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    Thread: Big turbo build- take two

    1. Member Doooglasss's Avatar
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      12-30-2011 03:33 PM #106
      50 minutes later and the head is off the car.

      time to go to NYC for NYE. The piece of **** car will have to wait till monday.
      -Doug

    2. Member DeckManDubs's Avatar
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      12-30-2011 10:28 PM #107
      Quote Originally Posted by The_RoadWarrior View Post
      I don't like that clacking noise ???
      Lifters? Or AC perhaps?
      -Noah

      PHENIX ENGINEERING

      Quote Originally Posted by ein View Post
      You couldn't dig a hole any faster with a nuke.

    3. 12-31-2011 01:56 AM #108
      Quote Originally Posted by DeckManDubs View Post
      Lifters? Or AC perhaps?
      Sounds like deflated lifters since everything has been sitting for so long. An hydraulic tensioner could make that noise too and if all that checks out something is contacting in the cylinders (we all hope that's not the case ).

    4. Member Doooglasss's Avatar
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      12-31-2011 02:00 PM #109
      When I ran it Friday the noise was gone. It was just lifters. During that video the AC wasn't connected actually.
      -Doug

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      12-31-2011 04:10 PM #110
      Yeah, lifters are (scary) noisy til they pump up. Not for the faint of heart on a slow engine build.

    6. Member Doooglasss's Avatar
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      01-04-2012 11:01 PM #111
      Back out there. Got head bolts and a new head gasket.

      After pulling the head last week I decided to hunt down my electrical problems. I replaced a coil pack harness on this harness during my motor install and it seems that the ground for the oil level sensor runs to the main harness then back up to the coil pack harness.

      I'd also suspect the Tach pulls signal from some line on this harness too. I've found the oil level sensor one. Next up is the tach and head/turbo re-install.

      Nice to know three out of the four issues are on their way to being solved. Now I just need to find a WG center-ring I dropped on the subframe and the head gets reinstalled.

      Did I mention it's 25 degrees out and I ran out of (double )

      Also all of the silicone hoses I ordered came in. Might be able to install everything correctly this time.

      -Doug

    7. Member Tempes_TT's Avatar
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      01-05-2012 12:27 AM #112
      How exciting dude! Find anyone to swap that lower grill yet?

      GJ so far man. I like this. Gets me excited for mine! (even though its not going to be nearly as powerful! )
      Quote Originally Posted by DCMS371 View Post
      You do realize women are biologically programmed to ruin men's lives by making them get rid of anything that they might enjoy more than spending time with the woman right?
      Quote Originally Posted by SchmidTT View Post
      Has anyone really been far even as decided to use even go want to do look more like?

    8. Member Doooglasss's Avatar
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      01-05-2012 03:06 AM #113
      Thanks and as long as you enjoy what you build- that's what matters. Nobody to swap the grille with yet, I'm just going to pick up an extra I think.

      Pic right before the head goes on. Now without studs I can slide the whole assembly in and out all bolted together. I'm pretty excited about that!

      With that said, it's 2am and time to quit. Real job time at 8, boo

      Last edited by Doooglasss; 01-05-2012 at 03:08 AM.
      -Doug

    9. Moderator PLAYED TT's Avatar
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      01-05-2012 07:32 AM #114
      Nice Doug. That harness should do the trick.
      Slammed Radio Flyer---flickr---My Build Thread--- Podi
      Quote Originally Posted by Marcus_Aurelius View Post
      if this really happens, I'm 'stancing' my car and going for some 'hellaflush'.

