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

[Andyrew]

Got a box of goodies today!

Gonna spend quite some time identifying everything... BUT

Top box is engine harness
Bottom box is dash harness plus the gas pedal (DBW)
To the right from the top down is: Ecu, Coils, Throttle body, MAF

Not pictured is alternator, and the dash cluster itself is on its way.


What I need now is the body harness itself. So that will be difficult/fun. I've got a couple local guys parting their cars out but I havent been able to convince them to let me at their parts car with three guys for a day... I can do pick and pull but Id rather have most of the stuff ripped out by someone else (IMG:style_emoticons/default/biggrin.gif)

[Mike Bellis]

All you need is the ECU harness, Dash cluster and harness, gas pedal and ODB plug. Everything else is extra. Wait, are you still going with the CCU?

[Andyrew]

Yup.. Doing the whole shebang. ABS, traction control, ect. So I want to pick up a body harness to replace all of my current wiring. Whatever I dont use will either be unplugged/coded out/resistors. I'll have my tuner just remove everything I dont need.

[Mike Bellis]

I'll be watching your wheel speed sensor solution... (IMG:style_emoticons/default/idea.gif)

[Andyrew]

My understanding is that the speed sensor is based on the abs sensor. My plan is 944 turbo front abs sensors and custom rear to match my overzised rear tires.

[Andyrew]

Oh and the rear will be on the cv adapter trans side.

[Mike Bellis]

Oh and the rear will be on the cv adapter trans side.

If you go with something like this http://www.pacificcustoms.com/mm5/merchant...r-drive-flanges I have 3/16" magnets for you to embed. I think I have 12 left over, 3/8" long.

[Andyrew]

Based on my understanding most abs systems have the magnet on the sensor side, but Ill let you know! The spacer/adapter will be custom milled I suspect.

[Andyrew]

Playing around with the tire calculator I realized that I can use a 245/45/17 tire up front instead of the 245/40/17 tire currently up front and all of a sudden the front/rear ratio is perfect vs being 1" off.... I'll keep this in the back of my brain as I go through the ABS stuff... This might let me use stock Porsche ABS rings in the rear vs milling my own rear rings (an extra 5% more slots to compensate)

I'll have to see what I can come up with for that.

I also found out some different ABS ring sizes that I can pick up so I might just mill that into my spacer for my CV's (should be relatively easy, make the OD on the spacer the same as the ID on the ABS ring, weld on.)

[JRust]

(IMG:style_emoticons/default/WTF.gif) Andrew I gotta say. My head hurts just reading about all that wiring (IMG:style_emoticons/default/confused24.gif)

I don't have the patience to do all you are doing. You & Mike are "Nuckin Futs" man. My kind of people of course (IMG:style_emoticons/default/evilgrin.gif) . Watching your thread to see this come together. Going to be sweet. Can't wait to go for a ride in it

[Mike Bellis]

You & Mike are "Nuckin Futs" man.

(IMG:style_emoticons/default/happy11.gif)

[Andyrew]

(IMG:style_emoticons/default/WTF.gif) Andrew I gotta say. My head hurts just reading about all that wiring (IMG:style_emoticons/default/confused24.gif)

I don't have the patience to do all you are doing. You & Mike are "Nuckin Futs" man. My kind of people of course (IMG:style_emoticons/default/evilgrin.gif) . Watching your thread to see this come together. Going to be sweet. Can't wait to go for a ride in it

I think Mike is a bit more nutz than I am to be honest! His wiring was way more difficult than what mine will end up being, and his whole car is just way more off the wall (In a good way)!

My wiring will be limited to plug and play. The MOST difficult thing will be figuring out the lights and a solution to the headlight relay. It WILL take a while for me to run the wires and eliminate the non essentials but the whole system can run with pretty much everything I am not going to be using removed.

The more difficult bits here will be the ABS fabrication, brake line fabrication, and figuring out the correct position of the stability control sensors and possibly tuning that code (Never heard of anyone doing it... so that will be SUPER difficult.. Luckily it can be switched off until its sorted out).


However all of that relies on someone actually buying the current v8 engine setup... I am at the point where I am getting anxious to put the 4 cylinder engine in place and start mocking everything up.. I can do a lot of wiring research in the meantime for what does what on the wiring harness and I still need to get my hands on a body harness....



I grabbed this and some other bits from my dads place.. This water pump should make a nice air to water intercooler pump. Pretty sure a lot of guys use this type of pump for this function.

[Mike Bellis]

I don't yet know what your donor car will be to get the body harness... When I did mine I went here: https://erwin.vw.com/erwin/showHome.do, paid a $35 for 24 hour access and downloaded every document VW ever made for my donor VIN. Well worth it. Full body wiring diagrams, tech articles, manuals, etc...

I don't know if Audi has a similar website but this was the best $35 I ever spent. I bet I downloaded 100 files or more.

[Andyrew]

Hmm.. Very interesting. This is what I've been looking for..

Mind sending me an example of one of the wiring harnesses so I can see what they have?
Or just posting a pic of it here?

[Andyrew]

I've been downloading some diagrams from the parts book, but there is no wiring charts or anything...
http://www.partscats.info/audi/en/?i=cat_v...567890&hg=9

[Andyrew]

One hour later and I've downloaded all there is to be known for the B5 A4 chassis.. Thanks Mike! This surely will be a help.

[Andyrew]

Been reading up on the stability control system and its requirements for the past 30 minutes... (IMG:style_emoticons/default/smile.gif)

Its doable! Requires more bits than I thought but still doable!

[Andyrew]

Had a couple weeks of no progress due to a vacation but I am back on it slowly!

Got an oil cooler and fan, currently have it hard mounted, but am debating putting some rubber in between the metal.

I still have one tab left to weld but ran out of time tonight.




I have the smallest SPAL fan behind it that fits nicely in the cubby I made. I will be using some foam between the oil cooler and the body to make a nice seal to the area below the headlight and cutting slits in the front of the fender well (directly behind the oil cooler) for the air escape and finally closing off the area under the headlights so air passes through cleanly.

Lines will be run basically straight back to the engine, likely in either the center tunnel or possibly in the dr side rocker.

Since I am keeping the factory oil-water cooler I dont need much of an external oil cooler. Still debating on line size but I might try to run 8-an if anyone knows of a pressure loss calculator for AN lines let me know.

[Andyrew]

[Andyrew]

Finished the mounting of the oil cooler and added a little padding.



Here you can see the beginning of the radiator mount, 1/8" bar makes up the radiator vertical support, the bit holes in the floor will be tig welded later to bring the strength back. Thats where the lower radiator mounts sit. There is a steel 5/8 x 5/8 U channel (commercial window glass stop....) that the lower portion vertical portion of the radiator sits in allowing for no air flow past the radiator. The floor is 16ga steel fully welded. Then everything is hit with zinc galvy.


And the weld joints hit with calking.


And painted rattle can.