:

When does my warranty expire.... ???

From what little I've read, this is extremely common. I think it it is probably best to try and fix/ modify the one you've got.