The Project Pad

I like this project! BTW I was trying to take a closer look at your excel table you posted, but all your Flickr pictures are private, so I can't read it.

lorge1989 wrote:I like this project! BTW I was trying to take a closer look at your excel table you posted, but all your Flickr pictures are private, so I can't read it.

PM me your email and I'll send it to you. I need to update it and send it to a few others too.

this is looking awesome.

You will be happy that you used 2.5" for the exhaust. My whole system is 2.5". The cat disappeared somewhere on the way in.
Had the same issue with the fan shroud and pulley interference. A little clearancing on the fan motor support takes care of that.
That rad is quite short.

Good progress man!

When the GT28R goes on I'll redo the downpipe in 3" and add a high flow cat underneath.

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Have been too busy slaving away to really do too much documentation or updates, but here we go.

To do in the next week:
*Bleed brakes
*Install desired taillights and seal
*Reinstall strut bar
*Install ABA coolant temp sensor
*Fix broken tabs on RS2 headlights and mount. Install HID
*Repaint and mount RS2 bumper
*Mount comp spoiler
*Test drive
*Get fresh gas (already drained a bunch of the 4 year old gas)
*Pass emissions testing
*Test drive, test drive, test drive and find any bugs
*Install chipped ECU and aftermarket diverter
*Clean, clean, clean. Car has 4 years of pollen on it, needs a very deep clean. Some sap removal.

If I have time (doubtful):
*Install black front seats
*Install carbon hood (if it utilizes the stock latch, I forget; won't have time for hood pins)
*Paint and install euro rear bumper

Things that won't happen before BBQ, but will come this winter:
*Big brake install
*Porsche Cup 1 wheel install
*GT28R install
*Powdercoat stuff
*Suspension?

Got lots of practice on my TIG skills fabbing up the exhaust...plenty of room for improvement for sure and lots of crappy parts fitup (I really need a band saw)

IMG_20161008_130911 by Vex Art, on Flickr

IMG_20161007_202553 by Vex Art, on Flickr

IMG_20161008_135647 by Vex Art, on Flickr

Got rains on boatloads, not fun. Got the downpipe mated up with the custom 3" exhaust I didn't fabricate. Used FID interlocking v-bands, worked well and didn't warp.

IMG_20161008_133844 by Vex Art, on Flickr

IMG_20161008_135737 by Vex Art, on Flickr

Gave welding aluminum a first try too for the diverter bung on my intercooler plumbing, once again need a lot more practice

IMG_20161008_143602 by Vex Art, on Flickr

Got the car started only to hear a horrible grinding noise coming from the front of the engine. Turned out to be bad bearings in the stock alternator. Couldn't find a replacement alternator in stock at any of the local stores, but remember I had a couple 40v V8 engines sitting around. Pulled one off and magically it has the same mounting and fits fine, despite being 150A and bigger.

IMG_20161008_175209 by Vex Art, on Flickr

IMG_20161008_182419 by Vex Art, on Flickr

Fabricated a bracket for the throttle cable since the B4 isn't long enough (and mine might be even shorter due to the V8 swap)

IMG_20160923_200628 by Vex Art, on Flickr

Got all of the coolant lines hooked up, filled, and bled. Radiator fans wired up and tested working.
Got all of the vacuum lines routed too, used all kinds of stuff that I had sitting around so don't really have any documentation on what's needed.

IMG_20161009_155117 by Vex Art, on Flickr

Wiring temporarily tucked up, I want to revisit this later and come up with a better ECU mounting point

IMG_20161011_210034 by Vex Art, on Flickr

Coolant gauge read high with the stock AEB sender, I ordered an ABA one which is supposed to make the gauge read correctly.

IMG_20161009_155052 by Vex Art, on Flickr

It runs!

VID_20161008_161506 by Vex Art, on Flickr

VID_20161008_182621 by Vex Art, on Flickr

Wiring issues/notes for me to expand on later, just want to get them down so I remember them:

*K-wire is mislabeled color-wise on AEB drawings, so go by the connector pin instead
*Don't wire in the L-wire to an OBD2 connector. It caused VCDS only to connect while the engine was running, if the engine was off it got communication errors. Unhooked the L-wire and all problems solved.

AEB OBD2 wiring:
Pin 4 = Ground
Pin 7 = K-wire
Pin 16 = +12v

Other accomplishments:
*Installed Aux input/USB to the VW Monsoon radio I have in the car
*Installed 3-spoke sport airbag wheel. Wanted to install a non-airbag sport wheel I've got but I'll have to reverse the clockspring mods that were previously done...not enough time.
*Performed throttle body alignment. Car would idle high when warm before this, now it idles perfectly.
*Oil temp and pressure wired in and working great with the aux gauges.
*20 mmHg vacuum

Other things to troubleshoot:
*Ambient temp display isn't working, did before so I probably didn't hook something back up in the cluster
*Hesitates under initial tip in with very light throttle...probably just old gas, we'll see. Might need to clean the MAF and throttle body.
*Didn't get the coolant level sensor wiring correct, not a big deal for now I'll figure it out later.
*ABS light is on

Great work!

