project stuka Options

[roadster fan]

(IMG:style_emoticons/default/wub.gif) One of the coolest projects going right now!

Jim

[rohar]

I did a similar swap about 10 years ago. 1.8 8v with Audi 5000 internals and a turbo. I managed to fit it in there without cutting any sheet metal.

The company that supplied Turbonetics with silicone connectors is here in town. For $100 they cut me a custom elbow that fit perfectly on the throttle body. IIRC, I had to fab a custom water flange on that end of the head as well.

Ran it for a couple of years, then it found a horrible end (nobody was hurt).

I recently picked up another chassis, and I've still got the Kennedy adapter and radiator setup that I pulled from the wreck and I'm headed for an ABA turbo 16v next. I've scheduled the swap for this winter (brakes and suspension first). Again, it appears no sheet metal will have to be cut as I'm ditching the distributor. Again, it looks like the flange on that end of the head will have to be fabbed.

I've been shopping for an audi box as well, but I'll probably try and kill the 901 first (IMG:style_emoticons/default/wink.gif)

[Todd Enlund]

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What size are the Cup Is? What spacers are you running?

[paroxysm]

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What size are the Cup Is? What spacers are you running?

The cups are 17 by 9 in the rear and 17 by 7.5 in the front no spacers, just said to the tire guy give me the same offset as a 72 911. I can check the offset tomorrow if you'd like.
more driveway shots!
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[paroxysm]

The reason this hasn't changed much
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is because I had to pour my heart into my wifes car first.

[Todd Enlund]

The cups are 17 by 9 in the rear and 17 by 7.5 in the front no spacers, just said to the tire guy give me the same offset as a 72 911. I can check the offset tomorrow if you'd like.

I would like... no hurry. I'd like to know if your 5-lug is a 911 front end also. When I get back to my car, Cup Is are what I want on it... although 9s are a bit wide for even a 2270 Type IV.

[paroxysm]

The cups are 17 by 9 in the rear and 17 by 7.5 in the front no spacers, just said to the tire guy give me the same offset as a 72 911. I can check the offset tomorrow if you'd like.

I would like... no hurry. I'd like to know if your 5-lug is a 911 front end also. When I get back to my car, Cup Is are what I want on it... although 9s are a bit wide for even a 2270 Type IV.

opps! I looked real quick and in the rear I did add a spacer from an 84 944, but the front there's no spacer, it's been so long that I forgot about the spacer.

[championgt1]

I dig the mustang! (IMG:style_emoticons/default/aktion035.gif)

[jpnovak]

Great project. Could you post more pictures of the radiator install in the QP? I Have a suby swap in progress and was considering this location.

[paroxysm]

You know the story not much time or money, plus holidays and cold equals little progress. Had a friend stop by and wanted to compare cars so I complied.
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[paroxysm]

I did clean up the wiring more in the engine compartment, and I also have all the signals, headlights, and most of the instruments working.
My boost piping was always just exhaust pipe for mockup reasons will eventually get some nice stainless.
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I think I might get flamed for some of this so flame suit on!

Here are some brake pics, on the rear you'll see what I believe are 911 m front calipers that I ground down to fit.

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The fronts are my 4 piston big V's, they're off a Volvo 240 with 3 inch spacing.
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I'll try to show how much pad is used/not used.
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[paroxysm]

