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

[K Simmonds]

just a very quick update to say I've decided to use the original povety spec front bumper to make the car look as mundane as possible. It's going to house a very light weight BMW intercooler manufacturered by Berh, roughly the same size as an RS2 Evo IC. This cost a mighty £12 delivered.

Now the evenings are light untill 7.30 PM I'm going to start trying to make use of them to get work done on my various cars outside to clear some foor space in there to get old Corrado's leather interior clean and fed.

The turbo is an Audi 200 K26 #6 which I want the water cooled core from to build up a super RS2/K26 hybrid turbo. It may be stinking dirty but it's in excellent condition and the turbine housing will be useful to make a Porsche 944 hybrid to sell to someone

I'm also picking up a new car tomorrow afternoon, well for me it's new.

Finally. John has been kind enough to sell me a spare ECU for my RS2, it's got a four bar MAP sensor and Marc at EFI Express was kind enough to ID it as one of his speed/density set up's for big turbo's.








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[John.]

Now the evenings are light ........

I'm hoping this'll give me the kick up the **** that I need too !?

Looking forward to seeing your modifications.

[K Simmonds]

Well, I collected my new car today but my phone was out of battery so I didn't photograph the process.

It's a 180bhp AJL 1.8T B5 A4 Avant quattro, which is the nice sport model. It basically came free with the complete ready to fit AJL engine that's been sat on an engine stand in my workshop for four years. The customer has totally lost interest in the car so it was a package deal so to speak, the engine in the A4 **** it pants in big way whilst I was driving it on the M5 back in 2019, cruising at 80 mph in the outside lane the top end locked up due to oil starvation and snapped the cambelt. Getting to the hard shoulder in heavy traffic with no power was terrifiying, followed by an extreamly long wait for recovery in December whilst wearing a a T **** and light summer coat, not a pleasant experiance.

Anyway, once we got it back I took the cam cover off to find total descruction, the exhaust cam had seized in the head snapping in two and cracking all the cam caps, however the bottom end survived unscathed, aside from an oil pick up full of carbon which I cleaned out, checked the oil pump and couple of bearings before deciding it would be fine.

So I put the sump back on and installed the bottom end back into the car, intending to source a replament head. A couple of years go by and a whole engine came up for sale on eBay for £250, turbo the lot so that was collected but never fitted.

I actually only really wanted the engine to go in my B3 80 but as the car came with it and was only three miles away away I couldn't really turn it down. I'm undecided with what to do with it, the exterior is solid but tatty and the interior which I though was really good has had some form of mould attacked the leather on one side of the rear seat which is now gone completely, the front seats are okay.

Also the car needs new front brakes as well as swapping the head off Dave's old engine onto the block which I'm not sure I can be bothered with when all I really want to do is rip the the engine loom and and ECU out and use it in my B3 80.

It would make a half decect car but there again it would also break pretty well, oh well it's now on my drive and my problem.

In other news my left elbow is a total mess requiring major surgery which doesn't fill me with joy, I had to literally demand to be seen by a consultant after three three years of being fobbed off by my GP. Only to be told my self diagnosis was correct. Trying to live with it has caused more damage, now I have arthritus and bone on bone contact only some of which can be repaired. If I'm lucky I might get the use of half my left hand back, I currently have two fingers and a thumb that work. I could get private stem cell treatment to help repair the damage but can't afford it so now will have to put up with restricted movement and pain for the rest of my life.

To say I'm pissed off is just a mild understament.

[Tractor Dave]

That A4 TQS was one car I would like to have kept. They are quite special. Looking forward to seeing some pics

[K Simmonds]

Been up all night scouring eBay for bargains as my eye still really hurts and I can't sleep or see very well . I've also doing research on VW Vortex regarding building my old 3A short stroke 2.0 engine as as 20 valve G60. Also twin charging options which isn't as mental as it sound now the parts are available to do it.

Just be clear this is for my B3 80 project not the A4.

The B3 80 is going to be a bit more experimental.. I'll have Wide-Band AFR, Llambda, EGT, Intake Temp, Fuel Pressure and super accurate Booost/Vacuum data that no only can I read live but also record information from WOT pulls etc and read it back on my little laptop.at my leisure.

