 Sasquatch Part III Audi 1.8t transplant..., PCV upgrades finally... |
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| Mike Bellis |
 Jul 4 2013, 05:59 PM
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#261
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Resident Electrician  Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None 
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As I await my Boxster/Cayman 6 speed to arrive, I decided to take the car out for a spin... Once up to temp and at speed, smoke filled the cabin and trailed behind the car... Oil pressure good, so I limped it home... Doesn't smell like motor oil, smells more like gear oil...
Pulled up in the driveway looking like a Cheech and Chong movie. (IMG:style_emoticons/default/smoke.gif) Opened the engine lid and the smoke is coming from the power steering pump... (IMG:style_emoticons/default/dry.gif) I had to install the pump because it drives the water pump. Before installation, I removed the veins that create pressure, capped the fittings and filled it with PS fluid. I have 300 miles on the car without any issue with the pump. Not sure what the exact problem is. Inside it is now just a spinning flywheel submersed in fluid. After the car cools down I am going to remove it completely. I think it will be OK since I'm now running an inline electric water pump. We shall see... |
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| McMark |
Jul 4 2013, 06:29 PM
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#262
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914 Freak! Group: Retired Admin Posts: 20,179 Joined: 13-March 03 From: Grand Rapids, MI Member No.: 419 Region Association: None |
Does it ever end? (IMG:style_emoticons/default/happy11.gif)
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| Mike Bellis |
Jul 4 2013, 06:32 PM
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#263
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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| FourBlades |
Jul 4 2013, 08:00 PM
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#264
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From Wreck to Rockin Group: Members Posts: 2,056 Joined: 3-December 07 From: Brevard, FL Member No.: 8,414 Region Association: South East States
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This is such a kick ass project. (IMG:style_emoticons/default/beerchug.gif) You really have kept after it... John |
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| Mike Bellis |
Jul 5 2013, 06:30 PM
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#265
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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Looks like it worked. I put on a shorter serpentine belt and bypassed the PS pump and water pump. Took a 30 mile road trip with no issues to report. Electric water pump is working just fine... (IMG:style_emoticons/default/smile.gif)
The bearings in the power steering pump are shot. (IMG:style_emoticons/default/sad.gif) I gained at least 1.5hp by disconnecting it. (IMG:style_emoticons/default/biggrin.gif) |
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| JRust |
Jul 5 2013, 11:50 PM
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#266
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914 Guru Group: Members Posts: 6,310 Joined: 10-January 03 From: Corvallis Oregon Member No.: 129 Region Association: Pacific Northwest
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Nice. Wish I could get a ride in it while I am down here. Where the hell do you live again (IMG:style_emoticons/default/confused24.gif)
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| McMark |
Jul 7 2013, 05:39 PM
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#267
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914 Freak! Group: Retired Admin Posts: 20,179 Joined: 13-March 03 From: Grand Rapids, MI Member No.: 419 Region Association: None |
I got a surprise visit today from Mike, out on a shakedown run. It was cool to share and compare setups. The sasquatch is quite a build. I was really impressed with how well the dash turned out. The engine fits in there surprisingly well and all the systems are neat and tidy. Performance was, of course, fantastic - including the handling of the chassis. Mike, you got a really well set up car there. Looking forward to seeing it again when the tune is finalized.
Thanks for dropping by! (IMG:style_emoticons/default/driving.gif) |
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| Mike Bellis |
Jul 7 2013, 05:44 PM
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#268
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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QUOTE(McMark @ Jul 7 2013, 04:39 PM)  I got a surprise visit today from Mike, out on a shakedown run. It was cool to share and compare setups. The sasquatch is quite a build. I was really impressed with how well the dash turned out. The engine fits in there surprisingly well and all the systems are neat and tidy. Performance was, of course, fantastic - including the handling of the chassis. Mike, you got a really well set up car there. Looking forward to seeing it again when the tune is finalized. Thanks for dropping by! (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/pray.gif) Thank You! |
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| Mike Bellis |
Jul 21 2013, 09:21 PM
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#269
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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And then this happened... (IMG:style_emoticons/default/dry.gif)
 I changed out the water temp sender today. Yes, little coolant came out. 1-2 cups of fluid escaped. I decided to take it on a test drive. No, I did not top it off. I made it 7 miles when the radiator hose let go with a violent bang! Steam spewed from my GT style engine lid and coolant was everywhere. The moment the check engine light came on I was turning off the ignition... Towed it home (See trailer thread) and parked it. Lesson learned. Always pull the air out of the system. (IMG:style_emoticons/default/chair.gif) |
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| Andyrew |
Jul 21 2013, 09:30 PM
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#270
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Spooling.... Please wait Group: Members Posts: 13,377 Joined: 20-January 03 From: Riverbank, Ca Member No.: 172 Region Association: Northern California
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Damn!!! Hopefully its an easy fix!