Thought I'd update a bit, had the car running and driving, but then it quit on me, in the driveway while bleeding the coolant.(thats a g60 for you)
I found it was the old hall sending unit and decided it was time to start the 16 valve swap, because it has a new hall sending unit.
old motor
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new motor
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I'm going to cut and weld the intake manifold so it fits above the lysholm supercharger and will now keep all the boost piping on one side right near the intercooler
here i will need to build a throttle body spacer to keep the tb from hitting the intake
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my motor will run on digi 1 still, and I had to get new injector cups to fit the 16v because it was cis motronic. I hate digi cups because there plastic junk and almost never come out. So I decided to try and cut down the cis cups and it worked, here it is with an old injector and the plastic cup and the left over cis piece.
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I also have been collecting parts to throw in an audi 5 speed, but really want to buy the aftermarket single mass flywheel thats 12 pounds compared to using a junkyard stock 25 pounder dual mass. Still need a starter, hydrulic clutch master and what ever I'm doing for axles?
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Here is the clutch fork from my 901 you can see it was rubbing on the pressure plate , is this from having adjusted wrong?
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I hope not to use the 901 again, but will do it if I can get this 16v motor together fast enough. I will need to change the compression ratio in the 16v, and drop it a point and then do a test fitting in the car.

[Mike Bellis]

Cool Build!

[silver74insocal]

i was wondering what happened to this build...i read it years ago and researched doing an engine swap for at least a month straight!! (IMG:style_emoticons/default/beer.gif) glad to see you are still fighting the good fight. Keep up the good work!! (IMG:style_emoticons/default/popcorn[1].gif)

[paroxysm]

I have been lurking for a while now but just got my parts to complete the passat tranny swap. Over the summer I built my shifter linkage (rough) out of old crap I had laying around (vw mk3 linkage) and my boxster shift cables.
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I also finally got my mustang home here the 914 and it meeting again for the first time in years
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I had to cut a hole in the garage to fit the mustang under the new deck I built for my wife, and then get it under there, for winters coming.
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This last weekend I spent 5 hours under a passat grabbing my parts I've been waiting years, for while I built my motor. I've flashed up my 16v g60 but I think the fuel pumps dying because it screeches, and I have to prime the pump with a lot of ignition turns to have it only sputter and die on me. Sometimes I can keep it running for a few minutes but it will die if I hit the gas. When I first flashed it up it ran and I could even rev it, then it started to only run if I unplugged the coolant temp sensor. I'll try a new pump here after my new transmissions in.

[Jon H.]

Winters Coming? Your in the 'Whack, it only rains in the winter with the odd snowfall (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/biggrin.gif)
Nice mustang!


Jon

[paroxysm]

Just wanted to update where I stand on this project.
One of my best friends who was building an all wheel drive syncro scirocco has finally given up on his car. He has MS really badly and can't drive standard anymore. He really wanted to see his motor run even if it was in a different car so I purchased it off of him.

I was fighting my motor in the 914 and was thinking my ecu was bad, so instead of finishing my motor I've now installed his.

The deal was i paid him $1200 and had to carefully take out his motor, and I would get everything to make it run.
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Heres a horrible shot of both motors.
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The new motor is an AWW 1.8t with a gt28rs big turbo and all the programing.
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All the junk I don't need.
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Me working out the piping placement.
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Piping done.
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Stupid old ecu was causing me to have injector grounding issues.
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The six or so wires that make this puppy run.
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The test firing stage, and it runs! All done in about 2 months.
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So now I have a ton of clean up to do, just had it run last weekend. I will fill it with coolant and redo my hydraulic clutch line, build an exhaust then do a test run.
I also have a electronic boost controller for it that I might pipe in. I will also need to tune it, right now its set for 15psi. The motor only has 5000km on it and the turbo was brand new never ran.
The first person to hear it run was my friend whom I'd purchased it off of, he was filled with mixed emotions, but was happy to finally see it run.
The old motor I will keep and probably put into a mk2 golf/jetta or corrado again.

[Cairo94507]

Man what a project. Very impressive and I can't wait to see a video of it running and driving. It should be a beast.

[Andyrew]

Awesome!

Do you have an active build thread on here? If not you should really make one, your build looks interesting! I think you have your engine about 2" forward of mine, do you have any cv issues and what cvs are you using?

What turbo are you using and what turbo is your stage 3 file for? I ran my turbo on my apr stage 3 file(made for a gr28rs) and didnt have any issues at 10psi but I was getting stuttering above that. You can get it tuned by some online tuners that give you a base tune and then fine tune it from logs you run.

