Andyrews Progress Thread, 1/16/22 A Trip to The Red Barn - Lets fab a Firewall! Options

[Mike Bellis]

They are meant to be bent on the ground with a handle and foot. Notice the ridged part on the right side of t your pic, this is for your foot. The tube hooks into the left side and pulling while stepping makes the bent. Curves and angles are very repeatable.


https://www.youtube.com/watch?v=zimw9PShuww

[Andyrew]

The video I saw earlier didnt show some of the stuff on this video. Great video! I didnt realize you use your foot for the pressure.

[Andyrew]

Well the SBC kit has been posted. http://www.914world.com/bbs2/index.php?showtopic=254491

On a more promising note I did receive my Boxster shifter and linkage!!

Also I have been playing around with fabric for the interior and practicing sewing (IMG:style_emoticons/default/smile.gif)


Deciding on colors for the interior, but I think I want to match this with orange stitching, and black suede for the seats/doors with leather accents.


I've always loved brown interior, never had it!

[Mueller]

Hey Andrew,

I bet it'll be a screamer with a built 1.8...I hope to go for a ride in Mikes 1.8 this weekend, at least around the block or a quick freeway trip! (hint, hint Mike! )

For bending the tubing, also look into filling with sand...depending on the radius, with or without heat...i have an oxy/acetylene setup if you want to come over if you need some extra heat.

A few youtube video and if you have a VCR, I have a tape you can borrow, or you can rent the DVD from here: https://smartflix.com/store/video/141/Working-with-Tubing

If you need anything CNC'd or plasma cut, don't be shy.

[Andyrew]

Mike,
I will need to come up with some axle flangr adapters, I think I am going to use the bus CV's that i have with the outer adapters and make some inner adapters for the Audi flanges. Ill let you know when i get to that point and let you know. (IMG:style_emoticons/default/smile.gif)

Thanks for the tip on the sand! My dad is finishing buildin a GSXr powered buggy so we have been playing with bending larger pipe with a HF bender, but judging from the bends ive seen I think the conduit bender might work better for the small diameter pipe Ill be working with. I do have a map/oxy torch and thatll get what i need red hot so that should be sufficient, but thanks!!

I also really want a ride in Mikes car (IMG:style_emoticons/default/smile.gif)

[Mike Bellis]

You guys will have to arm wrestle to see who rides first.

[Andyrew]

Got a little bit of work done. Hopefully I will finish up the shift linkage this weekend (IMG:style_emoticons/default/smile.gif)


The main pivot that I used was a timing belt idle pulley. I planned on buying a new one and this fit the bill really nicely! Most of it was made from flat stock, the bit that goes around the trans shaft was the most difficult as after 3 times going to the steel shop I got the wrong diameter... In the end I settled on doing what Mike did and have it bolt tighten vs just a slip tighten.

You can see there is a lot of extra metal on the setup and it will be trimmed off after all is said and done. What is left is fabricating the brackets to hold the cables in place then to test the system and adjust. My bench testing shows that it seems to work just fine, The linkage moves a bit more than necessary to find reverse, but I dont really see that as a long term issue.



I did some maths to figure out angles and lengths... Its interesting that my setup is so much different than Mikes. in terms of lengths and angles. I highly doubt there will be much if any difference in feel.


Oh and a fun toy (IMG:style_emoticons/default/smile.gif)
I hope I dont go overboard with this... But I plan to hide little Porsche crest everywhere, and a couple obvious one's in the headrests. If anyone wants me to imprint any leather or vinyl PM me. Its fairly small..

[Andyrew]

Purchased this radiator and took some measurements. It actually came in 2 days I think? 2-ROW/CORE ALUMINUM RADIATOR+BOLT-ON RED FAN SHROUD 00-05 TOYOTA CELICA GT/GTS
http://www.ebay.com/itm/180901154597


Comes in two boxes separately, packaged fairly nice. However one of my plastic drain plug screws was broken. I plan on plugging those with a bolt anyways.

Core height

Actual height with mounting points

Width inlet to outlet

width side to side top, also shows plastic drain (one in upper right and lower left)

Width of the side tanks middle

Horrible placement of tabs for the radiator shroud. I THINK it will bolt on but totally skewed angle and it doesnt really sit flat. I'll be using a gasket/foam underneath.

One hole lined up... This was with the shroud in what I believe to be optimum position.

Total width just under 6", Core width is a full 2"

Side note, Core is a true 2 row. You can see/feel inside where the hose inlets are, and it looks to be of fairly good construction.

I also tested the fans and they did not flow what I felt to be enough to cool the system, Especially if I have a condenser in front of it. Fans are a claimed 1250 and I suspect closer to 7-800. I have an old Audi 12" fan that pushed out noticeably more air in a more uniform fashion. Also my 16" fan just blew both out of the water (For kicks my Lincoln mark 7 fan pushed ME back...)

