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

[Mike Bellis]

Nice eBrake. (IMG:style_emoticons/default/av-943.gif)

Congrats!

From a 1937 Buick. Little taste of Rat Rod...

[McMark]

No this one. (IMG:style_emoticons/default/blink.gif)

[Mike Bellis]

No this one. (IMG:style_emoticons/default/blink.gif)

I have a real wheel chock on the other side. I misplaced the other one. Hopefully the car won't bein the street in the morning. Btw, it's happened...

[Mike Bellis]

Here's a run down of some of the electrical stuff and first shakedown run. I have 60 miles on it now.

I tried the wipers by accident. They work. I grafted the Passat wiper switch and relay to the 914 motor. I now have programmable delay wipers. All I did was match up the numerical connection point and got lucky!

I have to re-flash the ECU to activate cruise control.

Turn signals and hazards work too. I did order some german dual filament lamps with the correct contacts unlike the standard 1157 lamp.

I may have to reconnect the ABS module in order to flash it out of the system. I kept it but I need to find it. This is the only CEL the car shows.

My fuel sender controller (Spyida.com) is not working so one of the projects is to graft the Passat sender on to a compatible mount on the tank. The Passat is a 250 ohm Full and 10 ohm empty. The closest I have is a Chrysler 30 ohm full and 240 ohm empty. I flipped the guts but It doesn't read quite right. The instrument cluster only wants a basic potentiometer.

I ordered a 3 minute "on delay" timer to control the Intercooler pump, Intercooler fan and water pump. Right now the start every time the key is turned on. I'm going to use the fuel pump output as the trigger. That way it will only start if the fuel pump is running.

Headlight work as they should with no issues. I have not tried the fogs yet. Not sure why, just haven't gotten to it.

I decided not to run the factory BOV solenoid so I picked up some 330 ohm, 20W heat sink resistors. These trick the ECU to think the solenoid is connected and prevent driveability issues. If I needed to have the car inspected, I could use these resistors to fake the readiness of the EVAP and SAI systems too.

The boost controller seems to work but there is a screw in brass vent screen on the solenoid making noise. This is normal but irritating so I may relocate/extend it into the trunk. Boost is set at 10psi for now.

I still have to do final calibrations to the methanol system and some testing before I turn the boost up.

This engine has much less power (right now) than the rotary but is way more driveable. As the engine gets tuned and all systems dialed in, I will do a dyno run to see what it's doing. The Motronic 7.5 system is great. It's real nice sitting at a red light and not smelling unburnt gas. If I keep my foot out of it, it runs like a stock Audi. The exhaust is very quiet at idle and has a nice throaty sound under acceleration.

[tomeric914]

Great work Mike! Can't wait for the video! (IMG:style_emoticons/default/driving.gif)

[okieflyr]

On mine I cut the plastic arm very short on the accelerator pedal unit and mounted it on the front wall above/behind the pedal cluster. Using the stock pedal and heim joint arrangement to translate the signal to the shortened arm. All my pedals line up as stock. Nice work! (IMG:style_emoticons/default/biggrin.gif)

[Andyrew]

I ordered a 3 minute "on delay" timer to control the Intercooler pump, Intercooler fan and water pump. Right now the start every time the key is turned on. I'm going to use the fuel pump output as the trigger. That way it will only start if the fuel pump is running.

Do you have this 3 min delay on an override switch? I fear if you take it to an autox you wont hit 3 minutes before you are needing it to pump (Say after its fully warm like in-between runs)

How is the powerband? When do you see full boost? You should see 10psi by earlier than 2700. This turbo should feel very natural with the engine. Not peaky, not laggy, not undersized, just very eager.

10psi on that turbo should be between 200-225hp 25psi and race gas should see closer to 375.

Do a couple of 1st and 2nd gear pulls for us! What redline is 034 going to tune to? My vote is 7300. You probably will peak around 6500, but its stays pretty strong up there.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.audizine.com-172-1370285354.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.audizine.com-172-1370285354.2.jpg)

[Mike Bellis]

I ordered a 3 minute "on delay" timer to control the Intercooler pump, Intercooler fan and water pump. Right now the start every time the key is turned on. I'm going to use the fuel pump output as the trigger. That way it will only start if the fuel pump is running.

Do you have this 3 min delay on an override switch? I fear if you take it to an autox you wont hit 3 minutes before you are needing it to pump (Say after its fully warm like in-between runs)

How is the powerband? When do you see full boost? You should see 10psi by earlier than 2700. This turbo should feel very natural with the engine. Not peaky, not laggy, not undersized, just very eager.

10psi on that turbo should be between 200-225hp 25psi and race gas should see closer to 375.

Do a couple of 1st and 2nd gear pulls for us! What redline is 034 going to tune to? My vote is 7300. You probably will peak around 6500, but its stays pretty strong up there.

I would only need to have the engine running 3 minutes prior to the run.

I will play witht he car (drive) when I get home today. I do get 10psi by 2500 rpm, faster if I go WOT.

[tscrihfield]

Car looks great Mike! You have rebuilt your car twice and I have yet to finish. Wanna make a trip out here? (IMG:style_emoticons/default/evilgrin.gif)

What's even more interesting is if you look at our shifters... We both posted within a couple weeks and have similar looking set-ups. That was quite funny really!

Great minds think alike I hear!

Thomas

[Mike Bellis]

Quick video, my cameraman (son) pressed stop too early... (IMG:style_emoticons/default/sad.gif)


https://www.youtube.com/watch?v=/FTEvDUC74yI


Here is a walk around...


https://www.youtube.com/watch?v=HXjezk3rby0

[Chris H.]

