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

[daytona]

Thanks for the info on the sleeve Andyrew.
Bill.

[dan10101]

Love love love seeing progress! Keep it up!

[Andyrew]

I haven't been able to work on the car all week as I've been iching to do, and my wife is going to the Catalina Wine Mixer so I'm going to be with Alina this weekend and unable to make any progress.

So while I had half an hour I recorded a couple vids showing progress and another showing how I make these connections.


https://www.youtube.com/watch?v=S--X4WNd4p4



https://www.youtube.com/watch?v=UrMz2ymxUNg

[Andyrew]

Odd I thought I posted about my repairing of the instrument cluster... I guess not..

I bought a $25 replacement LCD screen and installed it about a month ago when my daughter was asleep (perfect project for the kitchen counter).

Only drawback was I don't have a hot air solder.. so depinning the micro solder joints didn't go well.... However the pins I destroyed happened to be blank pins that went nowhere.

I was able to get the new LCD board on and installed. Flux was a big factor here to making this work.

Regardless the screen was fixed and I was pretty happy with the result. I should have gone with the OEM screen as if your not looking directly at it the screen doesn't show anything but those were tripple the price and difficult to find. It should work great though as the screen just shows diagnostic data and warning information.

[Andyrew]

Progress from tonight.

Pulled the windshield wiper motor and added a connector to it. I'll need to do some testing to see what wires ai need to hook up to it but I have the factory wiring connector to the Audi intact still and I have tested a couple signal wires so I shouldn't have any issues with it actually working. It's just a question of can I get multiple speeds out of the system.




I then also connected up the rear lighting to the OEM connectors. I still need to trace the reverse light but everything else is tested correct.


I hope to get more done this weekend. I'd really like to get the electronics testing in the car fully functional again by November.

This past month was busy with a vacation to New Orleans as well as a business trjp and a hell of a lot of stress at work.

[mb911]

I haven't been able to work on the car all week as I've been iching to do, and my wife is going to the Catalina Wine Mixer so I'm going to be with Alina this weekend and unable to make any progress.

So while I had half an hour I recorded a couple vids showing progress and another showing how I make these connections.


https://www.youtube.com/watch?v=S--X4WNd4p4



https://www.youtube.com/watch?v=UrMz2ymxUNg

There is such thing as the Catalina wine mixer? I thought that was just in step brothers.

[Andyrew]

I haven't been able to work on the car all week as I've been iching to do, and my wife is going to the Catalina Wine Mixer so I'm going to be with Alina this weekend and unable to make any progress.

So while I had half an hour I recorded a couple vids showing progress and another showing how I make these connections.


https://www.youtube.com/watch?v=S--X4WNd4p4



https://www.youtube.com/watch?v=UrMz2ymxUNg

There is such thing as the Catalina wine mixer? I thought that was just in step brothers.

It was an event that was made from the show. In reality its just a wine party on the island. They did have a helicopter for people to take pictures with.
https://www.visitcatalinaisland.com/event/c...wine-mixer-2018

[ValcoOscar]

Andrew, you’re a man with lots of patience…. (IMG:style_emoticons/default/idea.gif) (IMG:style_emoticons/default/burnout.gif) (IMG:style_emoticons/default/whistle[1].gif) (IMG:style_emoticons/default/yellowsleep[1].gif) (IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/shades.gif) (IMG:style_emoticons/default/hands.gif) (IMG:style_emoticons/default/blush.gif) (IMG:style_emoticons/default/gint.gif) (IMG:style_emoticons/default/gint2.gif)
I can appreciate fiddling with electronics and wiring but PATIENCE is king. (IMG:style_emoticons/default/icon22_2.gif)
Continue the good work and updates!!!
Oscar

[Andyrew]

https://www.youtube.com/watch?v=Zoc0Mr5Kpkg



Figured out the wipers (I think)!

[76-914]

Your having entirely too much fun. (IMG:style_emoticons/default/biggrin.gif)

[mgp4591]

https://www.youtube.com/watch?v=Zoc0Mr5Kpkg



Figured out the wipers (I think)!

So you're controlling your wipers from the stalks on the column, right? Do you have the intermittent functions and still using the stock 914 wiper motor?

[Andyrew]

Yes, in the video I'm demonstrating me using the Audi wiper stall and controlling the 914 wipers with the 5 stages.

Off
Single sweep
Intermittent (delay variable)
Low speed
High speed

[Mike Bellis]

Where's your Audi wiper relay? That's what I used on mine.

[Andyrew]

It's the big brown(looked it up, and I can hear it clicking at the appropriate times) one with all the other relays. It's still there. The pink plug was to go to the chassis harness so there was no additional relay.

[Mike Bellis]

Then you should be fine. I though the wiper connection would be harder to figure out when I went through this process. Glad you got it so quickly.

[Andyrew]

Then you should be fine. I though the wiper connection would be harder to figure out when I went through this process. Glad you got it so quickly.

I had it labeled back from when I originally was tracing all the wire connections. Then I double checked it when I thinned down the dash harness.

