Mr Simmond's G60 B3 80 quattro light weight experiment...

[K Simmonds]

I'm not very happy with Tapatalks new photo uploading arrangement, it was really easy to add pictures but it looks like I'll have to send future ones to my Laptop and add them from there. I'm off work now until the new year and I want to get my workshop clear and hopefully the C4 or my B3 80 actually on the road at last...

As for my 80 now it's decided to run properly again I think it makes sense to do the work required for the MOT and get it back on the road with the original engine as well perhaps the lowered S2 springs I got from John as it now sit's comically high.

As it been stood it requires a general brake service consisting of front discs and pads as well as rebuilding the rear calipers so the hand brake works properly, I don't think it needs any hoses or hard lines replacing.

The exhaust needs a simple decat pipe fabricating from a stainless Powerflow box I have knocking about, very simple compared to the C4 job, will take me a morning over the pit.

I also need to make a new cradle for the new fuel pump from scratch as the original one has disolved, I have parts of old cradles from other cars so this shouldn't take too long, again a morning over the pit.

Then I need to fit the new front end, I'm not sure what fitting a V6 Coupe front bumper to B3 Saloon involves so this may take a bit of time to get looking right, though I'm chuffed to bits to have everything required given how expensive the are now. I really didn't expect to get one! John and I did a good deal both ways on my old ported 3B head which I fully rebuilt for him and I got a nice bit of cash the bumper, four fog lights, a pair of genuine clear indicators and grills as well as the correct mounting hardware. The bumper does need a minor repair to one corner which I should do before fitting it, it needs the old repair cleaning up, I'll drill holes at the ends of the cracks to stop them spreading then I'm going to fire some hot staples into it.







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[John.]

That's quite a write-up, sounds like things are coming along.
Keep up the good work

[K Simmonds]

Cheers John, it's wordy I know but having three projects on the go does take a bit of time. Getting the C4 back on it's wheels was a major achievement, not technically but physically, my elbow was only just capable of lifting the subframe etc into place using a pair of trolley jacks. I was very pleased to get this job done at last!

After doing a lot of reading up one very tempting option is to leave the 3A block in place and convert it to G60 spec using the Corrado head as it has the right cam/sodium filled valves as well as use the G60 engine loom and ditch all the K-Jet stuff.

The compression would need to be lowered either by skimming 2mm from the pistons or using two head gaskets. The first option is by far the best as 3A pistons are the same basic design as G60 ones with a dish forming part of the the combustion chamber and I have access to the equipment to do it properly, I'd simply put the pistons in the lathe.

It would also give me an opportunity to hone the bores and refresh the head. With the short stroke 3A block this would effectively be a 2.0L G60 short stroker, so very free revving. Using the ECU/ 68mm pulley I've got along with an adjustable FPR and the this setup gives great results, 250BHP with an instant 300NM of torque.

Plus I retain the noise the charger makes and the larger cylinder capacity takes some strain off of it by lowering boost to about 1bar. It also wouldn't cost anything as I have new head bolts and a couple of complete 8V gasket sets in stock so I could fit new stem seals and lap all the valves, actually I tell a lie I would need to purchase a different outlet for the charger to make the pipework easier. It would also be pretty much unique, a couple of guys in the States have done it with MK2 Golf's but no ones done it to a B3 quattro as far as I can tell.

Anyway, that's all just theroy for now, getting the C4 finished and the 80 assembled and road worthy with the current engine are my main prioritys along with tidying up my workshop!

I'd still like to do something 1.8T bassed as they're such good value and parts are cheap. Really this route makes more sense.

Here's some random pictures I have on my phone of my V6 bumper along with one of the short S2 springs I got from John which are really nicely powder coated..

The new wing fitted, I need to do a bit of work to the very bottom as I trod on it but it's nothing serious and my new inviting interior.


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[K Simmonds]

Just a brief update to keep the thread going…

Been sorting out the workshop, which entails putting parts of the C4 I broke last year in the attic where they will require further sorting and stuff I don’t need listed for sale on here or eBay. I’m retaining anything I may want in future for my 1992 C4 Avant quattro which is nearly ready for an MOT. Just got an annoying brake pipe to contend with.

I’ve found my 1.8T engine loom, which is a result. Just got the ECU to dig out now, I can recall seeing it in a box of electronics so I have a good idea where it is.

