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

[K Simmonds]

I now have a choice of 8V exhaust manifolds, one moves the turbo back a couple of inches. Got all sorts of K-jet pipe work as well as another box full of S2 hoses so am sure I can cobble something together.

Will see which manifold fit's the 2.0 8V best quite soon and decide which of my turbo options to go with. I really want to stick the K27 on it but feel the K14 would be a more sensible choice. But, hey this isn't a sensible undertaking in the first place.

Have just purchased a complete low milage BAM head and cams to rebuild ready to go on the 06A block. Which I can fully refresh at my leasure, I really enjoy that sort of work. I hope I don't have to replace any valve guides but will do if required. Got wait for it to arrive first.

Am currently busy with MK2 Golf and Corrado G60 stuff but that's more important so must take presidency.

Golf thread will be starting soon, am picking up everything required to make it totally original and I really do mean everything!

Once the Corrado engine has gone I can get stuck in properly.



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[K Simmonds]

More parts amassing for my Golf. Along with the engine and box I have a stock 8V Digifant ECU, airflow meter & airbox, intake hose and front brakes all in great condition. Also a stock centre console to replace the one with VDO grafted in. The Audi center console with my Zetronix will be going in the 80 pretty soon.

As soon as the weather warms up I'm going to be tairing into my MK2... Still waiting for the Corrado's engine and gearbox to be collected, it's a lot of money I could now do with! The Polish chap who's purchased it seems to work every hour God send, he wants a host of of items as well.

Got a suspicion my Golf's G60 is from a Rallye which if it is a major bonus and if it as it will be getting torn to bits as those blocks are work big money as their slightly smaller capacity than a reguar G60 or GTI engine. It has a Rallye intercooler and some hoses but it imposiable to read the engine number with the front end on.

Am very seriouslly considering saking off turbocharging the 80's K-jet motor as its just more hassle I don't need. I want to spend all spare time and funds building up the 1.8T engine for that. I think I'll keeps that new K27 for it's final iteration, I like KKK turbos a lot! And I won't loose money on the other parts.

A MK2 Golf thread will be started shortly, no welding required just a lot of polishing!

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[K Simmonds]

On a positive C4 note I have these instruments from the V6 I broke last year, thought I'd see if they're plug ang play. They're in smashing condition and everything works properly.... I can recode the speed to the right miles if it bothers me. Though given its a car for the rest of my life it really doesn't matter, in fact I'd be happy with a functioning speedo. Can't run that car at the moment as the high pressure fuel line has sprung a leak from under one of the clips despite all three looking fine. Be warned people, this is a dangerous fault and it could have stranded me. I'll do all three while I'm at it.

Am actually glad as was getting the odd whiff of petrol while driving and was starting to suspect the tank. I have a spare but replacing the lines is easy and cheap and my current tank is solid.

At least it popped when the car was over the pit!

Oh yeah... I'm doing away with the ABS on my 80, I know I can simply switch it off. However there's a few kgs there and loads more engine bay space.



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[K Simmonds]

Just a breif update to say things are still slowly happening with my B3 quattro project. I've straightened out the bent S2 cross member so it bolts straight on to the front of the car. I now need to fabricate a mount for the drivers side of the intercooler as the rather crude one currently on there is for an RS2 intercooler and I'm using an ABY one. This is a bit of a fiddle as the metal is very thin and I don't want to blow a hole in the cross member, think I'll make the braket and get Jim to do it with the TIG at work.

Been kept busy with G60 stuff, I definatly made the right decision to break the car. It slowly going in bit's still waiting for the engine and box to be collected though.

Plus I have the fuel lines to sort out on my C4 which was not a job I was expecting to have to do as they look fine.

Have decided to retain either retain stock cappaicty with the 1.8T or make it 2008cc engine using the crankshaft from a modern 2.0 Audi, which is surprisingly easy. There's issue's with using a 1.9TDi crack such as a less than satisfactory rod angle which limits RPM.

Am considering using an aftermarket ECU. I'm still reasearching this as IT isn't really my thing, however it would allow me make any tweeks required myself and would be good to learn a new skill. If i can get my head around it then who know perhaps a boosted C4 2.8 quattro maybe on the cards once all VW activitys have ceased and I've got the money in from the Golf.

I also have an extension to build on my house this summer which is going to seriously take up time as it means I have to completly reroof the building to get it to comply with the latest building regulations which are a PITA to be honest. Still my chimney seriously requires attention and the planning runs out this year, my folks are paying for the materials I just have to do the work. It's all stuff I've done before but not for a few years, the scaffloding is going up this month so things are moving forward quickly, It's going to add 50% to the value of my home for not a huge amount of expense as it's all timber framing which was what I use to specialise in.

My left elbow has finally sorted itself out over two years after being broken, I've lost the feeling a couple of fingers on my left hand but I don't want to have any more surgery so I'm going to live it.

