Marc's 95 S6 Avant (daily driver)

GTIVR62801 · Post by **GTIVR62801** » Wed Sep 13, 2006 5:41 am

I was checking out the adapter harness Marc made while we were at WG2, it was quite well done. Frickin genious I tell you!

Highlander · Post by **Highlander** » Wed Sep 13, 2006 7:14 am

Mark that's going to be one serious car.

Thanks alot for sharing with the group the 034 to Motronic adaptor.

I was contemplating doing the same thing. It's nice to see someone not always in things for a profit. Where did you get the donor Motronic plug?

Thanks again Mark

Cheers,
Craig Cook

1986 4000 MC
1984 urq AAN

Post by **Marc** » Wed Sep 13, 2006 7:43 am

Highlander wrote:Mark that's going to be one serious car.

Thanks alot for sharing with the group the 034 to Motronic adaptor. I was contemplating doing the same thing. It's nice to see someone not always in things for a profit. Where did you get the donor Motronic plug?

Thanks again Mark

Cheers,
Craig Cook

1986 4000 MC
1984 urq AAN

Hi Craig,

I got the plug from VEMS (click the pic for the link to their online shopping cart)

Highlander · Post by **Highlander** » Wed Sep 13, 2006 7:49 am

thanks again Mark.

Keep us posted on the car once you have her dialed in.

Cheers,

Craig Cook.

Post by **Marc** » Wed Sep 13, 2006 9:42 am

went over my boost control settings and got that working :woowoo:

Click the pic for a link to the full logging page. This is just a short blast up the highway to the top of 2nd and part way through 3rd. I had more data but forgot that 'start/stop log' overwrites whatever was there before in the selected log file.

I had forgotten that I had disabled EGO feedback by setting the delay to 0 in the config as it shows with the steady 1.0 ego correction factor. looks like I'll need to lean out the main adjust a little bit as I'd like to be closer to around 12:1 on boost, right now looks to be around 11:1 on average. Getting there

The air temp display looks a bit funky too, I think theres an air leak around the sensor that I'll have to deal with, might be getting some outside temps on the sensor causing the strange readings.

JShadzi · Post by **JShadzi** » Wed Sep 13, 2006 12:59 pm

Exactly 8) Shows you've got a good intercooler setup, the air coming out of the intercooler is cooler than your intake manifold, thus cooling your engine as cooler air comes into it, looks good to me. Notice the spike when you shift?

Wizard-of-OD · Post by **Wizard-of-OD** » Wed Sep 13, 2006 2:20 pm

a4kquattro wrote:Here's the harness so far:

Overlord I think you should mass produce these and pass them to Nate (hint hint)
Looks great

engleg · Post by **engleg** » Wed Sep 13, 2006 4:19 pm

What epoxy did you decide on to fill your JPT55 connector with?

Post by **Marc** » Wed Sep 13, 2006 5:28 pm

engleg wrote:What epoxy did you decide on to fill your JPT55 connector with?

"potting compound". Same stuff they use on motherboards to hide circuitry. Made by MG chemicals. Click the pic for a link.

Post by **Marc** » Tue Sep 19, 2006 6:36 pm

alright, more progress on the daily driver today. I picked up a stromung 3" turbo back exhaust for the car.

Me being the type that never really leaves well enough alone, I set to work cutting up my new $1400 exhaust :-P

Its a nice system, but the 2 bolt flanges that they use on the system are prone to leaks:

The fix? v-bands, yo

Now if I had just remembered to wear jeans without holes in the knees.. got a strange sun burn covering about 8" around both knees :-P

One of the reasons I got the exhaust was because I knew I was going to be installing a GT 3071 turbo soon so I figured I'd do both at the same time. I just pulled the old turbo out tonight, should be able to install the new turbo tomorrow.

60# fuel injectors on order...

just in time for my car's 200k anniversary

:woowoo:

Josh · Post by **Josh** » Tue Sep 19, 2006 7:02 pm

i flip my jeans on backwards when I weld.. criss cross will make you jump jump... :bashtard: :bashtard: :bashtard: some one will reconize the beat.

PRA4WX · Post by **PRA4WX** » Wed Sep 20, 2006 4:15 am

Josh wrote:i flip my jeans on backwards when I weld.. criss cross will make you jump jump... :bashtard: :bashtard: :bashtard: some one will reconize the beat.

a daddy mac'll make ya........! :lol:

Jonathan · Post by **Jonathan** » Wed Sep 20, 2006 6:10 am

PRA4WX wrote:
Josh wrote:i flip my jeans on backwards when I weld.. criss cross will make you jump jump... :bashtard: :bashtard: :bashtard: some one will reconize the beat.
a daddy mac'll make ya........!

Mac-daddy make ya JUMP-JUMP
Uh-huh--uh-huh.

Ah, 1990 or so. Good times.

Derracuda · Post by **Derracuda** » Wed Sep 20, 2006 7:14 am

lets hope!

