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

[K Simmonds]

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?

That's the plan mate, the holes in the housing are already threaded but only M8, I'm going to drill them out and retap them to M10 for studs.

[John.]

CG125 Great wee bikes. I wonder if trying salvage sites/auctions might get you a cheap one ?

[K Simmonds]

Just checked my new China special T28 turbo and I was wrong, the hole's in the turbine housing are already M10 and are threaded so I just need to find some studs, I'm sure I have four in an old scrap S2 exhaust manifold I can pinch and reuse along with the special 15mm M10 x 1.5 nuts which are easier to sqeeze in and get at.

Have also made a major decision regarding the MK2 Golf and have purchased a pretty much complete orginal 1.8 8 valve Digifant engine to return the car to stock, the G60 conversion is going to be pulled out and sold in bits as the parts fetch really strong money. I also have a set of OE 16V GTI springs to return it to the correct ride height and some original 8V rear light clusters. It's a bit of work, however nice original MK2's are now hard to find and as the car has a pretty much full service history and is very straight and rust free I feel it will be worth just as much and be easier to sell if I make it totally original again.

And I get a load of money from flogging the G60 stuff. Same applies to my Corrado, I keep getting stupid offers for the car as a whole or the engine conversion, I'm sick of getting offers of a grand for it when the freshly rebuilt charger is worth that alone.

I need to have a shuffle about of cars in the workshop, I have enough room behind my RS2 for the Golf to go in backwards behind it leaving the other bay free to use the pit, I want to get the C4 finished and once I've fitted the decat pipe work and replaced a brake pipe it's actually ready for an MOT.

[K Simmonds]

CG125 Great wee bikes. I wonder if trying salvage sites/auctions might get you a cheap one ?

Yeah, I had one 20 odd years ago and it was great fun and extreamly frugal on fuel, they are however hard to find for reasonable money. Checking salvage autions is a good idea as eBay prices are crazy!

[John.]

Yeah, I had one 20 odd years ago and it was great fun and extreamly frugal on fuel, they are however hard to find for reasonable money. Checking salvage autions is a good idea as eBay prices are crazy!

My wife had one, I loved it more than she did ! Good luck getting one, hopefully something will turn up.

[K Simmonds]

Not super exciting but another vital part has arrived straight from the far east for £20 delivered. It's nicely made from stainless steel and even came with a gasket.

And far more exciting... The final bit of wood trim for my C4 which has taken ages to find, I really should start a thread of it's own for that car as I've done a lot of upgrades and it's going to be my daily driver until the B3 is done which is going to be a considerable amount of time.

Besides having to do quite a bit of work to my MK2 I have a full 1.8T engine to build up, though after having a proper look I've found that the 06A early block bolts straight into my B3 chassis which saves a lot of time. Though I'm still going to have to make custom mounts for the C4 gearbox, am 99% sure I can swap my little B3 driveshaft flanges for the 108mm ones.



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[K Simmonds]

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Just occurred to me I have a stainless steel 3" V band clamp and flanges in with my T3 turbo, saves having to buy one. God knows why it was in there as the outlet on that is 2.5", oh well that's paid for half the cost of the turbo.

Also found the postman's left me a couple of flexi joints in my conservatory in an odd size, they just fit inside 3" pipe and 2.75" pipe fits inside them. Stainless steel and only £10 each made to order from a UK eBay seller, will be using them again soon as I want two flexis for my C4.

So I can make a downpipe with the 3" pipe and bends I didn't use on my S2 and easily mate that up to the section of 2.7" Audi exhaust I've just acquired. I offered that under the car yesterday, it's the right length and the dog legs each end help center it in the tunnel.

It's pretty much made for twin side exits, If I was to do a bit of cutting and welding I have enough material there to do it without buying anything else. Very tempting to at least give it a try, the car is going to be really noisy inside anyway with mechanical racket so perhaps a nice loud exhaust will drown it out. Saves a bit of weight as well as the back box is a good 15/20kg, that Audi pipe weighs about 1kg.

The posty also left a grotty but serviceable MK2 Golf exhaust manifold I picked up for £15. I want to fabricate an adaptor that bolts on allowing me to hang that T3 off the existing 8 valve engine. This is for experimental purposes, Jim and I want to find the easiest way of making a pull through K-Jet turbo set up for a work project. So I can actually write off some of the cost of my time by using my car as a test bed for a couple of ideas we have while the 8 valve motor is still in there and running. That's what the adjustable FPR I purchased is for though I dare say it will come in handy in future.

And it'll be interesting as well give me something to play with while I get all the parts together to build up my 06A 1.8T bottom end.... Which could well end being a 2.1T if I use a diesel crank.

