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

[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

[Garland]

(IMG:style_emoticons/default/driving.gif) runs nice.

[Mike Bellis]

You took the long way to Taco Bell... (IMG:style_emoticons/default/smile.gif)

[Andyrew]

Mid weekend update. NEED SOME ADVICE!


OK, so my tablet Idea was just to far fetched, I cant think of putting a tablet on this dash and it actually looking someone decent due to the size. That being said I am planning on having my phone on the dash to give me the same basic stuff but without the added bulk. That being said here is what were looking at. Am I just ruining the dash with the phone spot being where it is? Should I just have a little magnetic arm to put it on? The covered area gives it sun protection for glare as well as heat and IMHO gives it a more sleek uniformed look.

I'll put details on the build later but looking for anyone to comment on the current left side of the dash idea.

The right side will slope off the left side to be flat and will be separate for ease of installation.





Old pic to show where the phone goes, My work iphone, my regular S5 is bigger .

[Darren C]

Great project Andrew.

As your asking opinions (and everyone has one) mine would be to loose the bulk of all that foam. Great for a truck or bus.... but not a sportscar. Your dash mat a couple of post back looked better!

With the position of your gear lever I'd make a dash that has a pod/binnacle much leaner and similar to the original 914 or a Mazda Miata over your instruments and a sweeping centre console that looks like a Porsche Carrera GT.

http://images.gtcarlot.com/pictures/10017731.jpg

You could combine your i-phone insert in the centre console just below the gear lever in portrait or landscape above the gear lever. Audi TT style grab handles with combined knee pads either side of the i-phone insert (if fitted below the gear lever in portrait) would look real good.

http://justgermanparts.co.uk/ekmps/shops/6...7645-4021-p.jpg

[Andyrew]

Darren,

Thanks for the advice.

This is my original design concept.
(IMG:http://www.914world.com/bbs2/uploads/post-172-1444716948_thumb.jpg)

Center console will remain. The two raised areas around the phone will flow down around the shifter and form the center console starting point.

I also thought about trimming the fat on the left side.

I agree its a bit bulky and truckish, thus my posting for some help. Let me see what I can do from here.

[Darren C]

Great sketch, thats exactly what I had in mind, but incorporating the TT kneepad grab handles for a little Homage to your donor.
Rather than re-inventing the wheel here, have you thought about cutting out the gauge pod/binnacle section of your donor dash and incorporating into your design rather than using the foam?

[Andyrew]

Great sketch, thats exactly what I had in mind, but incorporating the TT kneepad grab handles for a little Homage to your donor.
Rather than re-inventing the wheel here, have you thought about cutting out the gauge pod/binnacle section of your donor dash and incorporating into your design rather than using the foam?

I have no donor dash.

Also the foam is just for me to template with, I will fiberglass the foam when done with the template an remove the inside foam, sand smooth and cover with vinyl.

[veekry9]

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A huge job,one that is complex with many details to do right:
1 ) Attach polyurethane foam to naked dash base.
2 ) Shape,using surform and sandpaper to pleasing result.
3 ) Apply grp to create male 'plug'.
4 ) Attach 'returns' and mount details.
5 ) Finish to high polish,and apply 'release'.
6 ) Apply grp to build female 'mold'.
7 ) Detail and reinforce mold.
8 ) Apply epoxy grp/cf to create dash and console 'skins'.
9 ) Finish sand and built mounts,detail,aircons,defroster,iphone,satnav,stereo,instument cluster,switch panel and more.
10) Make patterns for padding and cladding in leather or synthetic materials.
11) Cut and sew the coverings,then staple,glue and screw over the multi layer foam underlay.
12) Design,fabricate and chrome or polish bezels and trim accents.
13) Install console and gear,ebrake,aircon,and the rest of it.
14) Install the wiring and switchgear with the trim bezels and panels.
15) Start on the doors,ceiling,floor and console.
16) Details that I've missed mentioning,and much more.

Here is the most beautiful custom work,done for mids,of an American origin.
The methods used,and demonstrated here are labor intensive,the results glorious and leather clad.
http://www.fiero.nl/forum/Forum3/HTML/000091-49.html
So,yeah,a custom interior is a ton of work,easy to get wrong,with crude results.
Sewing and stitching is involved. (IMG:style_emoticons/default/unsure.gif)
(IMG:style_emoticons/default/happy11.gif)
This is nice,even the early dash that I prefer,tho done in the two tone,the console narrow like the 14's.
https://www.google.ca/search?q=porsche+944+...HtQht90OLqLM%3A
(IMG:style_emoticons/default/evilgrin.gif)
/

[Andyrew]

Lots of things going on at once.

It appears my timing belt is off a tooth, not causing any mechanical failures just enought to loose torque and cause a code. Thus my tuner is being a B and telling me to fix it before he does anything. Luckily I think I can do that with the engine in the car comfortably if I jack up the rear and drop the trans to the floor. Should give me great visibility and room.


I started making a shift knob, but alas cant find anyone with a lathe to turn it for me. If anyone here has a lathe and can turn a shift knob let me know!


Finalized what I want to do with the dash. I bumped my dash design up 10 years to give me a smoother sleeker look. It just worked out better for the fit issues I was working with. I think you guys will like it when you see the final product.


Random gas fill up this week (IMG:style_emoticons/default/smile.gif)

[76-914]

Lots of things going on at once.

It appears my timing belt is off a tooth, not causing any mechanical failures just enought to loose torque and cause a code. Thus my tuner is being a B and telling me to fix it before he does anything. Luckily I think I can do that with the engine in the car comfortably if I jack up the rear and drop the trans to the floor. Should give me great visibility and room.

Damn it! I hate it when that happens. Only time that happened to me was on an Escort timing belt. It's more difficult to mis-match when dealing with timing chains, IMHO. Looking good kid. Keep it up. (IMG:style_emoticons/default/beerchug.gif)

[Andyrew]

I'll post an update tomorrow, but heres a video of last nights ECU logging. My friend tagged along and took video while I logged.



https://www.youtube.com/watch?v=jk5V1cL0pbk

[Mike Bellis]

Cool video!