    10. Member l88m22vette's Avatar
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      01-05-2012 09:28 PM #115
      Holy crap that housing looks huge in the pic, I didn't realize the scale
      Audi TT mk1 FAQ zero Porsche wheels given

      Quote Originally Posted by silverspeedbuggy View Post
      TCL 1991 edition - Can't afford a CRX, what would TCL do: Hyundai Scoupe vs. Toyota Paseo vs. Geo Storm

    11. Member Doooglasss's Avatar
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      01-09-2012 12:24 PM #116
      Little status update:

      Something is funky with my head. There are inserts that the head bolts sit on that are a different size than other 1.8T heads. When trying to use stock bolts my head decided it would shave down the threads on the top of the bolt. I just got my digital caliper back and plan on taking measurements & photos later.

      Before figuring this out we went through a bunch of headaches: Swapping in three new headgaskets and two sets of OEM bolts (spending a couple hundred bucks)- I finally ordered new ARP studs.

      Sidenote: ARP won't warranty their products unless you have the build number off the side of the box.

      Entire car is back together as of last night (minus the battery). Tonight we should be firing it up for the second time. I have hopes that I have fixed the oil light issue and a couple of ideas on how to diagnose & fix the tach. - Bad cluster connection, missing ground loop like the oil light or bad cluster.

      I oil'd the AC compressor on Big Phil's recommendation to fix the squealing and Ed fixed my intercooler pipe after I mangled it because I wasn't thinking. If all issues are fixed I just need to fix my ProSport Wideband gauge and that's it.

      I'll update later.
      -Doug

    12. Member 1.8 skeet skeet's Avatar
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      01-09-2012 12:58 PM #117
      That thing is going to be a monster

    13. Member DeckManDubs's Avatar
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      01-09-2012 01:13 PM #118
      Quote Originally Posted by DougLoBue View Post
      Little status update:

      Something is funky with my head. There are inserts that the head bolts sit on that are a different size than other 1.8T heads. When trying to use stock bolts my head decided it would shave down the threads on the top of the bolt. I just got my digital caliper back and plan on taking measurements & photos later.

      Before figuring this out we went through a bunch of headaches: Swapping in three new headgaskets and two sets of OEM bolts (spending a couple hundred bucks)- I finally ordered new ARP studs.

      Sidenote: ARP won't warranty their products unless you have the build number off the side of the box.

      Entire car is back together as of last night (minus the battery). Tonight we should be firing it up for the second time. I have hopes that I have fixed the oil light issue and a couple of ideas on how to diagnose & fix the tach. - Bad cluster connection, missing ground loop like the oil light or bad cluster.

      I oil'd the AC compressor on Big Phil's recommendation to fix the squealing and Ed fixed my intercooler pipe after I mangled it because I wasn't thinking. If all issues are fixed I just need to fix my ProSport Wideband gauge and that's it.

      I'll update later.
      Doug, your running an AEB head no? Some where in my brain it comes up that there is a difference in studs between AEB's and AMU's/BEA's. AMU bolts being larger

      But good to hear you got it sorted. Only like four months or so till Lime Rock
      -Noah

      PHENIX ENGINEERING

      Quote Originally Posted by ein View Post
      You couldn't dig a hole any faster with a nuke.

    14. Member Doooglasss's Avatar
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      01-09-2012 01:55 PM #119
      Quote Originally Posted by DeckManDubs View Post
      Doug, your running an AEB head no? Some where in my brain it comes up that there is a difference in studs between AEB's and AMU's/BEA's. AMU bolts being larger
      You got that right. AEB head on my car. AEB was 11mm x 96mm & Small port is 10mm x 115mm IIRC.

      So I assume the block can take the longer bolt but the issue with my head appeared to be with the fitting in the head inserts. Tony at FFE stuck my bolts through a bare AEB head and the worked fine- so that's why I think my head is weird, I have zero luck or I'm retarded. No comments Noah

      Quote Originally Posted by DeckManDubs View Post
      Only like four months or so till Lime Rock
      Phil was telling me about the Lime Rock track day and I'm all in. Going to have to get a monster tune by then and some track skills.
      -Doug

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      01-09-2012 02:13 PM #120
      All blocks besides AEB accept 10mm bolts. AEB's take 11mm's. The head doesn't care which you use, only the block, aka I run an AEB on my AWP block with standard OEM 10mm bolts.

