24vVR6T CQ Project: EATSGTR rear firewall fab.

[my2000apb]

and you think you're only $10k away.... BWAHAHAHAHAHA!

(revisit this next year)

yeah I am, no paint no cage

[WOMBAT]

Well ok then

[my2000apb]

well lets just make it 20k then

[my2000apb]

UPDATE!!!!
I got the DP relief area cut out and prepped for welding

DP relief area to be filled.jpg (1.61 MiB) Viewed 38734 times

DP relief area to be filled2.jpg (1.88 MiB) Viewed 38734 times

dp relief ready for final prep.jpg (1.38 MiB) Viewed 38734 times

I put a pair of simples in the sheet to help strengthen it.

DP relief dimpled.jpg (1.64 MiB) Viewed 38734 times

Here it is all prepped and ready for welding.

DP relief ready to weld bayside.jpg (1.21 MiB) Viewed 38734 times

[my2000apb]

more

DP relief ready to weld inside.jpg (1.44 MiB) Viewed 38734 times

All welded up, getting a lot better with sheet metal.

DP relief welded engine bay side.jpg (1.49 MiB) Viewed 38734 times

DP relief welded engine bay side upclose.jpg (1.57 MiB) Viewed 38734 times

DP relief welded inside cabin.jpg (1.45 MiB) Viewed 38734 times

DP relief welded inside cabin upclose.jpg (1.74 MiB) Viewed 38734 times

[my2000apb]

UPDATE!!
Since I’m running HT Motorsport steering arms on my uprights, the steering rods themselves have several different setup positions. In order to be able to utilize the full range of adjustment, I needed to open up my steering arm holes in the chassis, and move the rearward a bit.
Cutting them out.

cutting out Drivers steering arm hole.jpg (1.24 MiB) Viewed 38734 times

cutting out pass steering arm hole.jpg (1.39 MiB) Viewed 38734 times

Here they are, now in larger format ahah

drivers side steering arm hole cutout.jpg (1.09 MiB) Viewed 38734 times

pass side steering arm hole cutout.jpg (1.41 MiB) Viewed 38734 times

And here are the pieces that will get cleaned up, and welded back on a bit further rearward.

steering arm holes surrounds cut out.jpg (1.77 MiB) Viewed 38734 times

[my2000apb]

UPDATE!!
I had Ryan seam weld the inner and outer where the DP meets its v-band. I hit the inside with a carbide bit and then flappered it to clean it up a bit, all in the name of FLOW!!

dp inner cleaned up.jpg (1.62 MiB) Viewed 38734 times

dp inner cleaned up detail.jpg (1.58 MiB) Viewed 38734 times

I also removed all the casting marks and cleaned up the inside of the Holset hotside. It’s now all nice and shiny, needs a bit more polishing but its 95% there

hotside cleaned up.jpg (1.53 MiB) Viewed 38734 times

hotside casting cleaned up detail.jpg (1.51 MiB) Viewed 38734 times

[my2000apb]

UPDATE!!!
I got my front x-member back from Ryan after having the majority of the tacks seam welded. I also got the vertical pieces on that will support the lower IC. Radiator mounts are fully welded as well.

Main bar ad IC supports weld detail.jpg (1.3 MiB) Viewed 38725 times

radiator mounts and ic support bar.jpg (1.15 MiB) Viewed 38725 times

radiator mounts and ic support bar2.jpg (1.48 MiB) Viewed 38725 times

I still need to do some verticals for the far sides of the lower tie bar and some lower IC mount tabs. And lastly carbide out the through holes for upper IC mounting so they can be sleeved and welded.

Radiator mount weld detail.jpg (1.27 MiB) Viewed 38725 times

radiator mount weld detail2.jpg (1.23 MiB) Viewed 38725 times

[my2000apb]

I also got the Vanjen ferrules welded to the inlet and outlet of the IC. The inlet and outlet also have small extensions/bends as well to keep things located where they are easy to get to, and more so to allow the joints to have some movement in the proper directions.

