S2 ABY 400cv Project

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  • javispa
    S2Forum Addict
    • Jul 2007
    • 292
    • Country: Spain

    #16
    Once decided to rebuild the engine, the best thing was to buy good stuff to make it reliable.
    The first thing to come were the rods, which came from Hungary, from our friend Aronmatic.
    Attached Files
    Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

    Comment

    • javispa
      S2Forum Addict
      • Jul 2007
      • 292
      • Country: Spain

      #17
      More bits to come... from USA:

      - JE pistons, 81,5mm bore, 8,5:1 compression ratio.
      - Ferrea titanium valves.
      Attached Files
      Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

      Comment

      • javispa
        S2Forum Addict
        • Jul 2007
        • 292
        • Country: Spain

        #18
        The next step... strip the engine and take it to the machinery. The original pistons and rods didn't seem to be that bad:
        They may be used in a future 1,8 16V Turbo Golf II... probably with a S2 turbo...
        Attached Files
        Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

        Comment

        • javispa
          S2Forum Addict
          • Jul 2007
          • 292
          • Country: Spain

          #19
          Meanwhile we had time to take te car for a bath . The washing is next to the mechanic where the car is. These meetings of friends, while the car was being done, were fun and helped to let the time pass faster.
          On the first picture there is Ferni308, who is doing most of the work on this car. A really good friend. His car is almost finished and now he is building Kilian's.
          Attached Files
          Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

          Comment

          • javispa
            S2Forum Addict
            • Jul 2007
            • 292
            • Country: Spain

            #20
            The block was bored to fit the new 81,5mm bore pistons.
            Attached Files
            Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

            Comment

            • javispa
              S2Forum Addict
              • Jul 2007
              • 292
              • Country: Spain

              #21
              The crank was checked. It was okay.
              Then, it was balanced to zero, lightned and sharped. I think the job done to the crank is very good. As the car will be for street use, we didn't want to lighten too much. This is why the flywheel has only been balanced.
              Just the lighthened crank and the lighter rods and pistons should be more than enough.
              The result is this:
              Attached Files
              Last edited by javispa; 7 June 2009, 22:04.
              Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

              Comment

              • javispa
                S2Forum Addict
                • Jul 2007
                • 292
                • Country: Spain

                #22
                A RS2 campulley was also bought. The car will be running a RS2 ECU with chipset for RS2.
                Here is a picture of the campulley with the rods.
                Attached Files
                Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

                Comment

                • javispa
                  S2Forum Addict
                  • Jul 2007
                  • 292
                  • Country: Spain

                  #23
                  Some more pictures I found of the bits that the car will be running.
                  K27 turbo, Avus V-Max wheels, Blow-off valve.
                  Attached Files
                  Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

                  Comment

                  • javispa
                    S2Forum Addict
                    • Jul 2007
                    • 292
                    • Country: Spain

                    #24
                    All the bits put together, before going inside the engine. With the bits, our friend Ferni308.
                    The clutch is a Techniclutch reinforced paddle unit for 3B engine. The car, as I said before, will be running 3B flywheel.
                    On the second picture, piston and rod meeting each other before going inside the engine.
                    I like this two pictures very much.
                    Attached Files
                    Last edited by javispa; 7 June 2009, 22:27.
                    Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

                    Comment

                    • javispa
                      S2Forum Addict
                      • Jul 2007
                      • 292
                      • Country: Spain

                      #25
                      Block and head done. I think the job is very good, specially the head. It has the new valves fitted, ports widened, valve guides skimmed (not too much), exhaust port polished and inlet polished but not that much. Unfortunately I only have this picture of the head .
                      The block, as I said, is bored to 81,5mm, skimmed and mounts new oil and water pump. It has also been painted.
                      Attached Files
                      Last edited by javispa; 7 June 2009, 22:32.
                      Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

                      Comment

                      • javispa
                        S2Forum Addict
                        • Jul 2007
                        • 292
                        • Country: Spain

                        #26
                        Before closing the engine, a video of what will be impossible to see once closed:



                        It is a good way to exercise the arm.
                        Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

                        Comment

                        • Knight Rider S4
                          S2Forum Possessed
                          • Mar 2005
                          • 3541
                          • Country: Scotland

                          #27
                          Originally posted by javispa
                          All the bits put together, before going inside the engine. With the bits, our friend Ferni308.
                          The clutch is a Techniclutch reinforced paddle unit for 3B engine. The car, as I said before, will be running 3B flywheel.
                          On the second picture, piston and rod meeting each other before going inside the engine.
                          I like this two pictures very much.

                          I would be very careful using that !!...I do not rate them for high power ...very cheap for a reason I found out !
                          93 S2 Avant Parting
                          91 URQ RR
                          02 A4 tdi Avant

                          Comment

                          • javispa
                            S2Forum Addict
                            • Jul 2007
                            • 292
                            • Country: Spain

                            #28
                            Well... for the moment these are the last pictures I have. The engine closed and ready to be fit in the car. It has been cleaned with ultranoise.
                            I have some pictures of the clucth but I do not have them here. I will post them some other time. I also will keep you updated with the car's evolution. We hope it will not take too long to see her running.
                            Cheers and thank you for visiting this thread.
                            Attached Files
                            Last edited by javispa; 7 June 2009, 22:54.
                            Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

                            Comment

                            • javispa
                              S2Forum Addict
                              • Jul 2007
                              • 292
                              • Country: Spain

                              #29
                              Originally posted by Knight Rider S4
                              I would be very careful using that !!...I do not rate them for high power ...very cheap for a reason I found out !
                              Thanks for the advice. The fact is that the clutch was originally mine, but Kilian was willing to ride the car and he got it. The idea was to change the paddle and instead of it use a reinforced organic disc that a local speciallist would provide us.
                              We are still in time to do that but the owner is very anxious to have the car allthough the car will not be running many miles a year. I will tell him and see what we do.
                              Cheers.
                              Audi Coupé S2 '92 -- VW Golf 2 GTI '91 (v2) -- Renault 4 TL '84 -- Audi 100 2,3E '92 (Dad's) -- Suzuki SV 650 S '08

                              Comment

                              • Bram
                                S2Forum Fiend
                                • Aug 2006
                                • 2582
                                • Country: Netherlands

                                #30
                                WHy do you choose to run a RS2 setup with a K27 turbo? That RS2 ECU software is not optimized for the other turbo. Better get a custom map.

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