Transformation of pleasant family car to politically incorrect monster

[gedu]

Damn, Damn, F***!

Block is broken . On other news, now I have perfect reason to "upgrade" to 2.7tt engine

Will try to catch my block to take pictures of it, I left it at the machine shop, scrap metal doesn't pay anymore

[A80Avant]

im sorry to hear that...how did you manage to do all this damage??

[gedu]

I really have no idea. Most likely I have f'd-up when assembling it all back together

[quattro20v]

Hmm, i was wondering why you are selling all the parts.

Really sorry to hear this, hope you get new engine in soon.

[gedu]

I has a new engine!



Exhaust bits are on the way to me (originally for b5 s4, will see what they need for fitment). Turbos are going to be a pair of GT28RS. ECU is on the way, decided to go with tatech this time, as I wanted an ECU that control all aspects of engine already (variable valve timing, electronic throttle and such). Bought b5 s4 gas pedal with sender also, will see what needs to be done to mount it

PS: engine is just stored in engine bay out of way, not properly mounted

[Bram]

The project continues.......

Did any upgrades on the engine itself?

[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]

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]

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

[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]

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]

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

[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]

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.

[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