    16. Member Doooglasss's Avatar
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      01-09-2012 04:14 PM #121
      Quote Originally Posted by 20v master View Post
      All blocks besides AEB accept 10mm bolts. AEB's take 11mm's. The head doesn't care which you use, only the block, aka I run an AEB on my AWP block with standard OEM 10mm bolts.
      This isn't a great picture but this is what was happening. The bolt threads into the block just fine only after the head sheers the threads off the top of the bolt and then it fits perfectly. After removing the head and dropping a bolt with the thread VS. a bolt that had the threads sheered off- the sheered bolt drops down that much further. On the AEB head @ FFE they both dropped through equally.

      Weird no?


      Last edited by Doooglasss; 01-09-2012 at 04:20 PM.
      -Doug

    17. Member Doooglasss's Avatar
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      01-09-2012 11:19 PM #122
      Okay. She runs!

      Alternator squeal is all gone
      Valvetrain noise is normal again
      Oil light & tach still don't work
      Wideband gauge/sensor still obviously have issues
      The base tune is pretty spot on. Low idle. Dead on AFR with low correction
      Clutch doesn't chatter like crazy at idle (yet maybe)



      The car is cooling down now after a heat cycle. Preparing for ARP re-torque procedure to 80 ft/lbs. Dash and cluster are already out to be swapped for trouble shooting. Regardless if I figure that out or not I'll probably take it around the block a few times tonight.

      -Doug

    18. Member bklnstunt718's Avatar
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      01-10-2012 12:33 AM #123
      hey man! thing looks awesome!!!! nice and clean!!!

      thanks for helping out on the phone the other day.. it was a bad connection to the alternator... turned out i spend 300bucks on a new one that i didnt even need

    19. Member Doooglasss's Avatar
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      01-10-2012 12:49 AM #124
      Not a problem Jaymo!

      Re-torqued head studs- didn't snap any
      Swapped clusters- I don't have any wiring issues, I purchased a bad used cluster

      Put 6 gentle miles on the car - I couldn't be happier.

      Oh and I have to mention. Eurodyne > Unitronic any day of the week.

      I come to a stop and my car doesn't rev-hunt, bog down or stall. Acceleration out of boost is smooth. I cannot comment further as of now but so far I'm impressed.
      Last edited by Doooglasss; 01-10-2012 at 12:52 AM.
      -Doug

    20. Moderator PLAYED TT's Avatar
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      01-10-2012 08:37 AM #125
      Success!
      Slammed Radio Flyer---flickr---My Build Thread--- Podi
      Quote Originally Posted by Marcus_Aurelius View Post
      if this really happens, I'm 'stancing' my car and going for some 'hellaflush'.

    21. Member DeckManDubs's Avatar
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      01-10-2012 10:13 AM #126
      Quote Originally Posted by DougLoBue View Post

      Oh and I have to mention. Eurodyne > Unitronic any day of the week.
      -Noah

      PHENIX ENGINEERING

      Quote Originally Posted by ein View Post
      You couldn't dig a hole any faster with a nuke.

    22. Member Doooglasss's Avatar
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      01-12-2012 03:19 PM #127
      Max & me start tuning Saturday. Last night drove the car and logged it- it goes off the charts lean as soon as it enters boost. Maestro log reads 58.something AFR after the 02 correction maxes out.

      Ignition upgrades part 1:

      -Doug

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      01-12-2012 03:27 PM #128
      Quote Originally Posted by DougLoBue View Post
      it goes off the charts lean as soon as it enters boost. Maestro log reads 58.something AFR after the 02 correction maxes out.

      I thought Maestro was the shiz?

