Transformation of pleasant family car to politically incorrect monster

[gedu]

Well, from what I gathered in that thread, mechanical side of engine fitting should be plug and play?

Electrics will cause a lot of work. I'm going to use "mix-and-match" sensors from AAN and AGB. ECU won't be OEM, so it won't cause problems with things, original ABS works without OEM ECU, that I do know

[Acidburn]

This guys fitted a supercharged 30v and might be of use to you

http://audifans.net/modules.php?name=Forums&file=viewtopic&t=26067

look forward to hearing how you get on.

[gedu]

Well, engine mount arms from AAH engine fit into block nicely, I will however do test fit before block goes to machine shop. I have gathered that B5 AAH block is indeed same as in 30valve N/A. we'll see, if it's the same block

Oh and C4 chassis AAH engine mount arms have slots for engine to move fore/aft 1-2cm

[Acidburn]

Is it mounted now in the engine bay? (or was it at some point?) did you have to do much work to get it to fit?

[gedu]

Hehee, well, haven't been able to do much. Heads are dismantled, bottom end needs to come apart. We'll see if block is in shape, previous owner didn't seem to bother put storage oil into cylinders, so a shade of rust inside (not too bad though), all debris is more likely the problem. Good I didn't just lift engine into place do plumping and start it...

Weekend 2 weeks away I have reserved for dismantling. After that all things are going to machine shop along with new cams and rods. Balancing act is going to be done, I want over 1000rpm more than stock rev limit allows (new valve springs and titanium retainers are also going to be installed)

[Acidburn]

First time i've seen them rims in 5 stud looked good when I had a set on my old tdi in 4 stud.

Have you done anymore with this

[gedu]

Brake pr0n

There you go, pic of my brakes.

All tubes and flanges for exhaust manifolds are in my hands... Still need to clean up my apartment to rent it out to make ends meet, and need to fix up daily "beater", pic of that too attached.

[gedu]

Right, long time, no update. In last 8 weeks, I have moved from being single to being a father figure for a 4year old boy and other things that make a family Also a daily-driver has been bought, 100q avant, 12valve 2.8l V6 with slushbox (why you ask? well, basically I wanted a car that just can't be power upgraded)

Also as with seems to be norm in my projects, things got out of hand, again. New rods, new cams, cam springs and spring retainers have been delivered. 342x34mm 4piston monoblok brakes up front are on order. Singlemass steel fw and SRE clutch with organic disk have been delivered, why organic disk? Well, I think I'll rather live with organic disk when car will see occasional "daily" use. If it can't take full boost, then it can't and boost will be lower

I'm missing 1 tool (at my old post office most likely), loads of pipework, hoses, loads of machine shop love, oil-cooler and intercooler. Haven't even had the time to measure width for IC. Radiator and IC will be tilted forwards and suitable placement for vent holes in bonnet will be cut. Oil cooler will sit in urs4 stock IC location in front of left front wheel, on right side will be reservation for gearbox cooler. Why all this cooling you ask? even though Finland isn't known for high temperatures I want to be able to run this beast on track, even on those hot days, without overheating

Next steps wont be taken before I manage to rent out my appartment, and can schedule time from missus and boy for continuing this project.

[gedu]

48h after ordering, 10 timezones and through customs. Oh, and of course Mistress of Inspection was satisfied with goods

[gedu]

Couldn't justify $250 more for 28RS compared to 28R, so 2* GT2560R and flanges on the way. Engine mounts to body were delivered yesterday and spacer to be fitted between engine and gearbox is on the way. Why spacer? Decided to take all available space to run downpipes from engine bay to underside. Left hand turbo will need some planning, as there is ABS and all kinds of things in the way. Right hand side is quite straight forward, as there just isn't anything right now

B5 S4 exhaust seems mostly usable, only need to redesign it's hang arms to mount it to C4 chassis.

Intake will most likely be fabricated with single filter, intake on right hand side, where stock airbox used to live. Pressure sides of turbos will be combined before IC and plumbed to IC from same side as filter.

Routing from IC to throttlebody is still under think cap, there just doesn't seem to be room to run it from "stock" location to throttlebody in sufficient size. Still thinking between BOV/By-pass options, breather assy is still only in my head, different options running amok.

IC will be "as large" as possible, don't have any idea how deep I can go, until I have everything mocked up. There should be room for at least 3" deep maybe 4"

[gedu]

Some calculations

Right, used spreadsheet from here (don't remember who did that originally). Used it to first to approximate VE for stock engine with stock boost and AFR (Lambda 1, unless EGT rises above 980C, then fuel is literally poured in). After that started recalculating with GT28RS compressor map... Only thing that isn't taken care in that calculation is waking those potatoes up, dunno how 1,35 liters per turbo is going to work

Oh, and some shiney new parts came:

[gedu]

Yeah, those h-beam rods are now sold. set of 5, in the end I had 3 sets of h-beam rods for i5

[Bram]

At first I thought these H-beams conrods on the left on your picture were tools, but once I looked better I saw they are internal engine "tools" That's why I asked.

[gedu]

Nope, only exhaust manifolds and inlet tract are getting some sweet love this round. Need to MOT it at stock power level

Some gaskets need to be changed, as there are oil gunk around the engine. Will measure compression once I have it fitted into engine bay and can turn it over with starter.

[Bram]

The project continues.......

Did any upgrades on the engine itself?