Sasquatch Part III Audi 1.8t transplant..., PCV upgrades finally... Options

[jeff]

I had a bit of bad luck today, although I solved it too.

I was drilling for some rivets to hold down the aluminum diamond plate tunnel cover. The fourth one I drilled I sment gas.

I had to cut the tunnel open to get to the hard line. Yep... Hole through and through. Since the fuel system is already complete and I didn't fell like re-plumbing, I got a compression coupler from HD supply and fixed it. The aluminum hard lines use -6AN compression fittings anyway. They are designed for a brass ferrule, so I figured the brass compression fitting will be fine. It was a pain cutting the tunnel open with my air saw. No sparks!

There is a small boxed section on the passenger side next to the shifter. When I ran the hard lines, one of them made it into this small cavity. It is just big enough for the 3/8" line to fit through.

Good thing I picked up some .023 wire last week. This made rewelding the thin sheet metal easier. All fixed!

I then switched to plumbing the fire system. Might come in handy some day...

Lesson of the day... Know where your fuel lines are!

Don't take a chance, make a new line & double check all mounting points & fittings and whatever else you have in the fuel system....you don't want to deploy that Fire system.....

[Mike Bellis]

Don't take a chance, make a new line & double check all mounting points & fittings and whatever else you have in the fuel system....you don't want to deploy that Fire system.....

That is partially why the motor is out. I'm checking every nut, bolt and fitting. I'm peening the exhaust connections and paint striping every other connection, so I know it's done. I need a couple weekends of fiddling around and then go back to final assembly.

(IMG:style_emoticons/default/beerchug.gif)

[effutuo101]

Great build!

[jeff]

Awesome! I'm not trying to be mother hen but it's always on my mind, I'm a firefighter and have had some terrible experiences with car accidents involving fires...

[Andyrew]

I pulled the motor today in order to finish some odds and ends. Just about every peripheral component needed to be tightened down. I had to make custom 12mm wrenches to get the exhaust bolted on. There isn't much space and a conventional box wrench would not work. I have about a dozen custom tools fabbed up for the series of engine swaps.

The methanol injector was mounted to the outlet of the intercooler. This is a 330cc injector good for 350hp @ 7500 rpm. Right in my range. Notice the tip is recessed. In theory, this allows the spray to form a "cone" before the air flow (passing by) cuts into the stream. By doing this it promotes better atomization. There is some debate on other forums about installing the injector within the intercooler. The argument revolves around pooling inside the cooler. In my case, I am running a solenoid before the injector to prevent dribble thus avoiding pooling. In addition, the injector will not open below 10psi and/or an analog signal from the MAF.





The Audi/VW motors suffer from sludge build up in the PCV system. There was even some law suit over it. I decided to mitigate problems by using a crankcase evacuation system. 034 Motorsport hooked me up with a machined aluminum fitting that plugs into the system. I added some 5/8" aluminum hard line and brass compression fittings. This is the main line that heads to a custom built 1 gallon catch can. From the catch can the line continues to the vacuum venturi welded to the exhaust. This type of system is usually found on V8 drag cars. As the exhaust flows past the venturi a vacuum is pulled on the system- on the engine crank case. It was originally designed to help seal rings on high HP engines. So I get the best of both worlds. Reduced sludge and better sealing combustion chambers.





Here is a pic of the turbo oil drain. I used the lower original oil drain and some high temp hose with an -10AN fitting. After cutting the factory stainless hard line, I rolled a bead on it to keep the hose in place. I finally got to use my mini bead roller!

All great things in this post!!

I havent seen very many sludge issues as of late, But your solution for the PCV system works great! I just dump mine (IMG:style_emoticons/default/smile.gif)

[Mike Bellis]

All great things in this post!!

I havent seen very many sludge issues as of late, But your solution for the PCV system works great! I just dump mine (IMG:style_emoticons/default/smile.gif)

I will dump my catch can too. The difference is my exhaust Venturi will generate vacuum under boost. In fact, the more air (exhaust) flowing past it, the greater the vacuum generated. This is why it's great on a boosted engine. The factory PCV system closes and stops working under boost conditions.

[andys]

It's a 944 seat belt setup.