As soon as the weather perks up a bit more I'll start the MK2 Golf GTI total OE restoration project thread, due to the size of my workshop I'll be pushing the car outside to do most of the work as I want to keep the other bay clear for C4 and B3 work. Plus a lift is planned for this year so I need to be able to get the RS2 out as it's going where that currently lives, it has to go that side as the ceiling is too low in the other bay. I also need a bit of work space to sort out Corrado parts, the interior needs a really good clean and leather treatment before I sell it as the front seats are a bit fadded though all the bolsters are solid. And black leather Corrado interiors fetch serious money so it is really worth the effort.

[K Simmonds]

Everybody likes photos so here's a few Turbo pictures.... I picked up a RS2 hybrid turbo actually for my RS2. It's got a complete K24 7200 coldside fitted with a Mamba billet wheel which gives over 10% more surface area and a more modern 6+6 design

The hotside is a regular #6 Turbine housing with a 56mm exit and the shaft that goes with it which has been back cut.... I have a #8 Turbine housing on the way.... I'm hoping it will perfom like the K26/7 that's on the car and look stock, if not differnt software could be on the cards.






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[K Simmonds]

Here's a comparison to a stock RS2 compressor wheel, it's hard to see in the pictures but the billet one is considerably larger though it still fits a stock housing, just...

Speakers with K27 turbo's on top make for interesting furniture....

And I have a rusty but brand new exturnal wastegate turbine housing for the larger of my Chinese turbo's which needs sandblasting along with a load of other stuff. Which I haven't had a chance to do as it's quite a heap of components and even with the big compressor it's slow goin and messy. This turbo is for my B3 80 K-Jet turbo attempt, I also have the little K14 but I have two Caddy manifolds so can try either and see how they fit, space is quite tight on that side of the engine bay....

The 1.8T will be getting the Chinese GT2871 to start with then I'm going to fit that masive K27 updated with a billet wheel.

I have a few interesting little turbo projects on the go, the RS2 one being the most important, the hybrid on there uses the same hotside as the one I picked up up and the compressor wheel is almost identical in surface area to the K27 one that MTM used 30 years ago so I'm hoping it will perform like the old K26/7 but look stock.... The #8 turbine housing should be intresting.

The turbo on my RS2 has ingested a few bits of those stupid plastic MAF screens and it's burred over the edge of the blades on the compressor wheel slightly. I think it happened when my diverter valve stopped functioning, which sounded great BTW, it still goes fine but obviously is sub optimal.

I've changed the screen to an S2 metal one but it's too late now the damage has been done, plus it's done 100K miles so is due a refresh anyway. So I'm hoping the MTM mapping can run my new hybrid happily, the #'8 turbine housing should make quite a difference. I will be running with a wideband gauge to be safe, it might be a case of getting some chips from Newsh.... We shall see.

Scafolding is going up on Monday/Tuesday if not Wednesday as well so I'm going to be roofing soon, to be honest am looking forward to doing some construction work again.




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[K Simmonds]

Scored a complete set of stock late MK2 Golf GTI 8 valve front hubs & brakes with new discs and pads as well as splash guards for £50. They just need a good clean and some paint, the G60 ones on the car fetch really good money, over £200.

On to my other hobby I've gotten this seriously rare Hifi set up working at last, it was top of the range in 1983 and that's Technics first CD player of much the same vintage...

I've continued the turbo on top of speaker aesthetic with that system.






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[John.]

for the Turbo'd speakers.

[K Simmonds]

Cheers John, I thought the combination of speakers and turbo's would be up your street.

Just pondering the Caddy exhaust manifolds, the one that moves the turbo back has a larger output, though it puts the wastegate in an odd place. They're only £15 each so they're a very economic way of fitting a turbo to an 8V engine.

I can get a billet compressor wheel for the K27 hybrid for under £100 from a British made company which should make it spool a little better. It made 500bhp on a 2.6cc Skyline so it should work fine on a 1.8T or 2008cc engine though it will be laggy. Fitting to my 2.0 8V engine would be fun though I don't think it would be at all practical. It would be the perfect turbo should I want to charge my C4's 2.8 V6 engine. Though I've got to learn to do one thing at at time!

Must go and see Dave soon and collect the damaged 06A 1.8T motor and various other useful parts such as gaskets. Got a bit side tracked by purchasing that new turbo for my RS2, though I got it for a bargain price. Less than it would cost to get the existing K26/7 hybrid rebuilt properly put it that way. I can always mothball that turbo and even the software if necessary.



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[K Simmonds]

Have also picked up a very good copy of the RS2 exhaust manifold, it's an excellent casting with all the right numbers on it just no Audi rings, I'd swear it was genuine otherwise. I'll sand blast it when I do all my turbo spares soon.

It's crack free and straight and I'd have no problem using it on my RS2. Have also got a spare wastegate flexi joint in great condition.

Have got to wait for my #8 Turbine housing to arrive before preceeding with operations.


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[K Simmonds]

Found a couple of nice useful bits for my 80's front end... A good Llambda sensor and the one for ambient temperature. I like to have ambient temperature gauges on my cars to warn of frost, it's also interesting to see just how hot it can get in the summer.

I know the Llambdo is good as it's one I replaced for no reason on an S2, got another couple of those tucked away as spares.