That's if I use my full Zeitronix kit... I have all the sensors to hand to set that up. I was going to use it on my RS2 but considering I'm not doing anything too crazy with that I think it makes a good deal more sense to use it on the B3 80.

I'm defiantly going to be using the GTX2871 MaxSpeeding clone I purchased last year which is outstanding quality for the money, not much point having it sat on a shelf dong nothing... It's good for knocking on 400bhp and over 450nm so rods are a must, again they can supply a set for about £300 as well as custom pistons for about the same money making a 2.1 20 valve engine.

Will be using the small port head and inlet manifold I have from a low mileage transverse A3 1.8T engine, apparently up to 400bhp the smaller ports are an advantage as they increase gas velocity... That's somewhat simplified but there is a proper explanation on VW Vortex which is an amazing site, I've lost hours reading info on there. That also the set up I have a wiring loom and ECU for from an 8L A3 I broke many years aio.

I'm half blind so looking at listings can take a while... I need another couple of engine stands, one to build up my MK2 Golf Digitant engine and sort the loom out ready to fit it. And another to put my old 2.0 3A block on...I've got a load of heavy duty 2" box doing nothing so when I can see properly again I can build a couple of custom stands that fit the VAG 1.8T block better etc better than the universal type, I even have six heavy duty castors in stock as I meant to do it a couple of years ago.

As I say I've been researching VW Vortex which is perhaps a little dangerous, they come up with some pretty wild combinations on there.

Anyway, at the very least I can say the 80 is now going to have much improved seats from the A4. I'll remove the air bag's from them as they're a little heavier than the old B3 Coupe velour affairs, which I may end up cutting up to make the really nice A6 S-Line seats fit my A4 properly. I can adjust the legs on the A4 seats to fit my 80 quite simply, being able to weld makes projects like this much less hassle.

Right time for some more pain killers and a cup of tea. am restricted to the house currently which is most frustrating.

[K Simmonds]

Purchased one of these to house my various impact guns and drills, will make a charging station on the middle shelf, no more wire's everywhere and all my tools to hand, well worth £30 odd.

https://www.ebay.co.uk/itm/356556627030

[K Simmonds]

Stripped that C3 water cooled K26 on Wednesday evening, despite being sticking dirty it condition is actually excellent, almost a shame to strip it down.

The #6 56mm exit turbine housing is in exceptional condition, no cracks at all apart from a very slight one on the web between the two half's of the housing internal layout. Over 90% of used KKK turbocharger's of this vintage have a hairline there, even little K24 7000's running stock 230bhp.

The only housing I've seen totally crack free is the #8 K26 I picked up from a Porsche 944S which I'm using in this build, I was going to open out the turbine housing but have decided it's quite large enough as it is. The turbine wheel/shaft will be a Mamba nine blade high flow item meant for the Porsche application.

The core will be refreshed with a 360 bearing etc, but not the super cheap Chinese items on eBay, Mamba Tek can supply them along with the various bearings and seals.

The compressor housing and back plate is going to be from a stock K24 7200. Though I've found a slightly larger billet wheel that I squeeze in if I open up the intake by approximately 3mm for the larger inducer. the exducer is also slightly larger but will fit with minimal machine work.

I have access to the lathe at work again, though times are somewhat sporadic. I'm a little rusty so I think I should practice on a scrap housing before doing the work to my K24 7200, even though it's pretty simple..

I'm hoping this will make a pretty good hybrid for those who what the stock look but don't mind a little lag and want strong top end power delivery above 3.5-4K RPM, and be able to hold high boost a little longer than a stock RS2 turbo.

I will take detailed photos of the assembly process but currently I'm out off action and besides I'm concentrating on my unexpected B5 A4 TQS project.

[K Simmonds]

This thread has drifted about a bit.... So back to the B3 80.

while I was getting space ready to work on engines it dawned on me the quickest solution would be to fit the complete good AJL engine into my A4 as I want that car on the road soon.