Have purchased a half decent new Turbo, it’s a T3 of some description, internally gated, V-band exhaust housing with the clamp and parts to start making a downpipe. I think it’s a T04E but would have to check, it’s a shop soiled item so it was very cheap with the auction finishing at something like 06.00 on Chrstmas eve. It was missing it’s wastegate actuator but I happen to have one so that’s no problem.

I now need to get the Golf into the workshop with the back end over the pit so I sort out the fuel system using bits from the Corrado, I was going to do it this afternoon but thought better of using a car with just a downpipe to move it on Christmas day. Still it’s ready to be shifted tomorrow. I can then crack on with getting it running again and ready to be sold, in the dry with all my tools to hand. It needs a new cambelt and both fuel pumps from the Corrado before it’s ready to start for the first time in ten years.

The 80 will fit in behind it and I’ve various ideas I want to size up, such as using a set of C4 front brakes to increase stopping power. I also have suspension to change to lowered stock S2 Coupe springs with various polyurethane bushings to fit while I’m at it.

Meanwhile I’m going to put some effort into braking my Corrado as I’d like to see the back of it, am keeping engine unless I get a decent offer for it.

[K Simmonds]

Haven't had a great week, seem to have caught a bug over Christmas, still that seems to be abaiting so I'm starting to feel somewhat inclinded to get on with something over the weekend.

Have deceided to put the 80 front end in first so it'll be over the pit, I have an exhaust system to fabricate from the turbo back to my Jetex backbox as well as pull the sump off to remove the pistons and drop the compression from 11.5/1 down to 9.5/1. It'll go back together with a metal head gasket, Inconel exhaust vavles, port matched manifolds and a turbo oil return on the sump. Which I figure is cosiderably more work than required to change a fuel pump and acumulator on the Golf. I might have a go at porting the head as this is a major restriction on 8V engines, I have got a KR16V one but no cams, I forgot to bit on completed one on eBay for which sold for £50...

My turbo is indeed a T04E T3, internal wastegate and V band exit the AR is 50 which is fine, it should be here tomorrow so I'll see what I get for my £50 punt. It appears to be the same as a type being sold from the UK for £140 with two years warrenty, it looks identicial so I have some hope that it'll last a while at low boost.

I have an exhaust manifold to buy or make now.

[K Simmonds]

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Turbo has arrived! It's a bit bigger than I expected but beggers can't be choosers, for £50 I really can't complain and I'm not going to need to push it to hard so hopefully it'll last more than five minutes. Am actually very surprised by the quality for money, nice clean castings, zero shaft play, balancing marks on the wheels and oil restrictor in place which I notice is missing on a lot of the eBay specials. Even came boxed with all gaskets, though the wastegate actuator isn't quite right so the bracket will need to be modified, no big deal though.

Now I've got to decide if I'm sticking with an 8V head, I can pick up a 16V one for very reasonable money which makes manifolds easier as they're the same as an S2 minus a runner even have a T3 Wagner knock off in stock. It also dramatically increases the power potential even with the 8V pistons, they will need valve pockets cutting which I can do on the mill at work. Though 9A Corrado pistons would be a better job and just need a light skim.

This is supposed to be a budget project so an torn, will ponder it while cutting wood tomorrow. Have decided I really like the Ronal wheels, they suit the ethos of the car. I had to move the it the other day for a tree to be felled so I took it for a quick blast up and down my 1/4 mile long 'drive'. I wouldn't say it's ground breaking but it certainly not slow now I've removed everything practical and it's decided to run properly, I was quite surprised!

Actually perhaps I'd be better of using the low milage 6A 1.8T I have in my workshop, in fact that probably makes the most sense.

[K Simmonds]

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After spending a couple of hours cleaning the floor with a broom and compressed air I got the B3 quattro project car and my MK2 G60 in the workshop at bloody last ready to work on them in the dry with all my tools close to hand!

Once the dust has settleded and I've cleared the benches I'll Hoover up in there as, the concrete will be gettong painted in the summer as it's best done at a high ambient temp.

Was a bit of a mission getting them both in square and centered by myself as my C4 has run out of fuel and was im the way, I had to shift it using my B3 as both cars wer parked down by the garage after a fairly large tree was felled the other day. I have a nasty suspision I'm going to need to fit my good spare fuel tank to that car as I get a slight waft of petrol sometimes when I open the doors... Oh well at least I have an excellent tank from the 1997 car I broke along witha pair nearlt new wings which will be fitted and painted once the car has an MOT.. .At least it doesn't leak in the rain at all and has two coats of wax so won't hurt outside for a while and I'll keep on top of washing it.

