Building a S2 mk2 golf

[Pirvu Eugen]

is that an Dual plenum IM?
Well done!
Super!

[GT500]

I`ve been tig welding about 7 years now and it still does my head in (sometimes i get it right) i`ve allways used the tig at work, but last year i bought my own for this project.

http://cgi.ebay.co.uk/240V-AC-DC-200...QQcmdZViewItem

Unbelivably cheap very good quality, arrived in a couple of daysfrom china too.

I have the same tig set up!
Great piece of kit!
Have you had the gas solonoid stick in the on position? gas pouring out long after it should be.
Changed my tourch to a Binzel with a valve on the handle to stop the gas when it does its "trick".
I paid a bit more than that, made a new fuel tank for a Aston V8 first job, Tig paid for and some in its first job!

[gnutz2]

I have said this in another project, but will say it again..

Good looking welds on that plenum. Good_looking_ design, let's just keep our fingers crossed, that it won't explode in first testdrives.

How thick plate did You use? I'd say You need at least 4mm plate for that design...

The backplate is 6mm and the sides are 2.5mm plate which is supprisingly strong, dont forget that the plenum is not finished yet because i have to weld in 4 internal rods to stop the plenum ballooning under 2.5bar max, and the five injector bosses which will stiffen it all up. I think the main issue is fatigue, because the plenum is subjected to +2.5 bar and -1.0 bar it puts the plenum through a lot of stress cycles.

It`s all development which is what i love about building cars

[repo]

I have said this in another project, but will say it again..

Good looking welds on that plenum. Good_looking_ design, let's just keep our fingers crossed, that it won't explode in first testdrives.

How thick plate did You use? I'd say You need at least 4mm plate for that design...

[Flat on my back]

well i thought tig welders were loads more than that. had always thought about getting a tig welder my self. is it hard to get used to? or is it just the same as other welding the more you do the easyer it gets.

If your a keen diy'er try here...and search for 'portamig'.

https://www.mig-welding.co.uk

[gnutz2]

Tig welders usually are more than that. you can expect to pay £1500 for a AC/DC 200A.

It is very hard to get used to and it does improve with practice. but the gas, filler rods and consumeables are quite expensive especially if you purge your joints.

The best advice i could give ror aluminium is keep it clean, clean and even more clean

If you cut the alloy with a angle grinder this contaminates the joint so you need to clean up the joint with a file then a wire brush and i all ways wipe the joints with some solvent to remove any greasy residue from my hands

[denniselbows]

well i thought tig welders were loads more than that. had always thought about getting a tig welder my self. is it hard to get used to? or is it just the same as other welding the more you do the easyer it gets.

[gnutz2]

I`ve been tig welding about 7 years now and it still does my head in (sometimes i get it right) i`ve allways used the tig at work, but last year i bought my own for this project.

http://cgi.ebay.co.uk/240V-AC-DC-200...QQcmdZViewItem

Unbelivably cheap very good quality, arrived in a couple of daysfrom china too.

[europeanme]

Sweet welds

I thought that......

[Flat on my back]

Sweet welds specially the 'tigging', whats your set up, how many years you been practicing?

[gnutz2]

Got the ecu, DTA s100 and also on the way is a 5 bar map sensor, water temp sensor, air temp sensor, crank shaft sensor, Trottle pos sensor and need to get a good quality wide band lambda, loom kit from this company http://trigger-wheels.com/store/ and i can start making the engine loom. thankfully no need for a cam sensor thanks to waste spark, and Audi CQ.

I started to finnish off the plenum now i know where everything is going in the engine bay, the kit i got from the US makes the runners come right out of the bonnet so i might cut and weld them to bend them down a little.

I won 6 x 670cc injectors off ebay which im going to mount on the back of the plenum, i`ll stage them in to take over from the standard injectors.

I was thinking about buying a fuel tank but i have no money left so i had to make one, funny thing is the fuel cap cost more than the aluminiun did to make it. I ported and polished the cylinder head too which you can also see in the picture.


I also orderd a davies craig 80 l/m water pump (for the charge cooler) and a 320 l/h fuel pump by Walbro. So i`ll be plumbing up the fuel lines soon and hopefully getting her fired up ready for 08 summer.

[Rocco]

is simply awesome you are GOD

i never saw nothing similar....

pd:here is spain i meet a forum friend with an ur-quattro with a hibrid engine made it of of him. with a pieces od aby,3b,rs2 and s4 parts. he loves this clasiccs audi cars and his nick is SPORTQUATTROLOVE you will be must his friend

bye master

[LHD_Kid]

Yep, great project, with a really interesting set of pictures and write up....
Really enjoying following this one......!
Chris

[Mark Halligan]

This is one sweet project

Fantastic attention to detail.

[Fat Audi 80]

Love it! Keeps the pics coming....