Post by **Marc** » Wed Sep 20, 2006 7:57 am

newt wrote:You welded those v-bands on, while on the car, right?

no, what I did was measure with a caliper the thickness of the v-band vs. the 2 bolt flange. I then marked the spot in several places around the face of the existing flange where the back of the v-band should rest on the pipe. I then welded the v-band on so that the face of the v-band wound up in the same place as the existing 2 bolt flange.

And yes, there is plenty of room around the flanges for the v-band, its roughly the same outer diameter as the 2 bolt flange at its thinnest point with the clamp.

Derracuda · Post by **Derracuda** » Wed Sep 20, 2006 10:05 am

:stupid:

Post by **Marc** » Wed Sep 20, 2006 10:16 am

no biggie, I just wasn't ready to pull the exhaust and needed to get the vbands welded on. if they are off, I'll fix it, worst case scenario I'll only have to redo two of the flanges since I can fix any error on the other end of the flange. I'll update this post once the turbo is in so I can fit the exhaust. Remember, the shop is an hour away from my house so I dont have the luxury of test fitting everything like this which is how I'd like to have done it.

JShadzi · Post by **JShadzi** » Wed Sep 20, 2006 10:49 am

You should be fine, plenty of room in those big cars 8)

JShadzi · Post by **JShadzi** » Wed Sep 20, 2006 11:03 am

Don't I know about V-bondage!!

:frustrated:

WOMBAT · Post by **WOMBAT** » Wed Sep 20, 2006 11:11 am

err.....must be a newtonian slip....or something

gotta love how the daily drivers can never be just a daily driver 8)

Post by **Marc** » Thu Sep 21, 2006 5:51 pm

GT3071 install is almost done. I'm just waiting for teh JB weld to dry on the airbox before I put it back in the car (got a little agressive on dimpling the heat shield and cracked part of the plastic),

some of the trimming necessary to make room for the biggah turbo

notch in the heat shield for the water line

for now I'm running a quick and dirty (ok, very dirty) cone filter I found in the basement.

stromung is in, the v-bands were pretty close to right on, the flange on the downpipe is a bit off and to be honest I'm very concerned about the stress on the exhaust manifold. Javad to the rescue, 3" flex bellows on the way 8-)

here's one I wasn't expecting.. my old turbo definitely ate something :wtf:

back out to the garage to clean up the pile of tools and button up a few things.

Post by **Marc** » Fri Sep 22, 2006 9:31 am

Got the airbox in now that the jb weld has dried :bashtard:

waterline clearance. toight, toight like a tigah!

On the exhaust saga, the flex bellows has arrived from 034motorsport :thanks:

edit: The reason for the difficulties in fitting my exhaust had nothing to do with the stromung exhaust but rather the difference in the GT turbo hotside placement. Its quite a significant offset from KKK fitment, enough to make the system nearly impossible to bolt up without putting _significant_ stress (as in, hang off the end of a 6' piece of pipe) on the pipes to make them line up.

Here you can see the fitment before modifying the downpipe

The fix will be to take about an 1/8" off the section of pipe near the top of the downpipe (the straight section near the o2 bungs) and then make that space up at the bottom when I go to install the flex bellows.

The car is driveable since there is enough tie rod clearance with the car on the ground but obviously under track conditions this would be a serious problem. I'll take the downpipe off the car at the shop and modify/test fit until I'm satisfied with it.

More tomorrow.

noriceforyou · Post by **noriceforyou** » Fri Sep 22, 2006 10:07 am

looking good Marc.....seriously, there isn't much more that can top a modded Avant. I'm eagerly looking forward to the finished product!

Post by **Marc** » Sun Sep 24, 2006 8:35 am

spent yesterday at the shop modifying the stromung downpipe.

Basically, aside from the downpipe interfering with the tie rods, the outlet on the downpipe sits a good 1" too far to the left and 1/2" down from where the midpipe flange sits due to the GT turbo hot shoe being different from a standard KKK fitment.

I fixed this by cutting and welding the pipe in multiple locations.. once at the top to remove about 1/8" of material to move the pipe away from the tie rods:

Next, I cut the pipe in the middle to rotate it to make up the 1" too far to the right condition and added about 1/2" worth of metal at that some location to lower it to fix the 1/2" too high problem.

Then I added in the flex bellows, and finally I have a system that fits correctly

Oh and BTW, the gt3071 rocks my world. a wonderful turbo for this car. Same boost onset as my other turbo (k24/t04b hybrid) but WAAAY more top end balls. I haven't even upped the boost controller beyond 20psi and the car already makes more power than the other turbo did at 28psi.

:woowoo:

JShadzi · Post by **JShadzi** » Sun Sep 24, 2006 8:48 am

Looks good Marc, car is really coming together 8)

Marc's 95 S6 Avant (daily driver)

Re: Marc's 95 S6 Avant (daily driver)