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

[Andyrew]

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It appears as if I need to do an intro for the "Build Off Challenge" So here are the details

Andrew Dalen
Andyrew
Modesto, Ca
73 914 1.7 (Previously 5.7 SBC swap)
New engine: Audi 1.8 Turbo (Low boost: 275hp, Daily boost: 400hp, Race boost: 500+HP)
Exterior Color: Orange (Hugger Orange)
Interior color: Cinnamon Whisp/ Black Suede, Silver Paint
Wiring: Audi wiring 100%
Engine management: Modified OEM Audi ECU
ABS: Yes
Traction control and Stability control: Yes
Launch control: Yes
Cruise control: Yes
Climate control: Yes
OBD2 full control: Yes
Front and rear trunk: Yes!
Anticipated total budget required: $6500 less sold parts

The 5 large obstacles that I need to overcome are below.

1. Wiring layout/strip and integration into 914 wiring(Lights and wipers)
A. Finish ID'ing every plug
B. Finish stripping wiring (Dash harness, body harness, and engine harness)
C. Finish removing 914 wiring as well as existing wire identification
D. Install Audi harnesses
- 1. Locate and test install engine harness in body.
- 2. Locate and install dash harness in body.
- 3. Locate and install body harness in body.
- 4. Install engine harness in body.
E. Run power lines to the battery
F. Install battery and check for any shorts
G. Wire up lights and wipers
(IMG:http://www.914world.com/bbs2/uploads/post-172-1441612878_thumb.jpg)
(This was just one of three harnesses required)

2. ABS Module integration (replumb all brake lines, abs sensor and pickup integration, revised pedal box)
A.
B.
C.
D.
E.
(IMG:http://www.914world.com/bbs2/uploads/post-172-1441615551_thumb.jpg)


3. Audi engine/trans install
A. Remove v8 and cut out all non essential brackets and shelving in the engine bay.
B. Mount the mock up engine/trans together and locate it in the engine bay.
C. Cut out sections of the trunk for clearance
D. Create motor and trans mounts and mount engine/trans
E. Mount turbo and route plumbing for intercooler
F. Mock up and measure cv joints for order
G. Mount new fuel pump and run lines
H. Rebuild engine and install forged rods
I. Locate water pump, water reservor and lines
J. Plum intercooler pump, reservor, lines and radiator
K. Plumb oil cooler lines and run turbo lines
L. Run transmission shifter cables to the cabin, bleed clutch
M. Fabricate exhaust system
N. Oil and water in engine, hood up electrical connections except spark plugs, crank engine for 2 minutes to generate oil pressure and check for leaks.
O. Check ECU for error codes and address as needed.
P. Finalize connections and fire engine.
Q. Figure out what went wrong, fix it, and actually start the engine
R. (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/driving.gif)


(IMG:http://www.914world.com/bbs2/uploads/post-172-1428991066.jpg)

4. Audi a/c and heater box mounted and plumbed in the front trunk, factory Audi climate control integration.
A.
B.
C.
D.
E.
(IMG:http://www.914world.com/bbs2/uploads/post-172-1441616589_thumb.jpg)

5. Full custom interior build from scratch (custom dash, doors,center,back,ect. Tablet install for radio/nav/onboard diagnostics)
A.
B.
C.
D.
E.
(IMG:http://www.914world.com/bbs2/uploads/post-172-1429336661_thumb.jpg)
(IMG:http://www.914world.com/bbs2/uploads/post-172-1429337218_thumb.jpg)
(Note, this is draft one, I already have a new concept in mind for the interior that I have been drawing up)

You can see from the pics earlier in the thread that the bodywork is done and painted. Trunks will be painted in the build as well as probably a repaint of the engine bay. I also will redo the bumpers, but this may not make it into the build.

[madmax914]

I'm suffering from turbo envy! This will be an awesome build. I've been watching this for several months now, that 1.8L motor is impressive!

[Andyrew]

Figured out my front end wiring 914 side. I was waiting for a friend to come by and help me figure out some of the audi wiring and I have been waisting a lot of time thinking about wiring but it didnt happen, so.....




I pulled the v8 engine (buyer found), Ill be putting this in a members 914 in a couple of weeks.

Looks like it takes about 4 hours to pull the engine myself with breaks and figuring out how to lift the car up.

Ordered some spot weld cutting bits so the next thing is cleaning up the engine bay and removing the shelf. Once that is all done I can mock the engine and trans up and work on mounts, then when its all mounted I can switch back to finishing up the wiring

[76-914]

What is it about wiring? The easiest part of a rebuild; physically speaking. Mentally; the most demanding part. I can see an entire build in my mind except the electrical. (IMG:style_emoticons/default/sad.gif) It's like entering a swamp. (IMG:style_emoticons/default/dry.gif)

[Andyrew]

The biggest thing for me is that since I am simply using the Audi wiring harness I need to keep all the major components. I have about 30 plugs that I can not identify yet and I have yet to completely label the engine harness (However I have a full diagram that is labeled). I had a buddy that has stripped a couple of Audi's that knows most of the plugs in the car so I wanted him to come and help me ID the plugs I couldnt identify yet so I can determine if there are any more harnesses I could remove, or at least so I can place the harness in the correct place. Once that is all done I can work down the list of my TO DO's on my wiring.

NOTE: I updated post 422 to reflect my wiring to do's and my engine related to do's.