This leaves me with a lot of choice, I could revive Daves old engine with a new cam chain tensioner and a serious clean.

Or I can use the excellent A3 180bhp 8L head and inlet manifold on the the low millage bottom end from the A4, this gives me the custom set up I wanted and have a loom and ECU for it

I've just finished lifting the A3 head from the block and it's in perfect condition.

All it needs is to clean the gasket mating surfaces and it's good to go, straight on a serviced block then into my 80.

I'll still be left with the parts to build a third engine, which I will do over the next couple of months, experimenting with fitting a G60 charger.

[K Simmonds]

Had a major organisation day yesterday, the 80 refused start, which was an very annoying, however.. . I will be pulling it's engine soon a doing away with the troublesome accumulator and fitting an adjustable FPR.

My solution to convert the tubular manifold is crude but will work very well, have ordered an M8 threaded 316 SS T28 flange as tapping that one is impossible, it's too hard. I guess I could have tried annealing it, oh well it'll come in handy at some point I'm sure.

Also, a selection of knock off Chinese power tools. Am currently just using them to see how well the last, they function perfectly and cost less than £30 a shot.

Got the ratchet free as the shipping was a week late.

And back in the workshop, the bench's are for repairing my RS2 bumpers on. I'd like to get the car MOT ready by the summer.

My Corrado leather interior which I have to feed and clean, only the fronts need more than one application of feed than it's ready to whack on eBay.

My adapter to a 3" down-pipe pipe.

Back in the other-side or the workshop, the boot of the 100 is vast so ideal for storing parts.

My replacement A4 engine waiting for a billet K04 which should be a straight fit, will be using a cast performance manifold.

Four of the five Boleros, once I ware the tyre's out they'll be professionally refurbished...

All the bits of A4 that have been in storage since 2018, just need to go back and find the fuel rail and injectors.

[K Simmonds]

Excuse the poor spelling and grammar, will edit this evening on my laptop

[K Simmonds]

Just had the pleasure of a quick visit from Dave, who did me a great package deal on a load of B5 A4 spares.

Also, my £75 GTX35 arrived. Don't need it right away but will come in very useful at some point when I can afford pistons and rods to convert my 2.0 block. It's oil and water cooled and brand new complete with the fitting kit still on it's bag so had to be purchased.





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[Jaswan]

Kit,

The b3 is going to be an absolute stealth rocket.

I kinda wish those turbos were about when I had my Scirocco 1.8t

ha

Jase

[K Simmonds]

That's bang on Jase, the prices for these turbo's is stupidly cheap, yet they're really good quality... I've watched a lot of independent videos on YouTube and people seem to rate them really well unless they're over driven in which case they will break. But that apply's to most turbos, apart from old KKK journal bearing units which are virtually bomb proof.

They must pay their staff in bowls of rice in the great empire run by Winnie the pooh! How they can now produce quality parts for such little money that's actually being backed up with proper testing etc is beyond me. I guess they just copy products that already exist.

I also now have a 1.8T T3 flange manifold so I can attach that GTX35 knock off in future. That's from another manufacturer but still Chinese and very tidily welded, complete with all gaskets and fittings, even a bag of a M8 exhaust nuts for £100, bargain.

I may put the S6 seats in my rat 80 as I'm cutting that car about anyway, plus the interior isn't in there to catch fire. It's a straight forward installation involving welding nuts to the under side of the seat runners.... A bit of a faff but as fitting seats from another platform goes very easy. The rest of the interior will fit the A4 rear with really quite minimal hassle. That's quite a rare car and I have hopes of spotting an affordable replacement set of seats on eBay.

I've lashed out a Sealy bumper repair kit as It seems there is no middle ground, it's either a really cheap one that will probably cause a fire and be annoying to use or the one I have which is very expensive but a really nice tool. It's been used once so I got it for less than half price, I need it to do a proper job of repairing my RS2 bumpers and will probably keep it given all cars now have plastic bumpers.

[K Simmonds]

Post erased due to it be a duplicate of the above.

[K Simmonds]

Something caused a glitch that duplicated my post...