aka "The Extensive Rad Fan Clocking". Obviously I uploaded these when I had access to some speed!!!
This is a continuation of the build in this archived thread, but now we'll add boost:
Without boost, it was good for 110Hp to the wheels, and was very fun to drive. But boost was the goal and boost it must be. I took the car up to my friend's place in November 2007, and he's a great fabricator with considerable turbo experience. I really owe him bigtime!! This was taken New year's Eve, a "before" picture:
The turbo was donated by a 1.6TD, and surprise surprise, there was soot! (the manifold needed tapping for the EGT probe too):
The car got jacked up, leading to "extreme angle duckie":
Exhaust got ripped off, to be replaced by a TT 2.5"/Borla setup:
Drew's 77 "Inga" is the sexy model for this piping, it'll be her turn next perhaps ?:
Of course, the stock 4K had to come off:
Grip is nice too:
Stock diff? Outta there!
I headed for Ohio in February to do some powder coating on the case (makes sense, it's winter, may as well drive 7 hours... ):
Back home to get the gearbox assembled by the neighbour :
Obligatory shot of new parts in packages, and dead stuff in a tub:
The finished gearbox...SO pretty!
Up and in:
Drew spent a lot of time modding the integrated wastegate to go at less than 11 psi of boost. That level would have been disastrous with those RD pistons (10:1 CR). This bench tested at about 6 psi after assembly with an additional "collar" of metal added (not pictured here) Anyway, this is what a wastegate looks like inside:
New oil pump gets put in, and we'll need an oil pan that accepts an oil return line:
In between trips North, I did a few things, like had the seats recovered:
And chopped a chunk out of the bracing on the good stock hood. It'll go on once the car comes home, but clearance is needed for that sexy intake manifold:
Sending this in case of connection failure...more in a minute or five.
Okay, back at it! Seems like this car has been in the air for a while!:
Now on the the plumbing. The intercooler was from an A3 TD, and IC piping was a blend of Canadian Tire exhaust pipes, silicon bends, and even a bit of my Bug's ex-exhaust. Intake air passes through a TD airbx which rests on the PS where the washer bottle was. Lots of welding and grinding too:
The fuel fliter got relocated out of the engine bay to a spot under the car, and the battery was already in the trunk. This cleared up space for IC plumbing too.
So....now it's May. Time to test drive this thing. Since the injectors had been upgraded from 210s to 305s, MS needed to be informed, and otherwise we used the fuel and spark map I'd driven the car up on. (Dan had tweaked it though, knowing what we were up to.)
Initial trips were really enjoyable. Boost built as we'd expected, EGTs were fine, as were AFRs, etc. No detonation, all seemed good and the car felt strong and smooth. Until "the noise". So Cincy was a no go for this car. I scurried hime and got a gearbox rebuilt and mounted up on the 16V for that trip instead. Luckily, (since the silver car had eaten a number of her gears), I had that nice 4K to use.... My neighbour the tranny rebuilder loves me.
Anyway, we did a post mortem after Cincy in June. Compression confirmed what we'd expected, with readings of 90/165/90/165. Symmetrical enough, but not so good eh? Anyway, off with the head, but the valves seemed okay, next off were pistons, and number one was missing a good part of a ring land:
Of course, it also scored the cylinder wall, so the block was junk. I take complete blame for this, since I'd not recognized detonation soon enough, and had done damage from an ignition map that was way too advanced. Yeah, I'm an idiot.
So due to incompatible times available, and some purple distractions on my part, progress in the summer was slow. Drew located a suitable JH and I went up and painted it with some POR 15, but that was about it.
Anyway, things got rolling again in the fall, here's the pretty result. This time it's a real JH, with its lower CR pistons:
IN it went...:
And it ended up looking like this:
The ride home was actually relaxing; the sun was shining, and I'd opted to leave the map as it stood, since it was too rich and retarded, and that'd be safer than the other option.
As it was, the thing got a bit squirelly on boost, and i know there's a LOT more there to tune into. Which I'd refere to do a bit closer to home.
Anyway, again, thanks to Drew for all the hard work (and dare I say planning??) We'll see how it pans out, but the first three hours or so were great!
Modified by punchbug at 8:14 PM 11-2-2008