A few comments:

The CF hood from me does have provisions for the spring pins and safety latch. It bolts in like stock EXCEPT for gas strut mount.
The AEB and ABA CLT sensors have the same resistance curve. I think you have a different issue. I swapped in the B5 gauge cluster too. That might be it.
Why did you put the ECU in the driver footwell? Isn't on the passenger side in LHD cars?
Lucky on the alternator!

First time moving under it's own power in 4 years! Uneventful test drive, off to pass emissions tomorrow.

2016-10-13_12-27-16 by Vex Art, on Flickr

ChrisAudi80 wrote:A few comments:

The CF hood from me does have provisions for the spring pins and safety latch. It bolts in like stock EXCEPT for gas strut mount.
The AEB and ABA CLT sensors have the same resistance curve. I think you have a different issue. I swapped in the B5 gauge cluster too. That might be it.
Why did you put the ECU in the driver footwell? Isn't on the passenger side in LHD cars?
Lucky on the alternator!

Cool on the hood, we'll see if I have enough time. We're supposed to get a storm from a dying typhoon with lots of rain and high winds the next few days...probably not hood changing weather haha.

The ABA I believe is what Dave used with his and it fixed his gauge. I thought I read that they have the same ECU side curve, but the gauge side is different. Guess we'll see, it was cheap.

I used a B5 harness which places the ECU on the driver's side rain tray/fusebox area so there's not a lot of length of interior wire. Ran it through the B4 wiring hole. I might have been able to put it on the passenger side, but that would've required a new hole in the firewall. This was the easiest.

awesome work Alex! Do you like that clutch and flywheel setup?

You are planning on driving to BBQ with this correct?

dana wrote:awesome work Alex! Do you like that clutch and flywheel setup?

You are planning on driving to BBQ with this correct?

Yep, so long as nothing breaks in the next few days.
Clutch feels great, very smooth engagement but a nice firm pedal.

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Fixed my high idle and passed emissions! 50 miles on the car and it's running great!

alxdgr8 wrote:

ChrisAudi80 wrote:A few comments:

The CF hood from me does have provisions for the spring pins and safety latch. It bolts in like stock EXCEPT for gas strut mount.
The AEB and ABA CLT sensors have the same resistance curve. I think you have a different issue. I swapped in the B5 gauge cluster too. That might be it.
Why did you put the ECU in the driver footwell? Isn't on the passenger side in LHD cars?
Lucky on the alternator!

1. Cool on the hood, we'll see if I have enough time. We're supposed to get a storm from a dying typhoon with lots of rain and high winds the next few days...probably not hood changing weather haha.

2. The ABA I believe is what Dave used with his and it fixed his gauge. I thought I read that they have the same ECU side curve, but the gauge side is different. Guess we'll see, it was cheap.

3. I used a B5 harness which places the ECU on the driver's side rain tray/fusebox area so there's not a lot of length of interior wire. Ran it through the B4 wiring hole. I might have been able to put it on the passenger side, but that would've required a new hole in the firewall. This was the easiest.

1. Yep, watch those storms. That's how I managed to have 3 hoods damaged. Keep in mind that you only have adjustability on the hinge bolts.
2. Interesting...Good to know if it works.
3. I see. The shop that did my AEB swap spliced in part of the B5 harness (T6 and T10 pin connector stuff) into the B4 harness. I guess because my car is RHD it is a bit different. The ECU cable loom goes through a hole in the fire wall under a firewall mounted battery tray on what is DS for you (B4 4 cylinder). My B4 RHD 4 cylinder is probably different from your B4 LHD V6 firewall.. This is one of the main reasons I followed my mentor's advice of making a PnP adapter for my VEMS instead of using the Lugtronic harness (which turned out to be wired wrong )

Wow nice!!!!!!!!!!! The car had quiete the transformation, had to read entire post to come up to speed.
Congrats and keep up the fabbin.

Awesome.

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Pre-BBQ Update:

Fixed the coolant gauge with an ABA temp sensor:

IMG_20161018_091239 by Vex Art, on Flickr

Fixed the cruise control somewhere in Oregon on the way down to BBQ. After spending 2 nights right before BBQ cleaning the switch and resoldering the module I was still having issues with the CC. It would engage but then disengage 0.25-10 miles down the road. Figured out it was the brake switch adjusted incorrectly was was right on the edge of the switch being off. Fixed that and the cruise worked wonderfully.

IMG_20161017_204827 by Vex Art, on Flickr

Pre-roadtrip clean. Really needs some heavy paint correction, but it cleans up alright. Reminded me that I hate black since it shows every flaw.