I have a spare G60 oil feed pipe and the stuff to make up a AN12 return to sump. So aside from fabricating an exhast adaptor it won't require any outlay. While the sump is off I'll pull the head complete with manifolds which will make getting the old Audi exhaust manifold off much, much less hassle, the nuts are very corroded and hard to get at with it in situ, I've already had a go at them and they're a complete sod. I can then pop the pistons out and skim them to reduce the compression ratio down from 11.5 - 1, for safety I need to get it to around 8.5 - 1.

Also gives me a chance to check the condition of the engine and give the bores a nice fresh hone, carefully clean the ring lands out as well as refresh the head with stem seals and pehaps some stainless steel exhaust valves, inconel is far too expensive for a low boost experiment, if the existing valves and guides are in good condition I'll probably leave them alone aside from lapping them.

Another job I need to get out of the way is carefully do away with the battery tray, it takes up so much space in the engine bay and is a good location for a catch can which I'll most certainly be using. I have the cables to do it in stock and as I'm going to invest in an Optima race battery I could put it pretty much anywhere in the rear of the car that makes sense.

Am also looking at using C4 front brakes and a V6 servo as the stopping power could do with a bit help, I've tried bolting up a C4 carrier to a B4 hub and that fits so I'm hoping I can make someting work.

[K Simmonds]

Found all my cars specs on this very handy site.... https://www.automobile-catalog.com/a....php#gsc.tab=0

Unfortunatally the stock 2.0L final drive ratio is an odd ball 4.556, which I've cross referenced with my AEX/AKT transmision codes and that check's out. So the C4 box is not a straight fit as that's 4.11, I need to do more reading up on building up a custom rear diff using the guts out of the C4 unit which isn't something I've done before though it can be done.

Still the rear subframe needs to be be removed, sand blasted and painted as it's at the stage where it's solid but starting to get rusty, I also have the poly bushes Andy gave me to fit, I know there's enough there to do the entire rear end appart from the rear diff mount which is an £8 MK1 Golf gearbox mounting. So will sort out the diff then, until the the orginal gearbox will be staying in place.

Also the 3A engine has a compresion ratio of 10.5 not 11.5, so a little boost could be added to the 8V motor without skimming the pistons. A BAM 1.8T has a comp ratio of 9.5 and people boost them like crazy on stock internals so I'm sure I could get away with something like 6psi safely with a bit of extra fuel.

The 1.8T engine is absolutly the way to go though for proper performance, they offer the most bang for buck out the entire VAG range, parts are readily available and cheap. Been doing far too much reading up on various forums and as I'll be upgrading the rods I could use a 1.9 TDi crank to incress the cappacity to various different displaments.

Aparently using an AEB bottom end with a small port transverse head and matching manifold is the way to go for the sort of power I'm after as it improves the intake velocity and isn't a restriction until you get up to silly 500bhp+ levels. The AEB bottom ends are getting scarce in the states now as they didn't get nearly as many 1.8T variants as we did over here.

It's also occered to me I've never had a chance to build a full engine for one of my own cars, done pleanty of top ends and full rebuilds at work on various motors so it'll be nice to get a chance to do one for myself for a change and will probably be the only one I ever do so I want to make it interesting.

Watched an interesting video on YouTube last night where a 1.8T specialist in the states destruction tests a stock engine in a scrap car, they kept adding boost and fuel as well as adjusting the timing until it finally pooped it's pants at 600bhp which is really quite an achivment! It was running something crazy like 3 bar of boost and still just about holding on. I'll see if I can find the video again and post a link to it.

[K Simmonds]

Had a productive morning/afternoon shuffling my cars about by myself which is a PITA, the Golf is now behind my RS2 backwards so I can work on the engine bay with the garage door open. I collect the stock PG motor tomorrow morning.

And while my 80 now starts first time despite having no exhaust or Llambda sensor hooked up much to my irritation one of the fuel pipes under my 100 Avant burst as I parked it over the pit. Oh well at least it's in the right place to fix it.

Edit... Oh yeah and there's an old Turbo Technics manifold on eBay whch would be perfect for mounting the T3 turbo I've got to my 80's 8V motor. It's just a bit expensive considering it has a couple of hairline cracks.

[K Simmonds]

Had a most fruitful day yesterday!!!

Ended up getting a nearly complete 1.8 8V GTI Digifant set up for the Golf, nice low milage engine with downpipes, flywheel and clutch as well as all auxiliary componanats.... And what really made my day was getting the guy to part with the close ratio 8V GTI gearbox that actually came off the engine I was purchasing for a very fair price. Taking pleanty of hard cash when doing a deal is the way! We canceled the eBay sale to save him the considerable fee's, which in turn made my engine £25 cheaper than the original price as well as got him to throw in the extra parts for nothing.