Awesome! Sounds really good. You've got amazing skills. Check out the HUGE exhaust!

[Andyrew]

Sounds eerily familiar! (IMG:style_emoticons/default/smile.gif)

[Mike Bellis]

For Andyrew...


Adjustable delay on timer. Triggered by the fuel pump relay. This timer is adjustable from 0-10 minutes. Just a turn of the dial. It is running: Water pump, Intercooler pump, intercooler fan. I have it set to 2 minutes right now. this prevents the fore mentioned equipment from starting as soon as the key is turned on...

[Mike Bellis]

The gearing is definitely short. I'm running smaller diameter tires and the trans was designed to pull a 3800lb wagon, not a 2100lb 914. COmbine that with a 4" exhaust (read: no back pressure) and the turbo spools very quickly. 1st gear is almost no fun. 2nd gear is just a hair tall to be used as first. My rear tires are 26" tall, I may need to go with a 28" and larger wheel or swap the ring and pinion to match the weight of the car.

I clocked and relocated the throttle pedal today. Much better and more comfortable position.

I need to lube up my diverter valve. I opened it and cleaned it during construction, but forgot to lube. The result is that sometimes during shifts, the pressure does not blow off and the engine revs up rather than down.

[Andyrew]

Pretty cool timer!

The Audi box has plenty of gears and such available. You might look at some 2.8 parts or even some TDI parts. I've got an audi box excel sheet somewhere with all the options, I'll post it when I find it.

[Andyrew]

Here you go Mike.

[rohar]

The gearing is definitely short. I'm running smaller diameter tires and the trans was designed to pull a 3800lb wagon, not a 2100lb 914.

There's solutions available for that. The 012 came in LOTS of variations. The OWW variant is very tall, you can find them on the 12v V6 audis pretty cheap in the strip it lots. The output flanges are different so you'll have to swap some parts over from your existing tranny.

EDIT: Dangit, I didn't see Andyrew's post before I posted. Need moar coffee...

[Mike Bellis]

Well I've been playing with my boost controller. What a PITA! You would think that just following the instructions, perfectly! would yield the desired result... NO!

Started the install just like the diagram on the left. Connected exactly as pictured. The boost would peak at 12psi max. I then replaced all my vacuum lines. Same result. I double checked the entire system for leaks. None found.



I then added a vacuum line as described on the bottom left notes. Max boost... bla, bla... Connect a line from the manifold to the wastegate can... Took it for a test drive and it immediately peaks to 30psi. No ramp up, just straight to 30psi and is virtually undriveable. In addition I broke down on the freeway (my testing ground). At 30psi the cap on the power brake fitting blew off and the car stalled. It took a few minutes to get it started, I then found the massive vac leak. I quickly wrapped the fitting in electrical tape and limped home.

Frustrated, I removed all the vac lines and drove without a connection to the wastegate. It again peaked at 30psi but was a smoother ramp, yet still quick.

Almost at my wits end, I swapped the #1 & #2 connections on the boost solenoid. NOTE: this should not work. It's now backwards. Well, it runs better than ever. Nice boost ramp to 20+psi. Drives perfectly! I'm not sure what's going on with my boost solenoid. Either there is a typo in the instructions or I was supplied with a N.C. when I should have got an N.O. device (or vise versa).

Either way, Holy shit!!!! This 914 hauls ass!!!!!
Way faster than my V8 and very close to the rotary but with more torque! So it feels like more power... (IMG:style_emoticons/default/smile.gif)

Now I need to get the axle and new tranny settled before I break something. The V6 Passat has the same gear ratio (almost) as the Boxster. The difference is .001 ratio per gear. The price difference between them is incredible. Used Passat tranny is ~$400. Used Boxster tranny is ~$1800. These are almost the same tranny, both made by Audi. (IMG:style_emoticons/default/bs.gif) Both final drives are 3.70. My 1.8 tranny final drive is 4.11, should make all the difference...



I also added some hood pins. My original latch was removed to clear the intake manifold and now won't fit. I drilled and tapped the roll bar and then welded a nut in place. This way I can adjust the height.





I also received my 5 year award from the PCA. Overall I have been a member longer but took a hiatus for a while...

[Andyrew]

Awesome!!!

20psi should be right about 330hp.

I know how fast my A4 was and how responsive it was with that turbo so ya... Excited for you (IMG:style_emoticons/default/smile.gif)

I ran 19psi for quite a long time. You might want to dial the boost down at lower RPM so its not to much torque for your drivetrain or your rods (weak link). I havent heard this turbo blowing a rod before, but you are running less weight so who knows how that effects it in the real world.


Get it dailed in, Get 034 to build a 100 octane file for you that will let you run it to 24psi (max safe level for the turbo). With a good tune that should be 375hp+. You can have the ECU hold both the files and you can switch it with the cruise stalk or a button. That should put you sideways in third (IMG:style_emoticons/default/smile.gif). But cruise it daily at 15-17psi is a safe and healthy number.

[Mike Bellis]

I'm running methanol above 18psi, effectively raising the octaine level above 100 in the high boost range (18-30psi). I added root beer fragrance to the meth. It's kind of cool smelling root beer every time I get on it on the freeway.

It's not boosting to high at low rpm now. Other than the 4.11 gearing, it's perfect. I can feel the LSD working as the turbo spools up. What an amazing ride!