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

[Mike Bellis]

One more just for fun...

Engine in the bay. I will have to make room in the rear trunk for the valve cover, exhaust and intake. I picked up a new aluminum intake manifold since the stocker won't work (angle problem) this one allows the TB to be installed in front of in back. I am mounting it in the back and it will also crowd the trunk a little...

[rohar]

Dude, we need to start a new club, the lightweight birdcage cradle club! It's looking nasty! I've got one more day of distraction with the 944 and I'm back to fab on mine.

Good on ya man!

[Andyrew]

What manifold did you use? The VW one for the transverse engines?

Engines are pretty low in vibrations so you should be OK, If you used the A/C it might be a bit shaky.

Where in the trunk do you have to make room?

Enjoying the progress!!

[Mike Bellis]

What manifold did you use? The VW one for the transverse engines?

Engines are pretty low in vibrations so you should be OK, If you used the A/C it might be a bit shaky.

Where in the trunk do you have to make room?

Enjoying the progress!!

I picked up an OBX (don't laugh), It's the only one I could find that would work for under $500. It actually fits nice and the quality is good. Believe me I was worried! Its for a transverse engine setup. The funky angle on the stock manifold just would not work right.

I have to make a hump just like some of the Subie guys do. I will used my roll cage as the corner and just box in around it.. I need to make the targa top fit. That is a priority!

[McMark]

Mark, what would you want with a lowly KO3? Planning to turbo your lawnmower?

Basically. (IMG:style_emoticons/default/evilgrin.gif) Should have it sorted with the Chinese K03 by New Years. I won't clutter up Mike's thread anymore with details, plus I'll have a whole build thread on it once it's done. If I post about it, it's on my Twitter feed. So if you're curious you can look through that. (IMG:style_emoticons/default/wink.gif)

Mike, the crade looks amazing! Do you have a mandrel pipe bender? I can't believe the engine fits as well as it does. If you want to make the intake work without cutting the truck, you're welcome to play with my TIG welder anytime. (IMG:style_emoticons/default/thumb3d.gif)

[Mike Bellis]

Mike, the crade looks amazing! Do you have a mandrel pipe bender? I can't believe the engine fits as well as it does. If you want to make the intake work without cutting the truck, you're welcome to play with my TIG welder anytime. (IMG:style_emoticons/default/thumb3d.gif)

As an Electrician, I have access to various pipe benders. I used my hand/shoe bender for these since it is such small diameter tubing. It would have been easier and lighter if I used thinner wall tubing.

You saw how my old cradle was sagging (rotary) due to the lack of a rear support. This time I wanted no sagging or flex. I think I achieved it considering the weight of the engine is sitting on a copper shim, sitting on the single 3/4" horizontal runner.

Time to get back to work!

I added some more triangulation since these first pics. I will add more pics when I get it finished...

[Mike Bellis]

Today was spent, all day, fabricating mounts. I did something smart, I made mounting tabd on the cradle to pick up the tranny and motor mounts. That way If I swap engines, again, I can re-use the cradle and only fab new mounts. I also burned up almost all my DOM. Surprised I didn't run out of welding wire or gas... I'm sure glad I can fab myself, although it would be nicer if I had a shop and slowed down a little. I could not afford to pay someone to do this. This is one of those days where you would have to explain to the customer that it actually did take 10 hours to create mounts. Then try to get them to pay...

I used the axle stubs to measure for level. There are no level parts on the engine. Everything line up great...

[Mike Bellis]

here is the final system welded. Need some more grinding and finishing but it looks pretty good. For those that are counting, the cradle weighs exactly 24.6 lbs. The engine and tranny mounts a few pounds more...

That's it for now. We'll see what I get done this week after work... BTW, the new oil stains on the driveway anr from the nounts. I gave them a dirty oil bath after welding. Apparently I missed a weld and the filled up with oil, then they drained out... (IMG:style_emoticons/default/sad.gif)

[Dr Evil]

Work of art, Mike (IMG:style_emoticons/default/thumb3d.gif)

[Mike Bellis]

Work of art, Mike (IMG:style_emoticons/default/thumb3d.gif)

Thanks Doc! That means a lot from a man of your stature. (IMG:style_emoticons/default/KMA.gif)

[Todd Enlund]

Man, that is slick.

[westtexass2k]

This is a cool build. I really like the Audi engine. Its very smooth and fat low end torque. Are you going to use a cable shifter?

[McMark]

That's awesome! And your insight to make replaceable mounts is genius. An engine sub-frame is the only way to go. Keep up the great work. (IMG:style_emoticons/default/smiley_notworthy.gif)

[Andyrew]

Looks fantastic!!!!

[Mike Bellis]

This is a cool build. I really like the Audi engine. Its very smooth and fat low end torque. Are you going to use a cable shifter?

I am using a Boxster shifter. I had to fab the tranny side linkage and it works great. Shifts just like a Boxster.

[Mike Bellis]

Here she is in all her glory. Engine mounted to the cradle. Intake and exhaust mocked up. The cradle sure makes it east to maneuver around. The nuts on the under side of the exhaust manifold will be a challenge. So far I cannot get a wrench on the center one... (IMG:style_emoticons/default/sad.gif)

Enough work for today. I'm tired...

[Mike Bellis]

The cool thing about the OBX (don't laugh) intake manifold is the ability to swap the throttle body to the front or rear. Right now it's setup on the rear. My AEM methanol injector is on the front. The shitty thing about the OBX manifold was the fuel rail. The one that came with the manifold is polished and the -6AN fittings arn't right. They do not fit a -6AN fitting. Shitty Chinese manufacturing. I just happened to have another OBX rail and it worked with a little modification. Aeromotive 75psi regulator is hanging on the end. Not sure I will leave it there but we'll see...







Here is the oil cooler attachment and Crankcase evacuation fitting visible. I removed the factory water cooled oil cooler and will run my -12AN oil cooler lines to it. (IMG:style_emoticons/default/smile.gif) I had to add a 45 elbow and -10 to -12 adapters. The elbow it for clearance between the -12 fittings only.

[rohar]

That's really comming together. I love that you stuck with the stock 15 degree slant, it'll make things so much easier shortly down the road.

[okieflyr]

Mike, have you checked your height and clearance with the OBX manifold yet ?

Are you going to use any rubber or material between the cradle and body?
The cradle will hold and transfer alot of vibration to the body. I used stock 911 mounts at my four points of engine/ body mounting and it is very effective with the vibration. My engine lid will get excited for about 2 minutes when cold, but everthing is quiet beyond that.

[Mike Bellis]

Mike, have you checked your height and clearance with the OBX manifold yet ?

Are you going to use any rubber or material between the cradle and body?
The cradle will hold and transfer alot of vibration to the body. I used stock 911 mounts at my four points of engine/ body mounting and it is very effective with the vibration. My engine lid will get excited for about 2 minutes when cold, but everthing is quiet beyond that.

I may have some engine lid clearance problems with the intake. Have to get it in and see. I can lower it down if I need to. Just have to fab new mounts. Lucky for me this is doable without messing with the cradle. (IMG:style_emoticons/default/smile.gif)

I have broken too many rubber mounts over the years. Including 911 mounts. These are solid just like my V8 was. I'm used to the added noise and vibration. I even have a set of aviation headsets for long drives when the V8 would drone on and on...