The Project Pad

alxdgr8 wrote:What are you using for a trans? 01A from the B5?

No, Ive got an 01E in there right now.

Haven't really started putting this 1.8t in yet. Got the donor car tore down and will be off to the junk yard tomorrow. Had a bit of free time today so I ran a couple errands first thing this morning and then back into the shop to get gear ready for duck season and MAYBE tinker with cars for a little bit. Actually got quite a bit done in the amount of time I had to do it in ha! Got the boat/dekes ready, a game plan scratched out with this car and got a little work done on the black 4k.

The motor had massive oil leaks and I needed to get it on the stand anyhow. Yank the clutch off and what do I see? A light weight single mass flywheel and a new stockish clutch! Hell yeah! I was planning on going that route later this winter but can now save the money.. So, got the motor on the stand and made a list of what the motor needs. I ordered up a complete lower end gasket kit, valve cover gasket set, shorter serp belt(to get rid of the viscous fan) and also 2 sets of throttle pedal bushings. It also needs a timing belt but I'll take care of that this winter being as I can easily throw one on in the car.

Also had a bunch of parts show up over the last week and a half. Nice order from summit came in along with my motor mounts from Issam. I'm shooting to have the motor cleaned up and new gaskets in, the axle flanges in so I can run AWD and the motor dropped in by the end of next week. We'll see how ambitious I'm feeling though, being as duck opener is on Saturday haha!

You ding dong, swap that timing belt while you have it on a stand! Do it right the first time.

Sorry Dane, but I'm with AJ here. Make life easier on yourself and do it out of he car

Other than that, glad you are getting on this. Will be fun in the dirt.

There is no difference with the motor on the mounts vs on the stand, except maybe a little bit of height. The front ends cut off the car lol. It'll get a timing belt on it this winter before it runs. I can't get all the timing stuff I need for a month or two and with it in the car I can start working on other things that need to get done. Jeewiz.... Lol

Now that the car has sat in time out for a couple months, I'm ready to get back at it lol. Had a pretty good season shooting ducks, got the black car pretty much finished off for the year and am now 100% focused on getting this pig together. Progress report!

While I was doing the gaskets on the motor I found a nice surprise when I pulled the oil pan! A set of SCAT rods looking up at me! Boo yah! Got all the gaskets done, clutch on and then went to put the motor in the car. First thing was I got sent the wrong mount, twice haha. I've now got two pairs of 4 cyl motor mounts sitting here and only the drivers side mounts will work on an AEB. Figured out the pass side mounts are for an ABA and will in no way work with a bottom mount turbo and it doesn't even bolt up to the block. Bit of a waste of money but so it goes.... I've got the motor in the car on one mount now and have a game plan to cut apart the stock A4 mount and rework it some.

So far I've got the motor in the car, skid plate/IC mount made, DP made, axles in, cooling and IC plumbing figured out and radiator mounts figured out. I should have the actual radiator mounted this coming week and I've got a decent order of parts coming so I can run all the plumbing for it and the IC.
The intake manifold is stupid close to the master cyl and it hits the proportioning valve, so I ordered up an adjustable valve to clear up some room. I'm hoping to have a good chunk of the mechanical shit sorted by the end of the month so I can get to wiring this thing in January.

I've also go almost all my parts for my BBSE setup. I'll order up my steel sleeves from Compbrake in January as well and that should be done too! Moving right along.... Pictures!

Couple quick shots..

Pics of the downpipe. Looks huuuuuge bolted to a ko3 haha. I made it about as tight and high up as I could for a 3" tube. I'll have to make a relief in the skid plate when the time comes, but I'm happy with it.

Merry Christmas or whichever holiday you celebrate this time of year! Hope you all are having a good holiday season!

I'd gotten a bit of time to work out in the shop this week and got quite a bit done! The motor, radiator and intercooler are officially done. I just need to make a small brace for the upper mount on the IC. Maaaaan.... Cast aluminum SUCKS to weld with a spool gun haha. My motor mount isn't the prettiest of things but it's solid. I ended up using a stock B5 mount mashed together with a URS4 trans mount. Should work well but I'm a bit relieved it will be hidden under the turbo!

I also had a bit of time to get a Summit adjustable proportioning valve installed. Some of you may have seen my post on "small chassis Audi" on the facebooks. To those interested, they're pretty much bolt on in 4000s by either getting adapters(1/8 npt->10mm bubble) or using one of Wilwoods units that is already tapped for 10mm bubble. I think my BV was ok, but I needed a little more room to clear he intake manifold.

I built a skid plate mount that doubled as my IC and Rad mount a week or so ago and I finally got around to gusseting it this week and finishing off the lower rad mounts. I used cut down hockey pucks which I sleeved with some small tubing I had. They fit in between the tangs of the radiator quite well and should work out just fine. The upper mounts are "Ls" welded to both the rad and core support, with bolts through. Another thing I noticed with this lower bar/mount is it was a little flimsy once bolted to the chassis arms(?). The mount itself was stout, it was literally the arms that had a bit of flex to them, so I ended up plating them with 1/8 plate. Not so much fun with a hacksaw but it made everything nice and solid. I figure too once I get the actuall skid plate mounted, the whole front end of the car will be really solid. A small hiccup I came across though was prior, the arms weren't square from sitting for a couple of years with no core support. At least that's my guess anyhow.... Once everything was mounted solid, they squared up and threw my rad mounts off a little haha. Fixed that and now it's all bolted together nicely now. Radiators a little off but should work out just fine. More so just bugs me than anything..... Lesson learned!

That's where I'm at now. It's looking like I'm keeping the schedule I was chasing and I'll be able to start wiring this thing next week! Wooohooo!

This week continued....
Here a few more pics. I'd also ordered some hoses and a reducer for my IC plumbing last week which showed up as well. I ordered a couple of wrong sizes so I wasn't able to finish that stuff off this week. Thinking week after next I'll order up some more things to finish it off, just need to let the credit card cool of for a little bit haha. At least I've got it some what sorted so I can just throw them on and the cooling system will be done while a tiny bit of fab work will be needed to finish the IC piping. Not too involved though so I'm going to cross those two jobs off the list that's on the windshield!

Look like you have gotten some nice work done! How strong do you feel your mount arms are? I know all too well how crappy cast Alum can be to weld, as I do it on the regular. I have never used a spool gun though, and thought they were really only suited to extruded Alum becuase of how they work.

Merry Christmas Dave! I got your text but haven't been able to reply, I haven't left my house at all today lol. I feel pretty confident in that mount. It's not the prettiest thing but it should work. The picture makes it look worse than it is. I tried heating it up some prior to welding to try and get some of the shit to come up to surface. Worked ok but that spool gun just doesn't have the cleaning action or something that a tig machine produces. I would stitch a little then clean with a sander. Weld a little more then sand, etc. The welds are in there, just not awesome on the eyes lol. I also boxed the whole thing and then stuck it in the vice and smashed t with a hammer.
Not scientific but it passes for now hahaha.
Hope you had a good holiday!