I know this is somewhat of a diversion from the B3 project, however selling the Golf and all the G60 parts I remove should really be my number one priority as it's how I'm going to fund my RS2 restoration as well as the 1.8T engine build which like everything is evolving a little. I don't have much work on for Jim this spring so I can really crack on with my own projects, have got the downstairs of my workshop 90% sorted and am over half way with attic.

Everytime I go looking for a part I invariably find other stuff I want for the future which I then put in a logical location. The idea is thin down my huge stash of parts to just the spares required to keep my three Audis on the road. All my VW stuff can finally go which will make lots of space and provide futher funds, there's also a fair few nice Audi parts I don't need which will get listed on here first. For example I have three very tidy S2 under bonnet insulation panels and I really only need to keep one.

I know this is the S2 forum but if people want to see a MK2 Golf GTI OE restortion I could start a seperate thread?

Same applies to my C4 Avant as I've already done a lot of work to the car inside and out by havesting the best bits off the high spec 30 valve I broke last year as well as fit a late S6 leather interior which I got for next to nothing as the drivers seat need's a minor repair. The idea is to make the car a practical luxury cruiser for longer journey's.

I have to say I love the C4 quattro platform, IMO I reckon they're the best cars Audi ever built. The only week point being the wings which seem very prone to rotting unlike the rest of the body, I'm very lucky to have a good pair of nearly new ones stashed away in the dry from the 30V.

The whole concept of my B3 80 quattro is to make a super fun budget car for blatting around locally, that can stay outside on my drive ready for quick use and my C4 and RS2 can both live where they belong in the dry which will help keep them in really nice condition.

Anyway, I know this wordy but this thread is a kinda blog of what I'm upto so back the the B3 at a last...

I've aquired a nice little K14 turbocharger from a 2.4TDI T4 van, a real eBay bargain yet again. Spotted while browsing for other parts it was already quite cheap so I put in a really silly offer, which I woke up yesterday morning to find had been accepted and it my basket which was a result! I'm determined to make a low boost K-Jet turbo set up using my huge box of metering heads, warm regulators, injectors etc along with an ABY S2 intercooler and cross member set up which I now even have the correct bumper for.

I want to save both my brand new Chinese turbochargers for the 1.8T engine, they're also a bit of a pig to fit the 2.0L 3A engine due to their size and it not being a cross flow design. Both manifolds are on the drivers side which limits space considerably so a little KKK turbo is not only going to be much easier to make fit but also provide a little boost nice and early.

I know this is going to rasie few eye brows but I'm going to use the section of 2.7" genuine Audi exhaust that spits really nicely into to two to fabricate a twin exit straight through system, it's too nicely made to not at least give it a go. I'm going to put a V-band on the engine end to allow me to leave it alone while I use different downpipes for the respective engines and turbos. I can easily cobble something together for the K14 and as I've mentioned elsewhere I have enough stuff left over from my S2 exhaust build to make a decent 3" downpipe for the 1.8T motor. The twin side exist also save time and weight as I don't have to use a back box.

And finally as you must be getting tired of reading my now... After extensive research on mainly US forums I want make my 1.8T build something a little interesting as it's my own motor opposed to one for work and I've never done a full engine build for any of my own cars. I've done a few head gaskets/top end refreshes back in my MK2 Golf days as well as replaced some rod bearings but never a bare block up build...

The 1.8T engine I have is the latter type with an internal water pump with what's know as the small port head, however the bottom end is not a straght swap for the 3A engine. Whereas the early bottom end has bolt holes for my existing engine mounts and a lot of the cooling system pipe work is the same, they even share a water pump.

Dave is doing me a cracking deal on the damaged repairable engine out the early A4 he rescued along with a selection of gaskets etc which has the early bottom end I'm after. The smaller inlet port head on my existing engine is actually better for my goals than the head off the early motor as the it flows very well at higher gas velocity and isn't a restriction until 500+bhp which is way beyond what I'm after. So the plan is to build up a hybrid enigine out of the two, using the best elements of both.

As this post is so long I'm not going to go into great details as to what I have planned but it could well involve a TDI crankshaft which I have along with readily available custom rods and pistons from the USA to make a 1.8T stroker. The capacity can be upped to as far 2089cc so effectivly a 2.1T which as I was already planning to use uprated rods isn't much of a deviation.