I still need to finish the exhaust sytem which I can do outside on my hydralic ramps ramps and axle stands, not as convienent as a pit, however I did the system on my Corrado like that and that was a right faff to get right lots on necking pipe down and adding hangers. I think I'm simply going to run the two downpipes straght from the manifolds to the system from the 30V I broke as that has an extra box and also starts with two pipes so it's not too complicated. Will see how it sounds and performs before making any adjustments.

Anyway, I used a pair of trolley jacks to move the two cars in the workshop about once they were both on the concrete and get them right in the the middle of that bay.. Got enough room to comforably work one of them at a time,just need the Golf back as far as it will go to work on the engine bay of my 80 and then push that forward to work on the Golf.

First job is to give them both a bed bath in the building with a couple of bowls of hot soapy water, the MK2 especially needs a very deep clean. I could push it back outside to wash it but everything is frozen up solid, I washed and waxed my RS2 in there and that came out really well.

I'm thinking a 1.8T makes the most sense for my B3 80 as I have a good low milage 8L motor in stock, the engine mounts will need to be custom fabricated which is a pain. However, I also have customer's longitudinal 1.8T on an engine stand and the nearside mount wouldn't work on that either.

I think the B3 offside mounts will work on either type of 1.8T with a bit of pissing about which at least gives me a start. I'll to fabricate a nearside mount out of 1/4" steel plate with strengthening gussets. The front snub mount fits okays and I still have the poly bush and cup I made for my S2 which I'm going to reuse. I'll take the bonnet off and use a block and tackle hooked to an eye on the beams in the ceiling to pull the 3A engine and lift the new one in.

The photos above are obviously not in the correct order, the last one with it all clean and clear was supposed to first but I can't change it around as it won't let me for some bloody reason.

[K Simmonds]

Here's some photos of the 1.8T motor and my benches which need a serious sort out. As well the centre vent replacement section I made for my Zetronix display and a boost gauge to instal in my 3B S2 Coupe which I will be fitting to the 80. A quick shot of the 80's engine bay as it stands.

Followed by some vice porn for Hunker, first one is a large Record with a small anvil section at the back. Lovey bit of old British kit, probably from the 1950' or early 60's, I've got a set of copper jaws for that one to protects parts. The second one is a pre war No 8 Parkinson which is almost twice the size of the Record. It works perfectly but needs a pair of new jaws fitting and a general service. I have a set of steel Jaws for it but am fabricating a pare of hard alloy ones instead so they'll grip steel components really well with no risk of damage. I also still have to mount to that bench properly with some coach bolts that go all the way through the 9"x 3" front beam.


As well as those two I have a very small Recorsd vice that was my grandfather's, so prewar again, that will also be getting alloy jaws, though softer stuff for working on delicate stuff components.

And finally the RS2 side the rear of it's bay which is serving as a Corrado breaking area. I have two genuine buyers lined up for either the engine and loom for a MK1 Golf conversion... The other guy potentially wants the whole car which would be great, if his wife would let him buy any more cars he's probably have done a deal today. Either way that car will be out of the way soon and my bank account more healthy.




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[John.]

Things look like they're taking shape Kit ?

[K Simmonds]

Things look like they're taking shape Kit ?

Cheers John, I'm getting there mate. My left elbow is still a little bit of a problem but it is getting better slowly so no more bloody surgery, so I've finally managed to really start getting stuck into things. Having that workshop is a God send and I still have tones of Hifi stuff to sell which has gone up in vaue considerably.

[K Simmonds]

Decided the T3 I purchased for £50 is too large, for now anyway, and for the money I don't mind leaving it in the original packaging on the shelf, hell it's big enough to go on my V6. And I want power as soon as possible not after 3.5K rpm which is what I'd be looking at if I was lucky.

So I decided to put my preconceptions aside and purchase a brand new T28 from 'Maxspèdingrods', the name alone puts me off.

However I used an eBay voucher and picked up a GT2871 clone with oil and water cooling, more work to install but much better for the life of the turbo. I also watched a couple of independent YouTube videos of their turbo's on 1.8T's and no one can fault them or their performance.

The build quality is excellent it comes with all gaskets and even instructions. Have to say I'm very happy with it. Now I have to either purchase or fabricate an exhaust manifold.

Also picked up a fairly cheap adjustable FPR, I wanted all black fittings but I got this set for next to nothing. Also came boxed properly with instructions.