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| Chris H. |
Jul 22 2013, 07:01 PM
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#271
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Senior Member Group: Members Posts: 4,048 Joined: 2-January 03 From: Chicago 'burbs Member No.: 73 Region Association: Upper MidWest
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Ugh....so that happened just because there was too much air in the cooling system? Good to know....
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| Mike Bellis |
Jul 22 2013, 09:48 PM
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#272
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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QUOTE(Chris H. @ Jul 22 2013, 06:01 PM) Ugh....so that happened just because there was too much air in the cooling system? Good to know.... It was near the high point of the system. My guess is a steam pocket... (IMG:style_emoticons/default/sad.gif) It was Fuching loud! |
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| Mike Bellis |
Jul 29 2013, 09:07 PM
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#273
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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My new transmission showed up today! (IMG:style_emoticons/default/piratenanner.gif) I'm going to clean it up and paint the crusty bits. This is a 2005 Boxster S unit. Other than being ugly, It seems in good shape and I can shift all 6 forward and reverse gears. Everything spins (IMG:style_emoticons/default/smile.gif)
  Same Bell housing as my Audi... (IMG:style_emoticons/default/evilgrin.gif)  The 130mm flanges, (Only on the S transmission) work with my 930 CV's but they require 6 bolts... (IMG:style_emoticons/default/smile.gif)  I'm old and lazy so I decided to install a SPAL power window kit. I used to install these regularly and the design hasn't changed. I did have to offset the motor slightly to clear the regulator. Once the panel is in you will never see it. It was always a PITA to use the handle since the roll bar arm bracket is in the way.  So I also decided to do proper door grommets. These are the rear hatch grommets from the donor 2001 Passat Wagon.   |
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| Chris H. |
Jul 31 2013, 02:43 PM
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#274
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Senior Member Group: Members Posts: 4,048 Joined: 2-January 03 From: Chicago 'burbs Member No.: 73 Region Association: Upper MidWest
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I'm doing power windows too Mike! Good call. I ordered door panels and vinyl from 914rubber a while back and asked Mark NOT to cut a hole for the window winder. Can't wait to get them in. How do the SPAL's work? Pretty well?
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| Mike Bellis |
Jul 31 2013, 07:33 PM
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#275
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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QUOTE(Chris H. @ Jul 31 2013, 01:43 PM) I'm doing power windows too Mike! Good call. I ordered door panels and vinyl from 914rubber a while back and asked Mark NOT to cut a hole for the window winder. Can't wait to get them in. How do the SPAL's work? Pretty well? The SPAL kit is cool for a universal kit. Very easy to install on just about anything. As for no holes in the panel. It might be possible. I tried to space the regulator back a little. Right at the crank the clearance is very tight between the glass and regulator. Less than a finger width. When I spaced it, the mechanism started the drag and bang as the window went up/down. I ended up just spacing the horizontal track right above the motor. I have late style regulators. You may need a power regulator from Electro-life http://electric-life.com/ I'm not sure if they have a specific 914 kit but I'm sure something could be modified. Then you would not have a crank at all to worry about. |
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| Mike Bellis |
Aug 3 2013, 06:54 PM
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#276
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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I pulled my 5 speed today. It came out pretty easy without the engine and cradle. I also pulled the Phantom Grip LSD and planted it int the 6 speed. The spider gears are a direct swap, although the 3rd member is bigger in the 6 speed. The whole tranny is a little bigger. I do have to fab rear mounts but that's no big deal.
