The Project Pad

And I have my spare VEMS ECU sitting around that I was going to use on the V8. Lugtronic makes an adapter harness for the AEB, so it would be easy to swap in VEMS.

And on second thought if I do rods then I should do the clutch, so more money. I'll probably stick with stock.

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Are you driving this to BBQ.

Audilard wrote:Are you driving this to BBQ.

Maybe! Tough choice between this and the CGT.

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Decided I'm going to keep the stock rods and clutch for now. I've got a line on some cheap ones of each, but I'm not first in line. If they come through I'll grab them, if not I won't worry about it.
I did remember I have a Garret GT2560R (GT28R) off a S14 Nissan that I used to have on a turbo Ford Escort. It needs rebuilt, so I'm going to send it to Pure Turbo. This should be a perfect turbo for a stock 1.8T and should net me around 250whp which is approaching the limit of the stock rods. I might limit myself even lower, maybe something like 200-220whp which should still be fun.

Cleaned up the engine, it's in really nice shape. Also deleted the mechanical fan and idler pulley. I modded the PS bracket to work with the V6 pump, and then talked to Dave and realize the A4 pump works just fine with the 90 rack so I put that back on since it's less work.

IMG_20160702_150939 by Vex Art, on Flickr

IMG_20160702_150945 by Vex Art, on Flickr

IMG_20160702_150955 by Vex Art, on Flickr

If you for some reason want to run the V6 PS pump, you have to clearance the rear part of the bracket to move the pump back a few millimeters.

IMG_20160702_142820 by Vex Art, on Flickr

You'll also need to fab up a spacer for the front bolt:

IMG_20160702_143436 by Vex Art, on Flickr

You'd then need a longer water pump v-belt and a shorter serpentine belt. Along with a bracket somewhere on the bottom to lock it in place. In the end I'd reccomend using the 1.8T PS pump as the fittings thread right in.

IMG_20160702_142906 by Vex Art, on Flickr

Seller was accurate in saying the timing belt was fresh, looks like a new tensioner too.

IMG_20160702_132654 by Vex Art, on Flickr

Scoped the cylinders and they look fine with not too much carbon built up on the pistons.
Also picked up a B5 V6 01A transmission for better highway gearing, and it was only $60. I contemplated swapping in the 5psd narrow 01E I have sitting around, but that would require converting to the B5 rear end and driveshaft and is more hassle than I want to do at the moment. And I'd have to give up the locking rear, which I kinda want to keep. Eventually I want to try and swap a 4.11 200tq rear R&P into the B4 rear diff as they will apparently work and allow you to retain the locking function.

Tiny turbo vs small turbo

IMG_20160702_172629 by Vex Art, on Flickr

Stock turbo/manifold removed to make way for the ADR engine mounts. Dave was kind enough to find a seller in europe and arrange for me to buy them. They should be here soon.

IMG_20160702_172834 by Vex Art, on Flickr

Swapped in the black rear leather seat I had (have fronts too) to see how the two-tone interior would look with black instead of tan seats. I'm not sold yet, I'll reserve judgement until I swap the fronts in too. I definitely think it needs at least black floor mats too, maybe black carpet. Regardless, the front passenger seat needed changed anyways so I figured I'd give this a try since I found the set at a junkyard for cheap in excellent shape.

IMG_20160702_203339 by Vex Art, on Flickr

17x7.5 ET 65 Porsche Cup 1 with 4x108->5x130 adapters line up perfect.

IMG_20160706_191611 by Vex Art, on Flickr

IMG_20160706_191604 by Vex Art, on Flickr

Parts collection

IMG_20160706_192225 by Vex Art, on Flickr

Picked up a B5 V6 01A for better highway gearing (nearly the equivalent of a 5spd 4.11 01E)

IMG_20160708_192309 by Vex Art, on Flickr

Ready to go in minus the engine mounts which should be here this week or next.

IMG_20160708_203048 by Vex Art, on Flickr

And got the B5 wiring harness installed (or at least routed). Need to get my B4 Bentley software working and find B5 wiring diagrams so I can start hooking stuff up. It'll be a bit more complicated since some wiring has already been messed with from the IIc days :(

IMG_20160710_130828 by Vex Art, on Flickr

Those wheels are sweet. What's the final colour going to be?

