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

[Mike Bellis]

Sensor at the engine inlet might be better. Water temp at the engine is more important than at the radiator.

I notice on mine the fans kick on at 180­° but the motor is running 190°. the water might heat back up a little as it returns to the motor due to heat soak in the hose.

[Andyrew]

It'll be at its hottest point right off the back of the engine so thats a plus..

Once I get the damn thing working I'll just pick a temp I dont want it any higher than and go. I was thinking 185* should be good. I had it at 140* just to make sure the system cycles properly. And if I can get it to maintain 140* in my garage on a hot day then it should prove the system pretty efficient.

[Andyrew]

So,

I finished off the radiator system, put the seals on the radiator and buttoned it up. Found a small leak on the turbo feed line and fixed it. Put the wheels back on and checked everything in that regard, backed it out of the driveway and took it for its first spin around the block (IMG:style_emoticons/default/smile.gif)


https://www.youtube.com/watch?v=Tl_GCoEC9-U


https://www.youtube.com/watch?v=YOCFI15nTfU


https://www.youtube.com/watch?v=36CBdqYQN-4



I'll be posting a youtube video weekly either as progress of the vehicle or myself driving the car (IMG:style_emoticons/default/smile.gif)


Findings of the first drive:

1. Steering needs to be fixed. Pretty sure the shaft got welded unevenly. I will be buying some new shafts and starting from scratch instead of trying to use mine. It works for now but who knows. You can see me struggling as the knuckle is binding. Everything is exactly in the same layout as factory its just 1/8" off center and I think that is causing the problem.

2. Clutch is on the floor. I will put some spacers behind the slave cylinder to get a bit more action out of the clutch. I'd like it to be an inch off the floor to halfway through the travel. Clutch is however very light and easy to modulate. Probably the reason why its all the way on the floor is I didnt give it enough travel thus making the action much easier. I will also re-bleed it and see if that helps.

3. The engine bar was loose after the run. I tightened it up with some red lock tight, It might not have been snugged down all the way the first time... If it keeps loosening up I might double nut them. I painted a line on the nuts like factory to determine if anything loosens up.

4. I need a smaller wheel and I need the wheel to be removable.

5. The water pump and controller work fantastic. I drove the car around for 5 minutes then let it idle. You can see in the video that it stays pretty cool. I had it set for a higher temp and dropped the controller down down in another video to see what would happen. The water pump turned on constant and the fans kicked on. Shut off the car and both the fans and water pump stayed on for one minute and then shut off (IMG:style_emoticons/default/smile.gif)

6. The turbo is not a low RPM turbo. I gave it 1/2 throttle a lot and fed into it a couple times and while the turbo will start spooling around 2500 it doesnt seem to really make much boost until about 3500. Similar to what I remembered, but the heavy weight of the Audi A4 made it hold the RPM's more thus spooling technically faster.

7. 1st gear is going to be a handful even at 10psi... You can see in one of the video's I give it about 3/4 throttle over 4k rpms (I had my hand in the way so I dont know what RPM I shifted..), I am pretty sure the tires spun because the RPM's climbed so quickly. I am really glad I have an 8500rpm redline because I am going to need that in first gear..

8. Its fast. Damn fast. I havent gone full throttle or even reved it out at all, but its going to be a monster.

9. Its F'in LOUD. The blow off valve is very loud and crisp. I know for a fact I cant drive it over 5k in the neighborhood or else I am sure the cops will be called. Im sure you can hear the blow off valve from a mile away. I'm going to have to route the blow off into the intake to quiet it down some.

(IMG:style_emoticons/default/driving.gif)

[76-914]

Good for you, Andrew. I foresee some speeding tickets in your future. (IMG:style_emoticons/default/biggrin.gif)

[914bub]

Andrew
If the car will be at any Modesto events, please let us know. I'd love to meet you and see the car. Looking GREAT, I've done several swaps, none were 914 and none so impressive.
Best, Erik

[Andyrew]

Erik,

Your welcome to come by any time (IMG:style_emoticons/default/smile.gif)

[Chris H.]