Mark,

So does the stock 914 seat belt tongue fit the 944 latch?
I made a flat steel bar stock extention to lenghten my 914 latch, but would have prefered to find something OEM that is longer than the stock 914 cable and latch assembly. If it's compatible, how much longer is the 944 cable?

Thanks,

Andys

[McMark]

Gotta use the 944 pieces. The 944 latch is either shorter or the same length as the 914 piece.

[Mike Bellis]

Andys,

Here is a pic of the seat belt buckles. Left 944, Right 914.

The 914 buckle I have absolutely does latch into the 944 receiver. Looks like it wouldn't but it does. I'm not sure I would trust it in an accident. Thats why I changed both parts.

[andys]

Mark/Mike,

Thanks for the quick response......Guess I'll just leave mine as-is.

Andys

[BIGKAT_83]

Those seat belts look the same as a set of aftermarket belts I got off of EBAY a few years ago. Even have the same #0701 on the buckle. The female end of the buckle has a long shaft and is high enough to be used with my Scheel seats.

Bob

[Mike Bellis]

Got the motor almost ready to go back in. I pulled almost every nut and bolt added some red, blue or green Locktite (depending on the application).
Bolts tight
Turbo oil lines done
Turbo coolant lines done
Exhaust manifolds tight
Coolant lines done
Vacuum lines done
Belts replaced

I also cleaned to oil (from the rotary) from the engine bay and resprayed the white. I used the "Awesome cleaner" from the dollar store. Thanks Lennie! Stuff works great. At one point with the rotary, I was racing a Carrera on the freeway. Under boost the oil filler neck popped off. A fine mist of oil was sprayed all over the car. The worst part was the top was off and I got covered. BTW, I won... (IMG:style_emoticons/default/biggrin.gif)

Here a few pics while I watch paint dry...

Hell hole looks pretty good.

[Andyrew]

Looks great!!!!

I forgot about all the weird chassis stuff thats been done to this car..

[Mike Bellis]

Spent some time cleaning and painting the rear trunk. I'm off tomorrow and Tuesday so I plan on getting the motor stuffed back in and commence final assembly. Paint in the engine bay has sat for 2 weeks so hopefully I don't screw it up. I'll have to be careful in the trunk.

I have a few cover plates for the trunk that still need paint. The engine side and over the exhaust are removeable.

[Andyrew]

Paint looks great! What are you you spraying and with what?

[Mike Bellis]

Paint looks great! What are you you spraying and with what?

This is just a case of rattle can. One of white primer and one gloss white. Many thin coast until the final to let it flow...

I'm keeping up with the racecar theme. One day the car will go on a rotisserie and get blasted and a proper paint job. But then I will be afraid to drive it...

[Mike Bellis]

Motor is in! Lots of stuff done. Lots more to do... More tomorrow...

[McMark]

Nice! (IMG:style_emoticons/default/first.gif)

[JStroud]

As always, very impressive Mike, I wish I had half your fabrication skills (IMG:style_emoticons/default/beer.gif)

Looks awesome

Jeff

[Mike Bellis]

More, More, More...

Radiator coolant lines: DONE
Heater lines: DONE
Intercooler lines: DONE
Intercooler pump: DONE
Oil lines: DONE
Oil pressure line: DONE
Intake piping: DONE
Recirc valve: DONE (Forge DV/BOV in DV mode only)
Turbo inlet: DONE
MAF: DONE
Aire cleaner: DONE
Fuel lines: DONE
PCV evacuation system: DONE


NEEDS:
fuel pump install
catch can drain
vacuum lines connected
wastegate connected
boost control connected
exhaust install
Wiring connected
Interior cleaning
Dash cluster install
Rear sway bar install
Fluids: motor oil, tranny oil, coolant
Axle measurement t, order and install
Clutch final bleeding

I can't believe how much stuff was bolted to this system. I waited until final assembly to plumb all the fluid lines. What a bitch. The area on the left side of the engine bay is very contested with hoses (heater, intercooler, heat exchanger, pump, oil, oil pressure).

I had one of those senior moments today. I lost my throttle body. When I took it off, I put it somewhere safe. It took me an hour to fine it... (IMG:style_emoticons/default/dry.gif)