    24. Member Doooglasss's Avatar
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      01-12-2012 04:07 PM #129
      Quote Originally Posted by 20v master View Post
      I thought Maestro was the shiz?
      I believe it is, but it needs tuning to get there. Out of the box it had a terrific idle and out of boost AFR's around 14-17 under load.
      -Doug

    25. Member Doooglasss's Avatar
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      01-16-2012 12:50 AM #130
      Issues: accessory belt falls off and rides outside of tensioner. Brand new tensioner and belt didn't help- anyone ever seen this before??

      Good news: Car is fully together and the tuning process has begun. Short of engine covers, catch can and new valve cover & coilpack adapters.





      -Doug

    26. Moderator PLAYED TT's Avatar
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      01-16-2012 12:58 AM #131
      Its falling off
      Slammed Radio Flyer---flickr---My Build Thread--- Podi
      Quote Originally Posted by Marcus_Aurelius View Post
      if this really happens, I'm 'stancing' my car and going for some 'hellaflush'.

    27. Member Audiguy84's Avatar
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      01-16-2012 11:52 AM #132
      use a straight edge and find out what pulley is not lined up with the others, suspect that one of them is off.

    28. Member Doooglasss's Avatar
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      01-16-2012 11:56 AM #133
      Quote Originally Posted by Audiguy84 View Post
      use a straight edge and find out what pulley is not lined up with the others, suspect that one of them is off.
      That's what I'm going to try tonight- I just cannot figure out which pulley would be off... Also I cannot recall if that coolant bolt bracket goes on the inside of the bolts or the outside.
      -Doug

    29. Member Audiguy84's Avatar
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      01-16-2012 01:24 PM #134
      its hard to tell in the pics but is the alternator straight?

    30. Member Doooglasss's Avatar
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      01-16-2012 01:54 PM #135
      Pretty certain it is- it's bolted in all the way.
      -Doug

    31. Member DeckManDubs's Avatar
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      01-16-2012 02:25 PM #136
      Doug are you using an ABA block?
      -Noah

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      Quote Originally Posted by ein View Post
      You couldn't dig a hole any faster with a nuke.

    32. Member Doooglasss's Avatar
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      01-16-2012 02:50 PM #137
      Quote Originally Posted by DeckManDubs View Post
      Doug are you using an ABA block?
      Negative captain.

      AWP block
      AEB head

      stock pulleys & accessories from my AMU setup including crank pulley.
      -Doug

    33. Member DeckManDubs's Avatar
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      01-16-2012 10:18 PM #138
      Quote Originally Posted by DougLoBue View Post
      Negative captain.

      AWP block
      AEB head

      stock pulleys & accessories from my AMU setup including crank pulley.
      It seems like your tensioner is sitting in ~.125-.250" towards the block. Do you have your old one to compare to?
      -Noah

      PHENIX ENGINEERING

      Quote Originally Posted by ein View Post
      You couldn't dig a hole any faster with a nuke.

    34. Member Doooglasss's Avatar
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      01-17-2012 12:24 AM #139
      The tensioner issue turned out to be my mistake...

      There is a small bracket for the hard water pipe to bolt to. I had it between the tensioner and the Acc. bracket, it belonged on the outside of the tensioner. Opps!

      I think I need a new wideband sensor for both my gauge and possibly the car as well even though it only has about 3 weeks of use on it. For whatever reason Maestro gets stuck reading lead 4.0 Lambra on my logs most of the time and since my WB gauge sensor isn't working I'm totally blind.
      -Doug

    35. Member DeckManDubs's Avatar
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      01-17-2012 01:05 PM #140
      Quote Originally Posted by DougLoBue View Post
      The tensioner issue turned out to be my mistake...

      There is a small bracket for the hard water pipe to bolt to. I had it between the tensioner and the Acc. bracket, it belonged on the outside of the tensioner. Opps!
      Glad you got it sorted
      -Noah

      PHENIX ENGINEERING

      Quote Originally Posted by ein View Post
      You couldn't dig a hole any faster with a nuke.

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