Sounds really good! It's running VERY cool for the first couple of runs. Never seen that before. Now the tweaking/adjustment period begins. But the basic conversion is DONE (IMG:style_emoticons/default/thumb3d.gif). (IMG:style_emoticons/default/beerchug.gif)

[914forme]

5. The water pump and controller work fantastic. I drove the car around for 5 minutes then let it idle. You can see in the video that it stays pretty cool. I had it set for a higher temp and dropped the controller down down in another video to see what would happen. The water pump turned on constant and the fans kicked on. Shut off the car and both the fans and water pump stayed on for one minute and then shut off (IMG:style_emoticons/default/smile.gif)

So nice to hear, sounds like it worked perfectly. (IMG:style_emoticons/default/piratenanner.gif)

[Andyrew]

All the lights now work (IMG:style_emoticons/default/smile.gif)
I spent WAY to much time on that... But hey its done!

I did a BUNCH of driving over the weekend and some tonight. Got a few logs in as well for my tuner. Hopefully we start to get to work on my tune soon.

I found out my rev limit right now is set to 7k, I'll have my tuner work on that I really cant wait to hear what it'll sound like over 8k (IMG:style_emoticons/default/smile.gif)

Below is a first and 2nd gear casual pull.


It may look at bit slow for you v8 guys but here are my gotcha's.
1. Baseline tune.
2. Only 9-10psi (out of 35...)
3. Breaking in the motor
4. Intercooler is not getting water through it yet, so IAT's are likely very high. Luckly big turbo and big piping with low boost mean its not detonating. Thats the goal for this weekend.
4. OLD gas, Trying to use it up some before I grab some new gas. Remember I will want to tune for E85 at some point which in and of itself has 35% more power potential.

(Apologies for the shaky video. My mount is not as good as I hoped. I'll start using the Gopro)

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


Side note, first gear typically rips off the tires, and its a one legger for sure. This car will need LSD and stickier tires for sure. Keep in mind they are relatively new 285's in the back.

Also of note, my front shock is rattling pretty bad I think its a good time for me to go Koni yellows up front instead of the worn out reds.

[914forme]

That car is going to be a beast (IMG:style_emoticons/default/happy11.gif)

[76-914]

Remember I will want to tune for E85 at some point which in and of itself has 35% more power potential.

Do tell..............

[dan10101]

I'm looking into this too, for my 944 turbo. I found this article that raised some possible issues.

The power potential is certainly there. The article mentions that manufactures of the E85 can vary the amount of ethanol from 51% to 85% which could pose issues. The article talks about doing it for cold starting issues in cold climates. For Andrew, not living in a snow country, they might not go to such extremes. I'm sure there's a way to check this chemically to make sure you don't hurt an engine.

$3 for E85 vs $8 for race gas certainly has it's appeal.

link
http://www.speedhunters.com/2015/04/everyt...-about-ethanol/

[Andyrew]

(IMG:http://www.914world.com/bbs2/uploads_offsite/i754.photobucket.com-172-1469587927.1.jpg)

There are E85 calculators you can use and the MFR's report the e85 rating at that time as well.

What I wish is my ECU had the ability to modulate its AFR based on E85 rating. Ford has an E85 inline calculator that calculates the ethanol content. Many use it for monitoring the tune, but say the newer ford tuners can have the tune adjust for the ethanol content from say 40-85%.

The reason why E85 works SO well on a turbo car is that it does many things.

1. The stored energy is simply better, it will give a much bigger bang.
2. Its effectively 110-115octane.
3. You can increase timing significantly to help with throttle response as well as lowering the boost level at the same time to prevent a normal sized turbo from running out of steam at top.

This fun video may help some of you newbies to E85 (IMG:style_emoticons/default/smile.gif)

https://www.youtube.com/watch?v=ltWcgiCm4NY

[914forme]

[quote name='Andyrew' date='Jul 26 2016, 10:47 PM' post='2376914'

What I wish is my ECU had the ability to modulate its AFR based on E85 rating. Ford has an E85 inline calculator that calculates the ethanol content. Many use it for monitoring the tune, but say the newer ford tuners can have the tune adjust for the ethanol content from say 40-85%.

[/quote]

Thus one of the reason's I spent so much time looking at MegaSquirt, as they can also do this using the GM sensor. Maybe I should have just done an LS swap (IMG:style_emoticons/default/dry.gif)

[Andyrew]

Final update for July:


Finalized the finishing work to the motor side of things. I plumbed and setup the intercooler cooling. As I had mentioned I had been running on essentially no intercooler, which was pretty impressive that I didnt have any detonating up top at 10psi. If anything it put a good about of strain on the motor which is good, Thats how I like to break in rings (IMG:style_emoticons/default/smile.gif).