Been really very ill all week with bloody Covid, well I assume that's what I've got as my mother has just had a confirmed case with very much the same symptoms. I couldn't talk for two days at the start of the week, not feeling quite so rough now but last night I crashed out at about 23.00 and woke up at 14.00 this afternoon and I did want to get up then. Am taking a Covid test tomorrow, wouldn't normally be that bothered but this is worst I've felt since I had fluid on my lungs in my 20's after trying to work with the flu. Maybe that all I have now, whatever it is it sucks.


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[K Simmonds]

Quick update, or perhaps not such a quick update... Thanks to another member being very reasonable I've got my 30V C4 gearbox back, which I'm collecting it this week. Will be very useful to have the box I wish to use on hand so I can work out things like the clutch and crank sensor locations.

It's far to much trouble making a transverse 03A engine fit in a B3 chassis so I'm getting an early 06A engine as well all sorts of other useful parts including a clutch and gasket set from Dave next week for a, very, very fair price, this is still a budget project after all!

Anyway back to the gearbox. The ratios are much better suited to an engine such as the 1.8T with a redline at around 7K as it came from an engine with the same redline, as opposed to at least 1000rpm lower from an 8V.

It's a straight fit to the engine after moving some dowls about and by rights a couple of bolts should be changed in length but I'll work those issues out once I have the box. There will be a bit of head scratching to do when it comes to drive shafts the final drive ratio which is 4.11 on the 30V box. However the car's rear diff may not be a matching ratio, I need to look it up, I have the code in the service book so nice and easy.

I can swap drive shafts flanges on the gearbox but unsure of the score with the rear diff, it's surprisingly compact for a car as large as C4 which is great as obviously the B3 is a small car.

When it comes to things like driveshafts if I can't mechanically make them fit I'll make custom shafts using the lathe at work to keep componants centered, we've done it before as a last resort, it involves a lot of work with a DTI gauge and a huge amount of grinding and welding. Any joints in shafts will be sleaved and I can get them ballanced locally for free.

Besides I have the C4 rear diff, apprently one can trasfer the internals to make it match. Failing that I can fabricate custom mounts for the entire unit as I have to do that with for the gearbox anyway. Will be done with a MIG, 1/4" and 3/8"s plate, nice a simple and strong!

That new turbo has a fair bit more puff than a K04, it tops out at 400bhp, though really 350bhp would be a safe limit, so rods are on the cards. The AR is 67, the hotside is quite small so it should spool up quickly, I put a fair bit of thought into which model would suit my needs best, I nearly went for a billet wheel model but decided it wan't worth the extra cost considering 300bhp is my target.

I have a throttle pedal and ECU to collect from a MK4 Golf GTI at work, as well as a couple of heads that will only end up in ths scrap otherwise.

I also have a set of 440ccm 'Green giants' injectors fully serviced by Will at VRS.

Photo's will follow as soon as I have the various parts to work with.

Will involve a 1.8T engine build from scratch with stronger rods and honed bores etc. So getting the block from Dave on an engine stand will be one of the first jobs. I'll probably get the shells an seals etc from TPS as they don't sell rubbish and deliver to my door and I can exchange stuff thats wrong very easily

I finally tested clear Covid this afternoon and am feeling a bit better, though my cheast is still very tight, I'll be fine soon. I feel a fair bit better today than yesterday.

Am also looking to get a 125cc pre 1983 bike I can use to potter about locally with no MOT or tax reqired. If anybody has anything in the back of a shed they want to part with please drop me a PM. Idealy I'd like a Honda CG125 as I;ve owned one before and they're bomb proof once running though the prices on eBay are mental. It can be two stroke or four, I don't really care what it looks like and it doesn't need to be a runner!

[K Simmonds]

Quick minor update...

Have picked up a nice quality tubular exhaust manifold second hand to modify to T28 as well as the flange required to fit my GT2871 knock off.

Also purchased a enough genuine Audi 2.7" stainless Steel pipe to fabricate an exhaust system, the price of materials has gone crazy so this was a much cheaper way of going about it. I have enough stuff to make a 3" down pipe and a back box in stock. Though it's very tempting to make a straight through twin side exit, would sound wild!

Also picked up the straight through twin box center section from a C6 to use as a decat solution for my C4. It's in genuine Audi and rust free and I can make it fit like stock. Bargain for £50.

For photo's see below, bloody TapaTalk isn't so user friendly now.

[K Simmonds]

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[Jaswan]

Just a thought,

Would it be possible to drill and stud the inlet flange on the turbine housing as an easier solution to mount the turbo?