[Andyrew]

3 1/2 months since the last update. Let me tell you all how much I've not progressed (IMG:style_emoticons/default/smile.gif)


Winter has been busy for me and family things, so I havent spent much time in the garage. The 944 developed an oil leak that is leaking onto the header so I cant drive it now like I want to. So i'll need to take it apart after I get the 914 back up and running (I can still drive it now, just smokey.. and I dont like oil fires..)



914 rewire progress.

I completed what I believe to be everything on the dash and engine side of the rewire.

I cut a new hole large enough for the new wiring harness to go through. I have decided I am going to use a small CV joint, cut it in half and glue it back together, then sandwich it with a cover plate to the firewall. I couldnt find a firewall grommet large enough to put my large engine harness through oddly enough. I needed about 3" x 2" Nothing was large enough and this seems like the best solution.

I put the engine harness and connected it all up, then placed my interior/dash harness inside the car and started mounting and hooking things up to test.


So far my tests resulted in the following.

1. Horn is stuck on (steering wheel wasnt even on the car). I found the horn wire to the steering column and unplugged it. Looks like my clock spring is broken so I'll get a new one of those.

2. Intercooler pump is on with just battery power no key. It should be on keyed power. I will need to rewire that.

3. Intercooler controller has no power. Either I have the wrong power source, a fuse is blown, or I wired it to the fuel pump wire (Entirely possible) and it wont turn on without the car being on. I'll swap the wire source to the keyed on and try again.

4. Brake likes non responsive. I traced this down to it being wired incorrectly. (I cut this connector off accidently and had to refind all my wires. But in the process of that I added some connectors on the engine bay side to be able to unplug the rear lights from the dash harness (Good choice IMHO).

5. Tail lights non responsive. Same as above.

6. Key ignition doesnt turn the car over. Suspect its because I have the wire from the starter disconnected (IMG:style_emoticons/default/biggrin.gif) I have the car battery in the interior as its the really small one and I was thinking of relocating it to save on the engine bay clutter.



What I do know that works/powers on correctly.

Headlights
High beams
Turn signals
Hazard
Wipers
AFR guage
Boost controller
Water pump controller


My wife (Six Sigma blackbelt..) asked me how much longer to complete the car for it to be ready for WCR 2019 (Planning on trailering it down) and I told her probably 200 hours to which she gave me this look (IMG:style_emoticons/default/blink.gif)

So then she's tasked me with making a list of the items that I need to do prior to WCR. So next post will be that list along with my anticipated timeframe for completing each line. Im thinking the 200 hours is going to go by very fast...

[mb911]

Six sigma will get you every time.. Good luck

[dan10101]

I'm only a Six Sigma Green Belt. She can kick my ass all over the Project Management World... (IMG:style_emoticons/default/ph34r.gif)

[Andyrew]

914 to do list

**Mandatory total: 121 hrs
Non mandatory total: 214hrs

Electrical: 32
**Fix tail light issue. 1
**Fix brake light issue 1
**Fix intercooler controller 2
**Fix intercooler pump 1
**Fix Horn 1
**Finalize testing of electrical components Test drive setup and heat cycle. 5
**Remove harnesses 2
**Finalize engine harness cleaning 3
**Finalize dash harness cleaning 6
**Reinstall harnesses 10

Steering: 40
**Mill down new steering shaft for steering component retry. 10
**Remove steering components 5
**Fabricate steering joint mounts 10
**Reweld system and test 5
**Adjust system 10

Suspension: 23
Fabricate front sway bar arms 20
Install and adjust 2
Test 1


Brakes:7
Bleed brakes 3
**Rebuild pedal cluster 4

Transmission: 16
**Replace transmission with spare 15
**Inspect clutch 1
**Check for rear main seal leak 0

Engine:29
**Drain fuel 2
**Replace fuel filters 3
Replumb fuel system for cleaner look 10
Clean engine of oil residue 2
Look for source of oil leak. 2
Fix oil leak 10


Body: 75
Fabricate trunk firewall 20
Fabricate and install roll cage 30
Fix targa top knicks 5
Repaint bumpers 5
Clean up front trunk for new paint 10
Clean up rear Trunk and paint 5

Interior:84
Design Dash Layout 3
Foam up dash layout 1
Finalize Dashboard 20
Fiberglass and prep dash for upholstery
Design and build rear firewall 20
Design and build center console 20
Design and build door cards 20



Send dash, Seats, Door cards, Center console, and Rear firewall to upholster for finalizing. (My tests revealed I don't have the skill to do this…)


Spares for WCR:
Trans
Axle
Clutch Disk
Serpentine belt
Shift Cables
Relays
Fuses
Fuel Pump filter
Fuel pump
Oil
Plugs
Coil packs



Items to purchase:
Spare trans $200
Spare clutch disk 200
Serpentine belt 20
Shift cables 150
Fuel pump filters 150
Fuel pump 75
Coil pack
Fiberglass door cards 200
Houndstooth cloth orange 3 yards 200
Upholstery work 2500
Roll cage material 150


I'll come up with a game plan over the next week (IMG:style_emoticons/default/smile.gif)