IC inlet and support bar.jpg (1.37 MiB) Viewed 38725 times

IC inlet vanjened.jpg (1.31 MiB) Viewed 38725 times

IC outlet vanjened.jpg (1.08 MiB) Viewed 38725 times

vanjen clamp weld detail.jpg (1.23 MiB) Viewed 38725 times

vanjen clamp weld detail2.jpg (1.35 MiB) Viewed 38725 times

[my2000apb]

MORE!!
Turbo oil drain to oil pan return got the 16AN bung welded on. I’m not going to finalize the drain location in the pan until the exhaust manifold is done.

turbo oil drain to pan and radiator hot inlet.jpg (1.46 MiB) Viewed 38724 times

The radiator will be a 20AN hot-side/inlet and a 24AN cold-side/outlet. Here is the inlet welded to its 20AN bung. It just needs to be turned down a bit to get the outer threads off, and it can be welded to the radiator.

radiator 20an hotside.jpg (1.53 MiB) Viewed 38724 times

radiator 20an inside transition.jpg (1.31 MiB) Viewed 38724 times

I also got a change to get down to Haydn’s to get my subframe transverse connector pieces bent up. Yes, I know, the bends aren’t the same on both sides. This is to allow the 4” downpipe and 3.5” exhaust to have good clearances. I wanted to be able to drop exhaust without having to touch the sub-frames.

bent tubing for subframe transverse members.jpg (1.92 MiB) Viewed 38724 times

[my2000apb]

UPDATE!!!
I had a few small rust patches in the rear wheel well area so I set to cutting it out and replacing the sheet metal.
Here it is all cutout and cleco’d in place.

driver rear wheel well patch cleco'd in.jpg (1.38 MiB) Viewed 38736 times

Seam welded in place and primed. It will get seam sealed as the rest of the chassis works gets finished.

drivver rear wheel well patch.jpg (1.28 MiB) Viewed 38736 times

dr rear wheel well patch primed.jpg (1.14 MiB) Viewed 38736 times

I also cut off the old brake line hangers. The part where the soft and hard lines meet, was a bit crunchy, not horrible but not cleeeean. So I cut them out and will be replacing them shortly.

brake line hangers removed.jpg (1.88 MiB) Viewed 38736 times

[my2000apb]

MORE!!!
I also started collecting a bunch of small rod ends, spacers, seals etc. to convert the 01e b5s4 shifter x-rod to a small spherical joint. It will use rod end seals and some alu. spacers to give it correct height and articulation. More on that later

o1e crossrod spherical in the works.jpg (972.62 KiB) Viewed 38734 times

I had originally relieved the t44 rear diff mount bracket for exhaust clearance (see pic)
But that just wasn’t up to my standards for the rest of the car, so what to do? BILLET!

exh clearanced v8 dif mount.jpg (1.07 MiB) Viewed 38734 times

Yup, so I grabbed a piece of ½” 6061 plate and dove right in!! I diligently marked all the holes on the mount first. Then I took a hole saw to the diff. input cup hole and also to the exhaust relief. And that’s it, haha not really. I sent it off to my buddy who works at a machine shop. Its going to be milled down along the edges, have a radius cut along the edges, the diff mount bushings are being recessed to make up for the oem vs billet mount plate thickness, and lastly a light fly cutting for sexiness. It should be here in plenty of time to go to the first round of anodizing. Pics!!!

rear diff mount bracket roughed out.jpg (1.56 MiB) Viewed 38734 times

rear diff mount bracket drawing.jpg (2.17 MiB) Viewed 38734 times

[my2000apb]

UPDATE!!!
The diff mount plate has been finished by my machinist I had the outer edges radius’d 1/8” and the mount bushings have been recessed into the plate as well.

rear diff plate outer trimmed.jpg (399.27 KiB) Viewed 38658 times

billet rear diff mount plate radius'd.jpg (1.66 MiB) Viewed 38658 times

billet rear diff mount plate radius'd2.jpg (1.68 MiB) Viewed 38658 times

rear diff plate finished back side.jpg (251.72 KiB) Viewed 38658 times

rear diff plate finished bushing side.jpg (238.52 KiB) Viewed 38658 times

[my2000apb]

UPDATE!!!
I also got over to Ryan’s to pick up a bunch of stuff from seam welding. I had to pop off one of the rear diff mount ears so that it could be fully seamed.

rear SF seamed, now to finish diff mount.jpg (1.61 MiB) Viewed 38658 times

more SF weld detail.jpg (1.24 MiB) Viewed 38658 times

I also added a jack point on the bottom of the rear subframe, this makes it sooo much easier to jack car up and move it around garage etc.