PRY4SNO wrote:Those wheels are sweet. What's the final colour going to be?

I'm thinking just regular silver, definitely not black. We'll see, maybe I'll find a shade of gunmetal or something that I like.

Gunmetal or anthracite with polished lips would be slick.

Nice to see more B4 AEB love.

A little jelly over here with those seats and your RS2 bumpers and head lights. I am happy I did not have to do the wiring. In my cars the loom goes through a hole right under the battery tray on the firewall. That's stock in the 4 cylinder B4s. I am getting ready to finally swap in the VEMS gear I have. The loom will be a bitch to get through that tiny hole with all the connectors.

A carbon hood huh? I wonder where you got it...

I've figured out all of the wiring to adapt and make everything work with the B4 chassis. I still need to get a tee to add an oil temp sensor since the 1.8T didn't have one and I'd like to keep the B4 aux gauges all working.

New clutch thanks to Dana; Southbend Stage 3 Daily with DMF.

IMG_20160723_150751 by Vex Art, on Flickr

New rotors thanks to Chris; 4x108 2pc 323mm to go with the 928S4/RS2 Brembo calipers I've got. Just need to get an RS2 adapter bracket and fab up spacers to account for going from a 304mm rotor to 322mm.

IMG_20160723_164222 by Vex Art, on Flickr

Fumoto quick drain valve installed. Had one on my UrS6 and loved it so I had to get one for this.

IMG_20160723_134230 by Vex Art, on Flickr

Got the ADR engine mounts finally, quick coat of paint. Due to time restraints I'm not going crazy with the powdercoat like I did with the CGT.

IMG_20160723_183149 by Vex Art, on Flickr

Played around with the smoked euro tails I bought a while back. They're a bit too much on a black car, but I might run them anyways for a bit and see how I like them. I'll probably end up going back to the red.

IMG_20160713_194204-01 by Vex Art, on Flickr

ADR mounts have bosses for the 1.8T heatshield, but they needed to be drilled and tapped. (ADR left, B5 AEB right)

IMG_20160724_171305 by Vex Art, on Flickr

Drilled, tapped, and mounted

IMG_20160724_174833 by Vex Art, on Flickr

Driver's side ADR mount on

IMG_20160724_175112 by Vex Art, on Flickr

Shorter belt for the mechanical fan delete

IMG_20160723_201909 by Vex Art, on Flickr

IMG_20160723_201923 by Vex Art, on Flickr

Jelly over here on the FW/clutch and brakes score.

glad to see the clutch finding its new home! I sure hope my new setup drives and holds as well as that one did!

V6 oil cooler and mondo oil filter installed

IMG_20160731_105803 by Vex Art, on Flickr

And the engine is in! Now for wiring and plumbing fun...

IMG_20160731_123118 by Vex Art, on Flickr


IMG_20160731_123131 by Vex Art, on Flickr

IMG_20160731_123125 by Vex Art, on Flickr

IMG_20160731_123208 by Vex Art, on Flickr

IMG_20160731_163351 by Vex Art, on Flickr

Are those hockey pucks? How long do you expect them to last in that heat environment?

PRY4SNO wrote:Are those hockey pucks? How long do you expect them to last in that heat environment?

They are. I've seen good results with them before, we'll see how they do. They're a temporary solution until I make some B5 ones work.

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PRY4SNO wrote:Are those hockey pucks? How long do you expect them to last in that heat environment?

I have hockey puck mounts in my 1.8T B6 and they have been fine for a year and close to 20k. I left the OEM head shield but didn't do anything else to protect them. I built a block in the center that spaces 2 pucks out to be 3.5" total and welded a stud to the center block, definitely a little stiff but they work great.

Pro tip: if you look you should be able to find weighted practice pucks. They are right about 75A while the black pucks are more like 85-90A so they make things a little less vibratey. I used these specific ones below and confirmed durometers with a durometer tester we had at my old work.

https://www.hockeyshot.com/Heavyweight- ... oCAHLw_wcB

Looking good! I'll have to come see what you do for plumbing to get ideas for my white car.

Been too busy to post an update for a while...BBQ is now 4 weeks away so I've been busting ass to get it ready. Doesn't help that my parents will be here for two weeks this weekend, so I won't be able to get too much done until right before.

