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6 monthly update 
I have been manic busy this year working flat out and trying to start my own business.
The car has taken a bit of a back seat. I did have ambitions to get to ADI but when that looked impossible back in August, I haven't really touched the car since then.
So a few little updates as it slowly comes together. Unfortunately I have lost a load of pics with a damaged phone so pics of progress are sporadic & apologies for the quality of some
Machined a bolt-on v-band wastegate adapter for the Wagner manifold. Designed for a Turbosmart Compgate:
With that I was able to install the turbo & start some plumbing. Air filter mock-up - looks like I will be able to use this AEM unit without cutting the inner wing. I will make a composite airbox/heatshield for it.
Downpipe modified to suit the larger hotside & new wastegate:
I am adding various sensors to suit the capabilities of the MaxxECU - Bosch NTC for oil temp and Honeywell PX2 pressure transducers for the fuel & oil pressure. I already machined a stainless 1/8NPT adapter for the M16 port on the block. A PX2 sensor replaces the factory 1.8bar pressure switch. An output from the ECU is fed to the dash to trigger the oil pressure warning.
The low pressure trigger is mapped against RPM and temperature and also configured to limit RPM or stop the engine if necessary. Likewise for oil temperature, a Bosch NTC temperature sensor is fitted to the sump and engine RPM & load is limited by oil temperature. Finally I machined an 1/8NPT boss which I welded to the fuel rail to add a PX2 sensor for fuel pressure. The ECU is configured to track live fuel pressure rather than a fixed rising rate enabling more accurate fueling, and fail-safes for low fuel pressure due to mechanical failure.
All connected up with some MILspec wiring - Spec 55, DR-25, ATUM etc.
I am using an RS3 e-throttle. I didn't want to cut & weld the Wagner intake to fit it so I have machined an adapter to mount it:
I am also using the alloy elbow from the RS3 / TT-RS - this includes provision for a Bosch TMAP sensor to replace the old PTC sensor that Motronic uses on the intake manifold. These sensors have better resolution than the OEM sensor and are cheaper and commercially available. The RS3/TT-RS as stock use an e-bypass valve which is cast into the intake elbow, but it is too small for the desired air mass as well as being in an awkward place to plumb in as I have AC/Climate.
So I chopped it off and welded the hole up. The position still needs a slight tweak but will marry up nicely to the Wagner intercooler.
Ironically I havn't got a coil harness for my car so will need to make one next. Then I can get the rest of the plumbing done and fire the car up so I can take it outside for a clean.
Before anyone asks I borrowed the fitting from work and I have no idea who Nick is.
That's it for now
I have been manic busy this year working flat out and trying to start my own business.
The car has taken a bit of a back seat. I did have ambitions to get to ADI but when that looked impossible back in August, I haven't really touched the car since then.
So a few little updates as it slowly comes together. Unfortunately I have lost a load of pics with a damaged phone so pics of progress are sporadic & apologies for the quality of some
Machined a bolt-on v-band wastegate adapter for the Wagner manifold. Designed for a Turbosmart Compgate:
With that I was able to install the turbo & start some plumbing. Air filter mock-up - looks like I will be able to use this AEM unit without cutting the inner wing. I will make a composite airbox/heatshield for it.
Downpipe modified to suit the larger hotside & new wastegate:
I am adding various sensors to suit the capabilities of the MaxxECU - Bosch NTC for oil temp and Honeywell PX2 pressure transducers for the fuel & oil pressure. I already machined a stainless 1/8NPT adapter for the M16 port on the block. A PX2 sensor replaces the factory 1.8bar pressure switch. An output from the ECU is fed to the dash to trigger the oil pressure warning.
The low pressure trigger is mapped against RPM and temperature and also configured to limit RPM or stop the engine if necessary. Likewise for oil temperature, a Bosch NTC temperature sensor is fitted to the sump and engine RPM & load is limited by oil temperature. Finally I machined an 1/8NPT boss which I welded to the fuel rail to add a PX2 sensor for fuel pressure. The ECU is configured to track live fuel pressure rather than a fixed rising rate enabling more accurate fueling, and fail-safes for low fuel pressure due to mechanical failure.
All connected up with some MILspec wiring - Spec 55, DR-25, ATUM etc.
I am using an RS3 e-throttle. I didn't want to cut & weld the Wagner intake to fit it so I have machined an adapter to mount it:
I am also using the alloy elbow from the RS3 / TT-RS - this includes provision for a Bosch TMAP sensor to replace the old PTC sensor that Motronic uses on the intake manifold. These sensors have better resolution than the OEM sensor and are cheaper and commercially available. The RS3/TT-RS as stock use an e-bypass valve which is cast into the intake elbow, but it is too small for the desired air mass as well as being in an awkward place to plumb in as I have AC/Climate.
So I chopped it off and welded the hole up. The position still needs a slight tweak but will marry up nicely to the Wagner intercooler.
Ironically I havn't got a coil harness for my car so will need to make one next. Then I can get the rest of the plumbing done and fire the car up so I can take it outside for a clean.
Before anyone asks I borrowed the fitting from work and I have no idea who Nick is.
That's it for now
Nice work, if you ever think of selling the car put me on what would probably be a long list of potentisl buyers
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