SF jacking point.jpg (1.26 MiB) Viewed 38658 times

SF jacking point 2.jpg (1.39 MiB) Viewed 38658 times

Lower portion of the DP has been seamed as well, now I can make a hanger for the trans tunnel area.

lower DP seamed.jpg (1.63 MiB) Viewed 38658 times

[my2000apb]

I also added some anti-crush sleeves to the trans support bar, tacked them in just to double check it all before seaming.

trans bar crush sleeves.jpg (1.78 MiB) Viewed 38752 times

trans bar crush sleeves-washers.jpg (1.53 MiB) Viewed 38752 times

Ryan has a nice new torch that is much smaller and can get down inside a lot more stuff than before. I had Ryan seam weld the INSIDE of the IM plenum/feed. I just need to carbide and flapper them smooth!!

inside IM plenum feed.jpg (1.72 MiB) Viewed 38752 times

inside IM plenum feed2.jpg (1.45 MiB) Viewed 38752 times

[my2000apb]

With the motor pushed back, there is very little clearance for the steering arms bracket to the bellhousing. So I got some m12x 1.75mm allens and counter sunk them into the upper bellhousing. This gains me a lot more room.

countersunk upper bellhousing bolt.jpg (1.62 MiB) Viewed 38751 times

countersunk upper bellhousing bolt upclose.jpg (1.75 MiB) Viewed 38751 times

I also added another bolt hole for the motor mount through the adapter plate.

motor mount through hole, added nut clearance.jpg (1.54 MiB) Viewed 38751 times

[Mcstiff]

Word is Audi Sport shaved those bosses off so it was easier to pull the transaxle.

[speeding-g60]

i know i did, on two different times, going more cut off each time. still had to mess with the steering knuckle thing.

[DE80q]

And then...

[highlander69]

Word is Audi Sport shaved those bosses off so it was easier to pull the transaxle.

They sure did.

Looking great. Lot's of fabrication going on...........brilliant.

Craig.

[kieron_32v]

Word is Audi Sport shaved those bosses off so it was easier to pull the transaxle.

They sure did.

Looking great. Lot's of fabrication going on...........brilliant.

Craig.

I don't get it, how does this make it easier to pull the gearbox off the engine? Any pics?

Sent from my HTC One X+ using Tapatalk

[kieron_32v]

Word is Audi Sport shaved those bosses off so it was easier to pull the transaxle.

They sure did.

Looking great. Lot's of fabrication going on...........brilliant.

Craig.

I don't get it, how does this make it easier to pull the gearbox off the engine? Any pics?

Sent from my HTC One X+ using Tapatalk

[Mcstiff]

Word is Audi Sport shaved those bosses off so it was easier to pull the transaxle.

They sure did.

Looking great. Lot's of fabrication going on...........brilliant.

Craig.

I don't get it, how does this make it easier to pull the gearbox off the engine? Any pics?

Sent from my HTC One X+ using Tapatalk

Shaveing the top of the bellhousing removes 2 (or 3) bolts and makes clearing the rack easier.

[kieron_32v]

Fair enough, so just having the remaining bolts is enough? Did they run any more dowels like that?

Sent from my HTC One X+ using Tapatalk

[Zerb]

Maybe I missed it on an earlier page here in regards to the intake mani fabrication. But why didn't you put extended velocity stacks in the plenum on the 3 runners that match the 3 ports on the "front" of the head. So they are all equal length.


Sent from my iPad using Tapatalk