Oh yeah, I must thank Studdly for giving me the five speed C4 box from my 30V back after a complete **** up involving easy instalation in a B3 car. That was also collected yesterday and it's the gearbox I'll use with the 1.8T engine as the ratio's are much more suitable than the box currently in the car.

Well done if you've gotten this far!

[Tractor Dave]

Yes, post the golf rebuild as a new thread here

[K Simmonds]

As it's been a month I thought I'd let people know what I've been upto. Between cutting firewood and tidying up my workshop as well as dealing with a leaking chimney I've not done anything of real interest to my own cars as it's been bloody cold and I can be in the house nice and warm working on audio equipment ready to sell on eBay. I don't need to drive anywhere really and walking is good for me.

However some progress has been made, I've sold the complete engine and gearbox with running gear out of my poor old Corrado. Well, I've had a decent size deposit and the chap who's taking it is after various other parts so have been taking pics of stuff and negotiating etc. I'm actually trying to get him to take the bare shell with all the other parts he's having as it will get it out of my way and probably be used to fix other Corrado's as he's in the trade and is a VW specialist.

I've also potentially sold my MK2 Golf's G60 conversion complete to local guy who wants to put it in his MK2. So I need to leave it in situ for the time being as obviously he needs to see it running before parting with a considerable amount of money. He's also very likely going to want me to fit it as well so that's potentially going to be a nice job.

He wanted the Corrado engine but as that's been sold he asked about the Golf's conversion which I was about to start pulling apart and selling in bit's. It's going to need to be carefully recommissioned but I'd rather do that than have to deal with packing up loads of stuff and probably be stuck with a block and head. It really badly needs a cambelt before being started again as the one on there is ancient and perished. Along with both fuel pumps which I have to replace regardless of what engines in there.

I have been picking up parts ready to put the MK2 back to stock once the G60 motor has gone. Am on a bit of a tight budget so have been sniping up bit's on eBay as they come up if the price and condition is right. It's surprising how many items I need, stuff like brakes and suspension parts add up quickly.

I still need to get down to see Dave to collect the 06A 1.8T motor and various other parts for my B3 80.

But in the meantime have also been slowly acquiring stuff to experiment with a K-jet turbo set up. Picked up a little K14 turbo off a C4 A6 2.5 TDI for £50 and an exhaust manifold from a VW Caddy which bolts on to my Audi 8V head and has a much easy flange to fabricate an adapter for. It will also fit really nicely and locate the turbo where I want it. It's about the best option I could find as none of the four cylinder manifolds are the right flange. The manifold complete with the downpipe and EGR pipe and valve cost £40, which was a bargain as I can probably sell the bits I don't want for as much as I paid for it making it effectively free. It also gives me the flange I need to fabricate an adaptor and a handy flexi joint with a bit of pipe.

The little K14 is the same bolt pattern as a K24, in fact the exhaust turbine is the same size as K24 7000. It's not designed for high boost applications, they run at between six and eight PSI which I figured would be probably be safe enough with a bit of of extra fuel...




.

[K Simmonds]

Just picked up this beast of a K27 hybrid turbo, it's from a Skyline and in good condition. Am tempted to fit is to my K--jet engine as part of the experiment

The Coldside could do with putting back to stock but that's no big deal with a TIG. Fitting this would be really silly but that's kinda the idea. As I'm about to make an adaptor for the Caddy manifold am torn between T2 and T3 flange options.

This turbo cost £30, so basically came free with the nice quality EGT sensor which works fine

It also has some useful pipes attached.






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[K Simmonds]

Some more pics because why not. The K27 is a hybrid between a couple of industrial turbos, it has a back cut turbine wheel and is actually quite close to a Sport quattro unit. It would be wild on an S2 engine, probably a 500bhp turbo with supporting mod's.

Caddy manifold ready for an adaptor and I have another on the way. I paid £15 for it so I can make T2 and T3 options. They're about the best solution to fit a turbo to an 8V engine. Can use the EGR port for a wastegate or blank it off as needs be.

All this is just pissing about. I'll be a bit more serious with my 1.8T build which Dave is kindly holding the basis for an 06A 20V motor for.




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[K Simmonds]

It's got lights now! Still got a fair bit of work to do making a V6 bumper fit along with an ABY intercooler and cross member.


1.9 desiel Caddy to T3 flange adaptor mock up, it will be hung so be in tension so quite strong enough for test purposes. Obviously the flexi joint needs to be removed, however this is welded inside the flange so will have to be cut off using a dia grider, will then go into my random exhaust stock.

Have also dug out my box of 16V Golf K-jet stuff, I have another box of hoses somewhere





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