IMG_20161016_181815 by Vex Art, on Flickr

Used a hot stapler and marine epoxy to add the stock mounts to the Reiger RS2 bumper. Screwed up the passenger side mount and will need to redo eventually...it sticks out too far

IMG_20161016_120752 by Vex Art, on Flickr

Black front seats installed with some Lloyds 'turbo' floor mats from my old Porsche 944 turbo. They fit decently well.

IMG_20161015_170500 by Vex Art, on Flickr

14589928_10106994703959128_3437467282730970167_o by Vex Art, on Flickr

Tried to swap the chrome door handles over to some brushed aluminum ones from an A8 that came with the car. Realized that wasn't going to work sadly...will have to source some Euro ones or do a brushed vinyl at some point.

IMG_20161015_092629 by Vex Art, on Flickr

Had a water leak right before I left, figured out it was a bad installation of the rain tray that was saturating the cabin filter and leaking in. Also found out I had bad foam on the fresh air flap so I fixed that with some aluminum tape.

IMG_20161015_105403 by Vex Art, on Flickr

IMG_20161015_114749 by Vex Art, on Flickr

Also got to carry an OEM RS2 bumper down to Vegas...wish I had gotten to keep it.

IMG_20161018_191421 by Vex Art, on Flickr

Post-BBQ update:

Had an amazing 5th year at Battle Born Quattro. Was nice to make it there and back in the same car that made me fly home from my first BBQ 4 years ago.
Overall, 3000 nearly trouble free miles. Only issues were having a few turbo to manifold bolts loosen up on the drive home. Fixed that and I was good to go.

Obersvations:
*Some sprints up to 8000 ft showed some of the downside to only having ~200chp with a stock turbo, but driving around town a chipped K03 can be a lot of fun so long as you shift around 5k RPM. A GT2560R will be going on this winter which'll alleviate some of those issues.
*Odometer didn't work the first half of the trip, but on the return I was able to clock 26-30mpg depending on terrain and speed. 30mpg was achieved at 65-70mph with a B5 V6 01A.

Things still to do:
*Figure out why the airbag and ABS lights are on
*Repair the chipped ECU that failed right before I left. Currently running on a different chipped ECU that doesn't have emissions delete so I get a CEL due to no LDP.
*Install GT2560R and 3" downpipe for more power.

Gripes:
*Hockey puck engine mounts and HPR poly trans mounts are too much noise/vibration for me if I'm going to DD the car. I swapped the trans mounts out in Vegas for the stock ones and that helped, but I need to figure out something for the engine mounts. Might try and make some B5 mounts work. Being an acoustics/vibration engineer by trade makes me extra sensitive to NVH. I deal with it in the Coupe GT which has poly everything because it's a weekend car, but I want to DD this car once VW (hopefully) buys back my Touareg.
*Exhaust has a nasty drone above ~2800rpm which is right around 65mph so the trip was pretty annoying. Some of this is due to the poly engine/trans mounts, but I also need to build a 1/4 wave resonator for the exhaust. Handy spectrum analyzer on my phone showed me it's right at 110Hz which should be pretty easy to fix. Pretty happy with the exhaust tone though despite it being a 4cyl.
*B3/B4 seats haven't proven to be the most comfortable for 3k miles. Picking up some black UrS4 seats that'll alleviate that issue.
*I'm kinda torn on the suspension. The Vogtland springs/Bilstein sport dampers road great from a DD perspective but are a little soft. I might do some coilovers in the future. Car is also a little low, I scraped quite a few times, but some of that is because of having undersized tires. I do probably need to tuck the exhaust a little better too.

Conclusion:
Super happy with the swap, I'm so happy to be driving this car again. Even with just a chipped K03, it livens up the car so much more than a V6 and gets better gas mileage.

And of course PICTURES!

P1150215 by Vex Art, on Flickr

P1150300 by Vex Art, on Flickr

P1150327 by Vex Art, on Flickr

P1150376 by Vex Art, on Flickr

P1150722 by Vex Art, on Flickr

Nice write-up. The car is looking real good. Your mileage is amazing. I get 6.8KM/L with E85. I guess I am also around the 200chp mark and it can be fun, but I would like some more. Like 250.

Wish I had that bumper. The FMIC is a little large for chipped K03, but with the 2560, should be just right.

No CF yet?

it was great to meet you Alex, congrats on getting the car done so fast and making the drive successful. The 1.8t looks like it belongs in there.

Those are some great pictures of the car Alex.

Awesome car, I'm looking at doing something similar with a 1.8T.

On the hockey puck mounts, before you scrap them try replacing the picks with orange weighed pucks. They're heavier to help with shooting and stick handling but they're 5-10 shore softer than regular black pucks and hold up just as well.

vt10vt wrote:Awesome car, I'm looking at doing something similar with a 1.8T.

On the hockey puck mounts, before you scrap them try replacing the picks with orange weighed pucks. They're heavier to help with shooting and stick handling but they're 5-10 shore softer than regular black pucks and hold up just as well.

Thanks for the tip, just ordered some from Amazon. We'll see how they work.