Nick's AAN into 4000Q thread. set backs.....set backs....

Hybrid_Hatch · Post by **Hybrid_Hatch** » Thu Aug 18, 2011 12:03 pm

Rallyfreak202 wrote:

that line looks pinched to me

Asmodasis · Post by **Asmodasis** » Thu Aug 18, 2011 11:41 pm

Ya, kinda does, but idk could work

vt10vt · Post by **vt10vt** » Fri Aug 19, 2011 8:09 am

Rallyfreak202 wrote:I leave for school August 18th and won't be back for awhile. Bummer.

It looks great Nick! If you're going to be home in december after classes end I'd love to come down for a few days or whatever and help out, since i'll be graduated and all

Also, what kind of intercooler is that? Looks like a 20v single pass maybe?

Rallyfreak202 · Post by **Rallyfreak202** » Sun Aug 21, 2011 9:53 am

Asmodasis wrote:Are you keeping the Lambda sensor on the catalytic converter or mounting on the down pipe?

I will be welding two bungs in the downpipe for the wideband O2 sensor and EGT sensor.

vt10vt wrote:
Rallyfreak202 wrote:I leave for school August 18th and won't be back for awhile. Bummer.
It looks great Nick! If you're going to be home in december after classes end I'd love to come down for a few days or whatever and help out, since i'll be graduated and all Also, what kind of intercooler is that? Looks like a 20v single pass maybe?

That'd be awesome Shawn. The intercooler is actually John Buffum's old intercooler!

my2000apb · Post by **my2000apb** » Thu Aug 25, 2011 10:29 am

the egt sensor should be pre turbo

Rallyfreak202 · Post by **Rallyfreak202** » Fri Aug 26, 2011 9:28 am

my2000apb wrote:the egt sensor should be pre turbo

That makes sense. Glad I didn't drill 2 holes in my downpipe yet.

death 4kqt · Post by **death 4kqt** » Fri Aug 26, 2011 9:32 am

best to put it in a running in the manifold about 1" from head port or so. Would be best to choose what you think would be the hottest runner.

my2000apb · Post by **my2000apb** » Fri Aug 26, 2011 9:34 am

put it in number 5!

Mentosman42 · Post by **Mentosman42** » Fri Aug 26, 2011 11:08 am

my2000apb wrote:put it in number 5!

Asmodasis · Post by **Asmodasis** » Fri Aug 26, 2011 12:10 pm

Interesting, never really put much thought into an EGT probe. good to know it should be pre-turbo

my2000apb · Post by **my2000apb** » Mon Aug 29, 2011 9:43 am

Asmodasis wrote:Interesting, never really put much thought into an EGT probe. good to know it should be pre-turbo

the closer to combustion the better

Rallyfreak202 · Post by **Rallyfreak202** » Mon Oct 17, 2011 8:03 pm

Came home for Fall break and worked on the Audi.

-Painted the intercooler, radiator shroud, and made/painted the intercooler brackets

IMAG0155

IMAG0157

Started and almost finished with snub mount mounting

IMAG0156

IMAG0152

Mounted the radiator

IMAG0158-1
Had to cut a little so the fan would clear.

IMAG0151
and grind a little

IMAG0150

Need to figure out some coolant hose to use for this windy route:

IMAG0149
Intercooler location

IMAG0144
Wheels

IMAG0141
The S4 was sent to the crusher. Got 350 out of it for scrap!

IMAG0133
Boost controller

IMAG0153
Oil cooler. NEEDS TO BE PAINTED. Might have to move it to clear intercooler piping.

IMAG0154

Still have lots of things to do before it will run. I hope to start it next time I come home which will be Thanksgiving break. Thanks for reading.

Rallyfreak202 · Post by **Rallyfreak202** » Tue Oct 18, 2011 9:35 am

To do:
-make throttle cable bracket
-AN line coolant turbo feed
-finish stainless steel coolant turbo drain line
-wastegate dump tube routed into the down pipe
-Intercooler piping
-battery tie down
-turbo bracing (any suggestions?)
-weld O2 sensor bung in to downpipe
-wire TPS
-find/buy flexible coolant hose.

my2000apb · Post by **my2000apb** » Wed Nov 16, 2011 8:34 am

does it run yet?

Rallyfreak202 · Post by **Rallyfreak202** » Mon Nov 28, 2011 4:30 pm

Ok, got lots done! Getting super close to running.

Left to do:
-throttle cable
-air intake
-Blow off valve
-PCV route
-coolant lines
-put fluids in
-misc stuff I can't remember and you don't care about. All you want is pictures!

Home made coolant line

IMAG0187 by rallyfreak202, on Flickr

Intercooler piping done

IMAG0205 by rallyfreak202, on Flickr

IMAG0204 by rallyfreak202, on Flickr

Downpipe almost finished. Pretty dang proud of it.

