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

[Mike Bellis]

Well the axles are 2 different lengths and purchased at different times. So one set came raw and one came red.

I now have several pairs of various size 28 spline axles. PM me if you need an axle and I'll see if I have one.

I also have 2 pairs of 33 spline if someone needs those... (IMG:style_emoticons/default/smile.gif)



Did anyone think I could make it a full year without tearing it apart again??? (IMG:style_emoticons/default/biggrin.gif)

[Chris H.]

Did anyone think I could make it a full year without tearing it apart again??? (IMG:style_emoticons/default/biggrin.gif)

Nope. (IMG:style_emoticons/default/biggrin.gif) Better than waiting for something really bad to happen though right? It'll be even more awesome.

[Mike Bellis]

So I finally put the car on jack stands (6) and started realigning the drivetrain. I purchased a motorcycle jack from Sears.com. It was only $140 and built a jig to hold the engine/tranny in position.

I started on the rear trannt mount first and over the next couple weekends will build the engine mounts. Lucky for me I built the cradle to accept modular motor mount attachments. I used ratchet straps to pull the motor rearward and right/left. I now have at least +2" in front of the motor now.

Here is the starting angle as viewed from above... (IMG:style_emoticons/default/sad.gif)



Here is the finish angle as viewed from above (IMG:style_emoticons/default/smile.gif)



I pulled everything out of the trunk area. Originally I built a dropped trunk floor to gain more space. The new trunk floor will be the same depth as stock.



I had to cut out a section in the rear to make room for the 6 speed. I still have the 5 speed but it is smaller so it should fit no problem. I am reenforcing the area with some 1", .120 wall DOM tubing, to tie everything back together...

[Andyrew]

Looks great!

[Mike Bellis]

Got my motor mounts done today. The fronts are complete. The rear I'm not happy with so that will get reworked. The rear is triangulated and gusseted but you can't tell from the pic. The pic makes it look like a hinge...

I managed to move the motor without disconnecting and draining the radiator hoses. I did have to disconnect and drain the intercooler. This was OK since I didn't like how the intake coupling to the throttle body set before. This time I connected the coupling and let the intercoole hang from the TB, than welded new mounts. Before the 90° coupling was slightly pinched due to the angle and location of the IC. It fits much better now.

So here's the list of things to do...

Change fitting on fuel rail to a 90° since the motor is relocated and there is interference.

Re-mount the IC water pump and fill and bleed the system.

Install new circlip on tranny stub axles.

Re-work exhaust due to relocating motor and new interference issue.

clearance engine cradle for relocated axle. gusset cradle at modification.

Rebuild trunk floor.

Remount methanol system

Re-install trunk electrics and ECU

I'm sure I'll think of more to do as I continue...

A few pics. You can see just under the axle flange where I cut the cradle to clear the CV. This is where the gusset/reinforcement will happen.





Rear mount looks like shit. I reused part of the old mount. Just not happy with the result but it is pretty strong.

[Chris H.]

Looks good Mike! Probably a lot of work. I just swapped mounts and it's taken me a couple of days to re-trim stuff so it all fits since it pushed the engine back a few inches (it's a good thing and the mount fits much better). Made me realize how hard it would be to MAKE a mount and get it level, plumb, at the right height, angle, etc.

[Andyrew]

Looks damn good to me!

[Mike Bellis]

Still pushing forward. Most of the engine bits are bolted back on. Exhaust is ready to install and then I can start fabricating the new trunk floor.

I drilled the fuel rail for safety wire to hold the injector clips. Works great! Now my injectors won't move lower into the intake manifold. Since I'm running fuel at 65psi, the injectors would walk down toward the manifold. New O rings on the injectors too. I painted the intake manifold red. Not sure why but it looks better than it did.



Looking down at the intercooler. The 60° reducing coupling from the throttle body fits better now. Here you can also see the methanol injector. it's mounted in the IC as this was the best place to get maximum-equal cooling.



I still need to deal with the wiring harness. I figure I will build the trunk floor then decide where to route things. I need to make room for the meth tank and pump somewhere too. I had a 4" drop in the trunk floor before. Now it will be stock height.



Here is the part that sucks. I had to cut the trunk shelf to clear the fuel rail and vacuum hose connection... Once I figure out what the finished product will look like, I'll clean up the cut.

[Andyrew]

Why not build a fiberglass floor that you can bolt on and off? Would make engine removal and workin on it a snap..

I mean considering the car and all the other bits on it...

[Chris H.]

That's a great idea. You could do a partial overlay if you didn't want to cut the whole trunk section out. I was just wondering what I could do to make mine a little prettier. You have weird little clearance cuts for the starter and clutch fork with a Subie.

[Mike Bellis]

I am making the trunk floor out of aluminum. Not fiberglass. But it will be removable. I rosette welded the old one and had to drill them out. Since this car has turned into a "drivetrain test mule" I want to make it super easy next time. I do not plan to swap engines again unless I get a deal on a water cooled Porsche 6.

[Mike Bellis]

I installed a new Stewart electric water pump and got rid of the Mezerie pump. The Stewart is virtually silent with only the slightest hum. Seems to work great, simply connected to the old relay.The tamp is a little low at 170° but it was like that with the old pump too. The bearing in the old pump was going out.

Car seems to be running great. No axle or CV issues. Good boost and good O2 levels. It's ready to be driven... (IMG:style_emoticons/default/smile.gif)


Looks like this new. Mine is black 1-1/4" in/out.


I cleaned up the rear trunk. Ready for the Werks Reunion next Friday.

[Mike Bellis]

I got poked by a member here for messy wiring in the trunk... (IMG:style_emoticons/default/poke.gif)

October 2013 while at the Porsche Escape I had to jury rig my water pump after a timer relay failed. Before that, I has some other unsightly wiring for the main power and fans. I let it run like this for almost 1 year.

Here is a before picture, at its worse...



Here is the after. I used the opportunity to pull the tank and install AN tank fittings. -8 for the pump supply and a -6 for the return. I also installed AN ball valves for maintenance of the fuel system. I run the return into the trunk before the tank for access. The fuel system consists of 3/8" Aluminum hardline (soft, 250psi burst rating) and braided hose. The fuse box is a marine grade unit. It's only rated for 125A but I'm claiming the NEC 10' tap rule. (IMG:style_emoticons/default/smile.gif)

[YoungCC]

Interesting project, just wondered if they flash the ecu, does that also do away with the key coding?
Geoff

Yes. the immobilizer will be eliminated.

(IMG:style_emoticons/default/santa_smiley.gif)

[Mike Bellis]

Merry X-Mas! Since you bumped it... Here's an update...

The 5 speed is going back in so the 6 speed can be sent out to Dr Evil for some surgery. I hope to get it sent out to Ohio early next year.

[Cairo94507]

Damn....a water cooled Porsche six huh? (IMG:style_emoticons/default/biggrin.gif)

[EdwardBlume]

Do you have any in car video of driving this thing?

[Mike Bellis]

Do you have any in car video of driving this thing?

No but I can come pick you up and let you film it... (IMG:style_emoticons/default/driving.gif)

[EdwardBlume]

Do you have any in car video of driving this thing?

No but I can come pick you up and let you film it... (IMG:style_emoticons/default/driving.gif)

Deal!

[914GTSTI]

Mike. will a 930 cv bolt up to the 012 FWD A4 output flange ?
Randy