The one on my 80 got damaged when I removed the Cat, though the £200 I got for it made it worthwhile, effectivley making the car free.






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[K Simmonds]

Have dug out my box of mainly S2/RS2 hoses along with some 1.8T ones...

My turbo/engine building bench is getting thined down, once I've built up a K24 7400 hybrid I think I might list the rest on eBay as a job lot just to get shot of it.

Though I have a Porsche 944S turbo on the way for it's #8 Turbine housing to make my new RS2 hybrid really special. this which will leave me with all the parts required to build up an RS2 K24 7200 hybrid much the same spec as a TTE 420.

I can now get new good quality centre sections from China and I have a spare Porsche 944 50mm exit #6 housing that I could get machined out to RS2 spec as I have a very good K24 7200 Turbine wheel/shaft spare. I'll also have the 56mm exit #6 left over from my new RS2 hybrid once I fit the #8 housing.and the shaft from the Porsche turbo which will make a nice hybrid with a billet wheel.

All my smaller VW spares, some will be required on my Golf project but the rest can now be sold at last. It's surprising how much money is in those boxes and theres loads more big stuff in the attic!

Got two 1.8T engine's, the one on the stand belongs to a customer but I have a feeling it's going to end up mine. That's fine though as I still want to use Daves block from his damaged engine as it perfectly serviceable, I want to drop a modern 2.0 crankshaft in it making a 2008cc engine.

Have watched hour's of YouTube videos on the subject and it's really straight forward if one is using custom rods which I am. It's the best way of making a 1.8T stroker and will allow me to use big turbo's. These projects always seem to creep a little, or in this case a lot, with that K27 fitted 480+ bhp and 700nm is on the cards.

And finally a decent spare 2.8 V6 block, who knows what the future holds for that. One thing I do have is time and it would be very cool to build up a boosted 2.8 12 valve V6 engine. They have cross flow heads so turbo or supercharging is viable. I could end up with a home made version of a C4 URS6, a bar of boost would see that engine putting out at least 350bhp and 500nm.

One thing at a time though, starting multipule projects ends in disaster. I want to get the B3 done and dusted before doing anything other than regular maintainace to my C4, the V6 engine in it currently makes it quite a brisk car as it is. It's lovely and smooth with buckets of torque in the mid range, the 2.8 V6 is an underated engine IMO, they're considerably better than the 2.6 version anyway.

My RS2 is really an investment now, I expect I'll do all the mechanical work on the underside of that before thinking about paint and it desperatly needs the headling recovering as does my C4... Don't have to worry about that in my 80, there is no headlining.



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[K Simmonds]

I did write a load of text with these pic's but somehow that's been erased will editing, it's too late to do it again so heres some random photos...

One more bit of important information is I intend to use an aftermarket ECU and learn how to map stuff myself, the price of good quailty aftermarket engine managment isn't so prohibative these days and being able to make adjustments myself will be very useful.

I've watched hours of videos regarding the matter as well as read up about it and it makes much more sense than trying to run a heavily modified engine on a stock ECU. It's new skill I need to learn.

My 80 now has a red offside wing fitted, the bonnet is plain black as opposed to metalic like the rest of the car and the V6 front bumper I got from Newsh has been colour coded a very dark purple. It needs a couple of minor cracks sorting which is simple with the tools we have at work. Anyway, once it's all together I'm not painting it other than a couple of small area where there's rust. So it'll be four different colours and can stay that way.

The rear subframe is solid enough but covered in surface rust so this is going to be removed and sand blasted along with all the wishbones and suspension struts which will then be powder coated black. The front subframe is fine due to oil from the engine and hydralic systems. Everything will be poly bushed a mixture of colours as Andy gave me a box with black, blue and red bushes, he's given me enough to do 90% of the car so I'll have to purchase a couple. I'd much rather spend money on the underside of the car than cosmetics.

Suspension will be Bilstien stock replament B4 dampers and shortened stock Audi S2 springs with new top mouts at the back and front with the fronts being fitted with mount savers.

Exhaust is going to be straight through twin side exit, I have a section of genuine Audi pipe that's almost made for the job and weighs about 1kg so a massive weight, cost and hassle savining.

The battery tray and ABS are going to make the engine bay as simple as poss, the battery will be mounted on the floor behind the drivers side seat so nice and easy to get to. I'm going to use the vacuum servo and master cylinder from the 30V C4 I broke, that should supply more than enough assistance. It will be fitted with a one way valve conected to the inlet manifold, simple.

I'm going to fit the PAS pump from a MK2 Golf for the steering, that bolts straight on below the the water pump.

My target weight is 1000kgs, I might not be able to get it quite that low but we shall see.

Anyway when I'm not building this summer I shall be working on my MK2 Golf to get it ready for sale, I'm making it absolutly bone stock orginal as I think that will make it easy to sell for good money and the G60 parts will make me a lot of money. Once that car has gone then the B3 will get it's new engine which I can build up in the evenings in my workshop.

A lift is on the cards for this year, but not until I've done my extension on the back of the house which will give me an upstairs bathroom and another good size bed room.

I'm going to have a very busy summer!









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