Been practising my TIG'ing (still pretty crappy) but I made the stock B5 cat/downpipe fit the B4 chassis. The B5 routes it up and over the axles, but the steering arms on the B4 get in the way so it must go in front and under the axles. Thus the cat has to be shortened and angled down. I could've done this with less welds and kept the stock O2 bung, but I didn't have any 2.25" pipe. I only had 2.5" which meant I had to replace the whole section of pipe between the cat itself and the flange. Still need to add the replacement O2 bung.

IMG_20160917_135230 by Vex Art, on Flickr

More practice on a v-band for the 3" exhaust. Still need to fab up the flex pipe and connection from the downpipe to the catback.

IMG_20160917_163434 by Vex Art, on Flickr

IMG_20160917_163543 by Vex Art, on Flickr

Found out my rockauto radiator despite being the correct width and having the outlets on the correct size is not the right height. Too late now, maybe in the future I'll try and source the correct one like Dave did, but this will do for now.

IMG_20160907_190413 by Vex Art, on Flickr

IMG_20160907_191225 by Vex Art, on Flickr

Also had some clearance issues with the fan and belt that Dave didn't have...might be due to the odd radiator too, not sure. I redrilled the mount arms in the upper core support to bring the radiator closer to the front which solved the clearance problem. But I don't think I should've had to do it.

IMG_20160907_191425 by Vex Art, on Flickr

I also bought the same radiator hose as Dave and it was too short. Once again, maybe related to the radiator, but I don't think so. Probably bad QC control from the hose manufacturer. Quick trip to the auto parts store and I was able to find one that would work.

IMG_20160903_151625 by Vex Art, on Flickr

Installed an 034 breather kit. Despite the bad things about 034, I'm still glad they at least make things like this because nobody else does.

IMG_20160902_201840 by Vex Art, on Flickr

IMG_20160902_201831 by Vex Art, on Flickr

Installed a VDO VW oil pressure gauge T and an I5 oil pressure gauge sender since the AEB doesn't have an oil pressure sender stock.

IMG_20160902_194819 by Vex Art, on Flickr

Rear coolant manifold as the new push-on style connectors. Found an adapter at the local auto parts store that allowed me to connect a regular coolant hose to it and clamp it. For the connection to the water pipe, I cut off the push-on connector and clamped to the pipe.

IMG_20160904_115652 by Vex Art, on Flickr

IMG_20160903_210915 by Vex Art, on Flickr

Won't have these installed for the BBQ, but I did figure out a big brake setup with parts I had laying around. A few months ago 034 was clearing out some C4 UrS4 Boxster (non-S) caliper adapter brackets for $60 shipped. Too cheap to pass up despite not owning a C4 anymore. Figured I'd see if I could use them. By pure luck, if you mount them backwards (they have engraged a 'vvv Rotor vvv' on them to indicate the direction of install) and using just a few washers as spacers they are the perfect adapters for my 314x30mm (Euro A8) rotors with Porsche medium black calipers (944/968 M030, RS2, 993 non-turbo). Still on the stock 4x108 B4 hubs, I'll probably need to recheck when I convert to 5x112 if the hubs are a different offset. They clear 16" wheels, but require a lot of 'spoke' clearance so I need spacers to clear my 16" TSW.

IMG_20160831_191058 by Vex Art, on Flickr

IMG_20160828_131523 by Vex Art, on Flickr

IMG_20160828_130301 by Vex Art, on Flickr

IMG_20160828_130209 by Vex Art, on Flickr

IMG_20160828_130958 by Vex Art, on Flickr

Redid my crappy bumper support since I needed space for the FMIC. Still not the prettiest, maybe one day I'll redo it in tube. IC fills up the RS2 bumper nicely. Bumper is just set on it, still needs some final tweaking to make everything line up.

IMG_20160920_203844 by Vex Art, on Flickr

IMG_20160921_200347 by Vex Art, on Flickr

IMG_20160920_204136 by Vex Art, on Flickr

And the more important news is that it runs! Albeit not well since there's no intake plumbing, but I hope to finish that up soon and start making sure all the wiring and gauges work correctly.

That ICis a perfect fit for the bumper- looks good!

in here for the comments..

also really wishing I had put the heatshield on the turbo side engine mount on mine now that i've seen yours, didn't realise it existed :(

keep up the good work