The turbo is a gt28rs, my program is revo stage 3 for the turbo. My motor is an AWW 2001 with only 7000 kilometers on it, I paid $1200 for it.
The motor came with a electronic boost controller(not hooked up yet), walboro fuel pump, wideband O2 sensor, genesis 500cc fuel injectors, all new never used.
Now for the CV passenger side is a stock 911 with a empty CV case from a passat B5 used as a spacer, drivers side is a bmw 540i that was the correct length. Don't know how long they last but I had to go cheap for now and that setup only cost $10.
Only problem I've been experiencing is sometimes the car refuses to shut off, place the key in the off position car tries to shut down but then it revs up and continues running, also if I put the car in reverse with the ignition off the backup lights are on.

Great build! Youve gone through quite a bit of motors!

One issue I see very glaringly is your intercooler setup, you dont have any air going through that intercooler and that is a small intercooler for that size turbo.
I would suggest a water to air intercooler or at least adding some ducting, some water injection and maybe an intercooler sprayer.

I think most of your issues could be wiring related, how much of the AWW wiring harness are you using?

I think its really cool you got an off the shelf axle solution

How much boost have you run so far? I love the GT28RS turbo on this motor, properly tuned its super responsive and gives a great amount of power.

[paroxysm]

Awesome!

Do you have an active build thread on here? If not you should really make one, your build looks interesting! I think you have your engine about 2" forward of mine, do you have any cv issues and what cvs are you using?

What turbo are you using and what turbo is your stage 3 file for? I ran my turbo on my apr stage 3 file(made for a gr28rs) and didnt have any issues at 10psi but I was getting stuttering above that. You can get it tuned by some online tuners that give you a base tune and then fine tune it from logs you run.

The turbo is a gt28rs, my program is revo stage 3 for the turbo. My motor is an AWW 2001 with only 7000 kilometers on it, I paid $1200 for it.
The motor came with a electronic boost controller(not hooked up yet), walboro fuel pump, wideband O2 sensor, genesis 500cc fuel injectors, all new never used.
Now for the CV passenger side is a stock 911 with a empty CV case from a passat B5 used as a spacer, drivers side is a bmw 540i that was the correct length. Don't know how long they last but I had to go cheap for now and that setup only cost $10.
Only problem I've been experiencing is sometimes the car refuses to shut off, place the key in the off position car tries to shut down but then it revs up and continues running, also if I put the car in reverse with the ignition off the backup lights are on.

Great build! Youve gone through quite a bit of motors!

One issue I see very glaringly is your intercooler setup, you dont have any air going through that intercooler and that is a small intercooler for that size turbo.
I would suggest a water to air intercooler or at least adding some ducting, some water injection and maybe an intercooler sprayer.

I think most of your issues could be wiring related, how much of the AWW wiring harness are you using?

I think its really cool you got an off the shelf axle solution

How much boost have you run so far? I love the GT28RS turbo on this motor, properly tuned its super responsive and gives a great amount of power.

Thanks for the compliments.
The intercooler does have a huge MR2 vent cut through the side of the car and into the engine bay supplying it with fresh air as long as I'm moving. I was thinking of getting one of those fat side mount intercoolers that replace a the stock unit. I also have a small fan that I can wire up behind the intercooler to draw in more air when sitting in traffic. I'll watch the intake temps and decide what will be my ultimate solution.

My motor came from a friends syncro car who was paranoid he'd break his awd and had the tune programed to max boost to 15psi.

The engine was wired into a scirocco by a local shop, I removed the engine and wiring myself and, dissected 90% of the spliced AWW/scirocco harness, just didn't rewire all fuel injectors and fuel pump relay. I should have checked out all of it further, but I'll eventually get to it. My ignition switch is also a little buggered and has been gutted so there could be a couple culprits.

I will throw this thing on the road this year if I can get a couple of other problems figured out like no brake lights, some water leaks from various fittings, and rebleed the clutch.