The bad news: The Boxster tranny does not have the electric speedo drive. I need to rig/fab something to work. Here is a look at the bell housing area. 5 on left, 6 on right. Notice the 6 has more clearance for a bigger flywheel. Bolt pattern is almost identical. The Audi engine does not use all the bolt holes on the 5 speed. But all the hole I need match up on the 6 speed. BTW, this is a GETRAG Audi 466 transmission.   Here are the 2 diffs. 5 on left, 6 on right. The 6 is clearly bigger. I was surprised to see the spiders were interchangeable. So no new machining required.   The PG LSD shows minimal wear. You can see wear marks but you can't feel them.  |
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| Mike Bellis |
Aug 3 2013, 10:41 PM
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#277
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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I muscled the tranny into position today. What a PITA! It is longer than the 5 speed and it hits the muffler bracket. I did a quick chop of the bracket to get it mounted. I noticed a small difference with the starter opening. The bolt pattern is the same but it is made for a slightly smaller starter. I need to machine 1/8" from the bell housing. So that means the tranny comes back out. While it's out I will modify the muffler bracket. A couple of the mounting holes I need to use need to be drilled out. I guess the Boxster uses the other holes. Once I get all this dealt with, I will fab mounting brackets for the new tranny.
So It is almost a bolt in swap. I figured it would go like this. At least the thing bolts up to the engine! (IMG:style_emoticons/default/sawzall-smiley.gif) (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/sawzall-smiley.gif) (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/headbang.gif) |
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| Andyrew |
Aug 4 2013, 01:25 AM
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#278
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Spooling.... Please wait Group: Members Posts: 13,377 Joined: 20-January 03 From: Riverbank, Ca Member No.: 172 Region Association: Northern California
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Great progress as always! And to think, I havent been able to change a fuel pump in 5 months...
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| 76-914 |
Aug 4 2013, 09:21 AM
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#279
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Repeat Offender & Resident Subaru Antagonist Group: Members Posts: 13,634 Joined: 23-January 09 From: Temecula, CA Member No.: 9,964 Region Association: Southern California
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QUOTE(kg6dxn @ Aug 3 2013, 09:41 PM) I muscled the tranny into position today. What a PITA! It is longer than the 5 speed and it hits the muffler bracket. I did a quick chop of the bracket to get it mounted. I noticed a small difference with the starter opening. The bolt pattern is the same but it is made for a slightly smaller starter. I need to machine 1/8" from the bell housing. So that means the tranny comes back out. While it's out I will modify the muffler bracket. A couple of the mounting holes I need to use need to be drilled out. I guess the Boxster uses the other holes. Once I get all this dealt with, I will fab mounting brackets for the new tranny. So It is almost a bolt in swap. I figured it would go like this. At least the thing bolts up to the engine! (IMG:style_emoticons/default/sawzall-smiley.gif) (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/sawzall-smiley.gif) (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/headbang.gif) Nice build Mike. It's always comforting to know that one doesn't have to look far for something to do. (IMG:style_emoticons/default/lol-2.gif) If it makes you feel any better, I ran into the same starter dilemma on my Suby swap, yesterday. (IMG:style_emoticons/default/popcorn[1].gif) I don't believe anyone has asked this yet but how does the new power plant compare to your previous ones? |
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| Mike Bellis |
Aug 4 2013, 09:40 AM
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#280
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Resident Electrician Group: Members Posts: 8,346 Joined: 22-June 09 From: Midlothian TX Member No.: 10,496 Region Association: None
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QUOTE(76-914 @ Aug 4 2013, 08:21 AM) Nice build Mike. It's always comforting to know that one doesn't have to look far for something to do. (IMG:style_emoticons/default/lol-2.gif) If it makes you feel any better, I ran into the same starter dilemma on my Suby swap, yesterday. (IMG:style_emoticons/default/popcorn[1].gif) I don't believe anyone has asked this yet but how does the new power plant compare to your previous ones? The power is awesome. If I dial the boost down, if is the same as my old 283ci V8, with slightly lees torque. If I turn the boost up (25+ psi) it is crazy fast and controllable. The rotary had more peak power but this feels stronger. Probably due to higher torque numbers at lower rpm. If it weren't for the fact that my axle angle was too severe, I would have left the 5 speed in there for a while. I needed the 108mm flanges from the 6 speed to use 930 CV's. I tried to buy just the axle flanges but none of the Porsche dismantlers would sell me just the parts. Now I have all the parts, I just have to make it work... |
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