IMAG0216 by rallyfreak202, on Flickr

IMAG0215 by rallyfreak202, on Flickr

IMAG0214 by rallyfreak202, on Flickr

More work on the front snub mount stuff

IMAG0190 by rallyfreak202, on Flickr

IMAG0191 by rallyfreak202, on Flickr

Put some Hella Euro tail lights on my GTi. Love the way they look. JDM as FECK!!

IMAG0195 by rallyfreak202, on Flickr

Uh oh

IMAG0206 by rallyfreak202, on Flickr

IMAG0203 by rallyfreak202, on Flickr

my2000apb · Post by **my2000apb** » Tue Nov 29, 2011 9:14 am

it was hard to see from the pics, but the turbos feed and drain need to be clocked to be plum vertical

Rallyfreak202 · Post by **Rallyfreak202** » Tue Nov 29, 2011 10:49 am

my2000apb wrote:it was hard to see from the pics, but the turbos feed and drain need to be clocked to be plum vertical

Dang, thanks for the insight Tim. I've never heard of this before. I can't clock the turbo because it mounts on the manifold at a fixed position :dur: , I guess I could alter the oil feed angle. Can anyone else offer some insight?

easterneurocoupe · Post by **easterneurocoupe** » Tue Nov 29, 2011 11:08 am

If u loosen the bolts on back of hotside the chra will rotate

Rallyfreak202 · Post by **Rallyfreak202** » Thu Dec 22, 2011 7:25 pm

Got the turbo clocked. Much heat and a lot of banging. Re did the hard lines for turbo. Lots of work was done in the past few days but it doesn't really show in the photos. Oh well, if anyone is reading, here are some photos.

Heat shield

Gauges

Trunk/battery

Relocation

Blow off valve

IMAG0260
Rear block coolant union

Water manifold to resevior tank union

Random fun shot

Front water manifold to top of radiator

IMAG0262
Broken:

Intake with provision for PCV

IMAG0259
Replacing center support bearing

Today

Rallyfreak202 · Post by **Rallyfreak202** » Sun Dec 25, 2011 5:12 pm

IT RUNS!!!!!!!!!!!!!!!!!!!!!!

CorradoGuy · Post by **CorradoGuy** » Sun Dec 25, 2011 5:25 pm

Rallyfreak202 wrote:IT RUNS!!!!!!!!!!!!!!!!!!!!!!

Merry Christmas indeed! That's pretty cool, basically just over a year later it is finally running, I'm sure it must feel good. My Jetta has been 2 or 3 years and counting and hasn't run but it is close.

Rallyfreak202 · Post by **Rallyfreak202** » Sun Dec 25, 2011 5:31 pm

CorradoGuy wrote:
Rallyfreak202 wrote:IT RUNS!!!!!!!!!!!!!!!!!!!!!!
Merry Christmas indeed! That's pretty cool, basically just over a year later it is finally running, I'm sure it must feel good. My Jetta has been 2 or 3 years and counting and hasn't run but it is close.

Thanks man!

http://www.youtube.com/watch?v=I7EYa1fE ... e=youtu.be

vt10vt · Post by **vt10vt** » Sun Dec 25, 2011 6:53 pm

Congratulations man!! :woowoo: sorry I didn't have that throttle cable, if you still need one lmk and I can check Rathe's when I go tuesday (they aren't open tomorrow)

my2000apb · Post by **my2000apb** » Fri Dec 30, 2011 2:33 pm

wooohoooo!!!!!!!!!!

Rallyfreak202 · Post by **Rallyfreak202** » Fri Mar 09, 2012 10:45 am

More progress while home on mid term break. It will stay running but only with the MAP line unplugged to ECU. I have some tunning to do with that.

More low quality cell phone pics.

A couple new gaskets. Installed more but they are not in the picture

IMAG0357

Heat wrapped the intercooler pipe since it is so close to the exhaust manifold. I think I'll make a heat sheild some day. Also bought/installed a upper timing belt cover.

IMAG0364

THROTTLE CABLE SOLUTION! I tried a Volkswagen Mk2 throttle cable and it works! Notice the radiator gaurd.

IMAG0359

I tried routing the hood cable through the (home made) front cross support but it was not long enough. I think I might route it on the backside of the support. I hate seeing it out in the open.

IMAG0358

Here is how it sits now while I'm back at college...not studying....and on motorgeek.

IMAG0363

And a very poor quality rev video once I upload it.

Thanks for reading.

Nick's AAN into 4000Q thread. set backs.....set backs....

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Re: Nick's AAN into 4000Q thread. Long-term project.

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Re: Nick's AAN into 4000Q thread. IT RUNS!

Re: Nick's AAN into 4000Q thread. IT RUNS!

Re: Nick's AAN into 4000Q thread. IT RUNS!

Re: Nick's AAN into 4000Q thread. IT RUNS!

Re: Nick's AAN into 4000Q thread. IT RUNS!

Re: Nick's AAN into 4000Q thread. IT RUNS!