building a sportquattro

[Rocco]

I am almost :corey: over this car it just looks SO F3CKING GOOD!

+9

[DS2]

more like +10
reading this thread made my face look like this the whole time, i still cant wipe the grin off my face

[Jeffer]

I'm quite pleased with the end result to. Still cannot imagine driving the thing though....

But there is some trouble in paradise. The new clutch arrived from Repo. Had some fitment issues. So now it's a sorry mess with the gearbox and subframe off. As soon as the replacement bearing is fit it will be mapped further.

[Jeffer]

Reupholstered my doorpanels today. New black vinyl, with grey alcantara and orange stitchings that suit the theme with the rest of the interior. Pretty happy with the result must say. I still need to source alloy 8 mm half round bar to put over the intersecting bits. Hence the rough edges now....

[fish]

Give Me Your Car!

[DS2]

nice work there... quite the handyman aren't you

[Billman]

How important is it to have a Quattro for basis? I would like to start a long term project but the quattro's over here are not very common. FWD cars can be found.

[robo]

How important is it to have a Quattro for basis? I would like to start a long term project but the quattro's over here are not very common. FWD cars can be found.

Get rhd quattro from UK it is very easy to covert from rhd to LHD.

[Billman]

the problem with this idea is the greek number plates. It would cost a small fortune (10000+ Euros) with the stupid import law here.

[fish]

if you dont have a coupé quattro, then get a gt coupé and an 80 quattro and change the floorpan. lot of work but fully possible..

[Bram]

I heard that the dyno mapping with VEMS has started Jeffer? Any initial results to share?

[quattro84]

I reckon that due to some minor upgrades the end results can take just a little more time before exposed to the public...

[Jeffer]

@quattro84 I don't know what the hell you are talking about.... You must know more then me in some miraculous way!

But here is my update of the last week or so.

Pretty exhausting last weeks trying to get the car finished map the car. The first dyno visit learnt that the wastegate was to small. So drop in a 60 mm tial for the 44 mm. And fitted the carbon clutch that came from repo. In the end everything fitted but there was a lot of work and stress involved there.!
Then it was of to the dyno again. Sadly when loading the car on the trailer i had my first damage to the frontend of the car. F*ck!
Did not crack the bumper luckily but it will need a respray.

Eventually on the dyno, we had to fiddle around with WG springs to get the base pressure right. This was then solved and mapping could commence. 3 lambda sensors later (they broke down) we then were able to make some boost. Mapping all went smooth and the first baseline mapping was done. However after lunch we did another run and EGO correction was off and in one case around 20%. So something was seriously wrong. We've trouble shooted everything in the car. Measured everything. Made new power lines to the ecu, even soldered and double checked the VEMS ecu itself. In the end we were down to the injectors. These were new 1700 cc's from bosch. And after changing to other injectors the problem was solved. This is pretty strange for new injectors, bought from bosch. So more research showed that maybe a very small drop in voltage from the alternator caused the injector time to be changed that substantially. After this we've already spent a 2 days till 11 at night figuring out what it was and doing test runs on the dyno... :S
So yesterday I went over to the dyno with the rs2 to swap over the 90 amps alt for the rs2's 120 amp alternator on the SQ and again to test if this would solve our correction problem. So this took a while, and finally at 6 last night we were able to fire up the car. The engine was cold, it hadn't run yet that day. Imediatly after starting we heard a load noise and saw oil flying everywhere in the trunk, and out the trunk. The RS2 was standing 2 meters behind it and was covered in oil from top to bottom. The trunk was one big oil massacre. Quite scary. What happend? The oil filter seal was blown out and oil was pushed out there. After removing the filter it showed that the internal filter element was collapsed completly. This was probably due to the 4 stages on the return pushing cold oil through it. But still it was weird. Even weirder was the oil on the hood of the RS23 that exposed aluminium shavings in it. Ow dear.... We were hoping it came out of the oil filter. but further inspection showed that this was not the case. Shavings were found everywhere in the system. Minor shavings, but still.... This is pretty serious. So next up is dismanteling the engine and drysump and see what the damage is and where it comes from. My first hunch is the oilpump.... But time will tell what it is exactly.
So last night again another late night and around 1o'clock in my bed.
One problem (blowing the oil filter) exposed another problem wich is way more serious. Hopefully damage is not to bad.

At least we have checked and double checked the car inside out. This also brought some new less fortunate stuff in the light of day. Compression is low on 2 cilinders. This was measured days before the oil incident. This however is not a really big disaster because a rebuilt of engine, and a new upgraded cilinderhead were already in the planning for this summer.
In the end we did map the car on 1 bar boost on the setup. Intake temps were nice and stable after the chargecooler. And in the end we made 374HP with a revlimiter on 7000 RPM. Boosting starts a 4K rpm and full boost is on at 6K. So for the first test it's quite ok. Just a shame we havent been able to turno the boost up to full swing. But, perhaps that saved me from having catastrophic engine damage.
One happy note. At least we have a video of the dyno run

http://vimeo.com/21545346

Off to get some well deserved rest now...
Cheers

[Acidburn]

not good to hear, hope you get it sorted as it will be mental once done

[G60Rallye]

Bloody hell Jeffry its fighting you all the way at the moment!

Strange to hear that the big bosch injectors might be effected by a small voltage drop but when you fitted other injectors they were fine? Did you get a chance to see if the RS2 alternator had solved the problem?

As for the oil filter going bang that sounds a bit strange? Do you have the oil filter plumbed in on the return line? I have put mine on the pressure side after the pump so its as close to the entry to the engine as possible.

Hope you get everything sorted out. The new engine build will be quite something with the spec you were telling me about a while ago!