[Andyrew]

Current interior concept.

[Mueller]

Neat drawing...looking forward to seeing this in person when you finish it.

[Mike Bellis]

I'm looking forward to Andrew actually driving his car... (IMG:style_emoticons/default/dry.gif)

[Andyrew]

Would be nice for sure (IMG:style_emoticons/default/smile.gif) I doubt I have more than 5k miles on the car in total (IMG:style_emoticons/default/sad.gif)

[Andyrew]

There Multiplying... (IMG:style_emoticons/default/blink.gif)

Delay in progress due to mini build on members car.

http://www.914world.com/bbs2/index.php?showtopic=267385

[Andyrew]

Happy Birthday to me! (IMG:style_emoticons/default/cheer.gif)

I received my new fuel setup in the mail. Very excited about this.


Bosch 1000CC EV fuel injectors (Can run up to a 93% duty cycle reliably) This puts me right at 545HP max at E85 with 43.5psi.

Fuel pump is the outstanding Bosch O44 which is one of the strongest and linear in the industry and can change the fuel pressure if I find that being required.

Now here is the fun bit (IMG:style_emoticons/default/smile.gif)
http://store.034motorsport.com/fully-enclo...-bosch-044.html

Fuel surge tank. This encloses the Bosch 044 fuel pump and allows for it to be submerged constantly(Less noise and cooler running). The surge tank is primed by a carb low pressure fuel pump and remains full constantly effectively preventing any possibility of fuel starvation in corners. This also has the added benefit of allowing me to use the stock style fuel lines since they will be under zero pressure and allow for 100% flow of the lines. I will put this surge tank in the engine bay and it will keep my expensive high pressure lines very short and allow for no line pressure loss due to length (IMG:style_emoticons/default/smile.gif)

Its a win win win!

Presents from my wife.

Ironically my wife checked out my amazon wish list and grabbed a couple items.

1.Low pressure fuel pump
2. Roller and corner roller tools for building the interior
3. Shades (Because you have to look cool)
4. Candy (IMG:style_emoticons/default/smile.gif)
5. Beer chiller

Finally had some friendly competition between my car and her car with her driving on Forza! Very proud that she actually beat me when I was using a stock 914!

[Mike Bellis]

turn up the pressure and turn down the duty cycle. I'm running at 4 bar (58.8 psi). 034 recommended my 330cc injectors at that pressure for my hp goal.

[Andyrew]

Really 330CC's? Im really surprised that your able to push those injectors that much... I had 440's that I maxed out and IIRC I was running a 4bar FPR, mind you I was making similar power that you are now. You sure your only on 330's?


And yes I don't plan on running my duty cycle that high, I'm just showing where the injectors currently are at the standard pressure. I am probably going to tune for 4bar FPR. Whatever my tuner thinks is the best for my needs (IMG:style_emoticons/default/smile.gif)

[Justinp71]

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With being a recent vw/audi owner (GTI), I am excited to watch this build.

Andrew are you pulling the motor out of the A4?

[Andyrew]

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With being a recent vw/audi owner (GTI), I am excited to watch this build.

Andrew are you pulling the motor out of the A4?

A4 has been sold as a driver. My daily being my Fiesta ST has given me no need for the quattro...

Motor I have is out of the junkyard. Im going to open it up to see if I want to built it. But I am keeping an eye out for a good usable motor. Maybe one with VVT so I can get some more low end.


End goal is to build a motor with cams, ported, oversized titanium valves and springs, rods/ stroker/pistons. Build it to rev to 8500 and put a larger hot side if I feel it needs to breath better up top. That would give me well over 4k rpms of usable power.

[76-914]

OT: Just saw your car in the calendar. Great shot! (IMG:style_emoticons/default/evilgrin.gif)

[Andyrew]

Last years calendar right? I specifically didnt enter this year as I was already in it last year and wanted to give more people an opportunity to pop in..

Besides I voted for the hillside shot of the "multiple" cars, my Fiesta ST is actually hiding in the back (IMG:style_emoticons/default/smile.gif)

[Andyrew]

Gotta get back on the horse!

Engine shelf removed/trimmed.






Test mounted the engine/trans then test set it in the engine bay. Looks like to make the axles level the pass side needs to be 1/2" higher than the drivers side when its on the movers dolly. Simple enough (IMG:style_emoticons/default/smile.gif)

[Andyrew]

Im still positioning the setup left,right, up, down, tilt, back. In my head the setup needs to come back an inch and up 2-3, or tilted forward about 5-10 deg to get the trans tucked up a bit more and the axles more level with the suspension. I'd like to get the axles almost level when the car is in its resting position.






Hard to see in this photo, but the trans is about 1" forward of the axles when the engine is touching the firewall.


And finally, started reinforcing the rear shock tower for my brace. I am going to remove the firewall where the blue tape is (did get a full pic of it) and rebuild/box it about 6" back where the shocks are. I'm going to have a local metal shop bend up some steel similar to the 914 humps for strength and weld it in to the 1" bar brace I weld in between the towers. I am going for a near factory look when done.

[rightpedal]

Are you going to add more support in the front corners of the engine bay? I ask because we were looking at my build car (cut out engine tray) and the parts car (tray intact) thinking that's a fair amount of triangulation/support. Just looking to what others are doing in that arena.

Steve