I suspect I will be replacing the fans down the road, probably before I even run them as they are just some Chinese fan..

[matthepcat]

No Chinese fans allowed

(IMG:http://www.914world.com/bbs2/uploads_offsite/s8.postimg.org-11125-1432974932.1.jpg)

(IMG:style_emoticons/default/smile.gif)

Looking forward to your build.

[dakotaewing]

Andy,

Are the radiator inlet and outlet on the bottom of the radiator?
I haven't bought one of these, but I have been looking for a while -
It always appeared to me that the photos showed the radiators upside down...

Also, can you tell me which tranny your using? I see the post about the boxter shifter and linkage, but looks like I missed the post on the tranny details...

[Chris H.]

Yeah I had to bend/open the holes to get the fans to mount. The radiator itself is pretty good. The fans should be enough for my setup but we'll see. Inlet and outlet are at the bottom, which is nice. I forgot to plug one of the drain holes on first start BTW...oops! Had to take the whole damn shroud back apart.

[dakotaewing]

Chris,

Do you have any pics of your shroud or the assembly of the shroud ?
It would be interesting to see what you did -

[Chris H.]

Sure. I'll dig them up.

[Andyrew]

Dakota,

Trans is from a 92 Audi 100 FWD v6.

I've got a spare A4 quattro transmission that I am going to see about pulling some gears from to make the V6 box more 1.8 friendly. I dont mind being long toothed (Drove a 944 turbo for many years) but I dont want it to fall out of boost...

[Mike Bellis]

I find my gears too short most of the time. The V6 gearing should be fine at your future HP level.

[Andyrew]

Well that GT28 is VERY responsive in comparison to the Comp turbo that I am planning on running. Here is a video of a guy with the same turbo in his 1.8. Since I am going to be spinning this engine higher it will help but I dont think I'll have nearly the powerband that you have, and with the turbo lag even in RPM, a bit tighter first and second should help. It'll still be longer than your 1.8 box. What is your trani code or gear ratio's? I cant seem to find any passat trani ratio's to compare to the Audi ones.
https://www.youtube.com/watch?v=s1BH_9IJKWw

I have been considering bumping my engine to a 2.0L when I rebuild my engine so as to help with the low end.

Below is a link to the spreadsheet of the three gearboxes and others.. The yellow one is the V6 box as it stands (Audi 100 V6 fwd), the first grey is the A4 1.8T quattro box, and the tan is the custom box with the gears listed on the side. I was planning on snatching a V6 A4 box from PnP that would have the taller 5th gear than my Audi 100 box. This would really help lower cruising RPM and noise. If anything I could open the box in PNP and just buy the gears or something...

https://www.dropbox.com/s/8kikaf08oij9ijx/A...atios.xlsx?dl=0

[Mike Bellis]

Mine is an EZG.

See spreadsheet...
 012___01W_Audi_VW_transaxle_data_simplified.xls ( 41k ) Number of downloads: 266

[Andyrew]

Aha,

Well thats the same FD,1st,2nd,3rd, and 4th as my proposed custom box... I need to go for a ride....

What size rear tires are you running, IIRC your running a shorter tire than me, combined with me running more RPM would make my gears feel much longer than your box. I remember when I had my KO3 and shifted at 6k I felt like it was a pretty short gearbox and hated going into 3rd for 60.. When I went with the big turbo and increase the limit to 7250 I loved the gear spacing.

[Mike Bellis]

Aha,

Well thats the same FD,1st,2nd,3rd, and 4th as my proposed custom box... I need to go for a ride....

What size rear tires are you running, IIRC your running a shorter tire than me, combined with me running more RPM would make my gears feel much longer than your box. I remember when I had my KO3 and shifted at 6k I felt like it was a pretty short gearbox and hated going into 3rd for 60.. When I went with the big turbo and increase the limit to 7250 I loved the gear spacing.

245/50/16
I love the spread of 3-4. 1st & 2nd are short and 5th needs to be taller. Oddly enough my 6 speed has the same final ratio (.003 difference), doing 80mph at 3200 rpm. 1st on the 6 speed is super short.

[Andyrew]

Got the cable shifter done yesterday. Very happy with it! I need to come up with some way of retaining the cables, right now there pretty tight I have to wiggle them with some force to put them in place, but its possible itll come out. Maybe a slotted hose clamp or zip ties (Or I could leave it... I seriously doubt it'll come loose) Whole shifter mechanism weighs 4.2lbs including the mounts. Better than I was expecting (IMG:style_emoticons/default/smile.gif)







https://www.youtube.com/watch?v=WN1-YbGolBw


I mounted the engine on a cart to push around a bit better. I think I am going to start with an engine bar mount bar similar to the 914 bar. Should be easy enough to fabricate.