I modified the stainless joiner pipes I had made so that they take account for most of the "U" turn on the radiator coolant hoses. Im happy with this decision as it makes for a cleaner engine bay as well as shorter hoses. That being said it appears as if I have one leak as well as the pump itself appears to leak a little. Im going to leave it for now and re-address it after 4 months when I pull the motor to clean things up and finish the metal work on the body firewall (I will address the oil leak at the front as well at that time and probably pull the pan and check the internals for premature wear).


I wired the water pump on the Audi's factory fuel pump wire (I have a dedicated 12ga wire for the fuel pumps), so it runs when the engine runs. However I have the small 4" fan wired up to my fan controller I bought for $12. I have the temp sensor taped to the intercooler and it works pretty well this way.

https://www.youtube.com/watch?v=tXcIDlWkGk0

If I needed to just have this work for say my radiator fans I would hook it up to a relay, but the amp draw on the 4" fan shouldnt necessitate that. Something for you homebrew guys to think about. This would work great for a dual fan setup running twin controllers at different temps. I currently have the fan setup for about 115degF turn on and it'll turn off at ~ 110. Its a small radiator and thus I imagine it could get hot, but on a quick test drive with a 1-2 pull I didnt even see the intercooler go up 5 degrees. It also pulled much stronger with the colder dense air.


I tried all weekend and late last week for my tuner to get to work on my tune but he is responding once and then ignoring me.. I might have to go to my back ups soon.


I also spent some time on the dash. I first worked on the "Mike Bellis Special" cardboard template but wanted a more solid foundation.. So I hacked up the stock dash base to fit.
The stock Audi dash cluster didnt have any provisions for bolting/mounting (apart from the front 2 flimsy ones) so I opened it up, clipped the noisy alarm charm, and put some bolts in the backside.


I'll grab some foam, tape, plastic, tin foil, and blades and start getting back to my "creative" side shortly. I hope to have the dash and center console completed by the time the competition is over. It would also be nice to have the rear firewall done but thats dreaming really tall....

[whitetwinturbo]

(IMG:style_emoticons/default/wub.gif) (IMG:style_emoticons/default/wub.gif) (IMG:style_emoticons/default/wub.gif)

[Mike Bellis]

It's amazing how much stuff ends up in the engine bay with one of these conversions.

BTW, I think you can just put alcantera over the cardboard dash and be done. I'll drive it just like that... (IMG:style_emoticons/default/smile.gif)

[914forme]

The stock Audi dash cluster didnt have any provisions for bolting/mounting (apart from the front 2 flimsy ones) so I opened it up, clipped the noisy alarm charm, and put some bolts in the backside.

you could not turn it off in software with a Vagcom?

[Mike Bellis]

The stock Audi dash cluster didnt have any provisions for bolting/mounting (apart from the front 2 flimsy ones) so I opened it up, clipped the noisy alarm charm, and put some bolts in the backside.

you could not turn it off in software with a Vagcom?

No. Vagcom only allows you to do "safe" things. You cannot flash out safety related features.

[Andyrew]

Some bad pics today...

I spent some time chasing the front end clunking that had me worried. Turned out to be the front strut collar holding the shock in. I had a suspicion that was the issue but didnt get to fixing it till this weekend. Luckily with my wheel well cutouts I could do the repair without even removing the wheel (IMG:style_emoticons/default/smile.gif) Jacked up the suspension a foot, unbolted the nut, pushed the shock down and brought it to the cutout, removed the dust cover and bam, loose nut (IMG:style_emoticons/default/smile.gif)

Cleaned up the wiring with some loom I bought and made everything ready for the interior redo forthcoming.


Mounted the passenger seat and seat belts and put the carpet dash cover on. Looks good enough I might just spend the next month driving it like it (IMG:style_emoticons/default/evilgrin.gif)


Nah, Hopefully I get some time tonight to prep and lay down my first layer of foam for the dash.


Had a good 10 minute drive with the wife last night after going to Jeff Strouds celebration party. I didnt take the car to the celebration as there was some clunking in the rear that I cant ID. Im thinking its RR CV joint as the mounts are all good and it only happens on minor accel/decel transitions, it SOUNDS like the axles are clunking.




OH and heres a quick video from lunch Friday (IMG:style_emoticons/default/smile.gif)

https://www.youtube.com/watch?v=hoWTgs0JoP4