sjw185 aby to rs2

[Vorsprung durch Technik]

Loving the superb update, garage with wall art and that rather awesome stacker.
Jeez how i wish i had one. If i could ask where did you get the B4 saloon poster
from and are the 2 post lifters as expensive as i imagine?

Still got your rear bumper.

[Michael S2]

Worth the wait for an update. Great work as usual

[sjw185]

Yea still got your old turbo Will be changing for something bigger soon.

Here is another picture of the cooler I found. Ended up using aftermarket hoses as one of my original hoses had damaged threads.

[piotr]

Very impressive

[Jonas_R]

Wow. Build really coming along and you still have the hybrid turbo

Do you have more pics of the oil cooler?

[sjw185]

…………………………….Over a year later!

I did finished refurbishing the front subframe and fitting forged wishbones with powerflex bushes.
Installed solid subframe and gearbox mounts and and got it all aligned.
I fear adding the solid subframe mounts to the already solid engine was a bridge too far

Last year was looking to change out my turbo for a RS2 unit.
After missing out on a few and looking at billet RS2 I ended up getting a Borg Warner 6758 kit from Marc at EFI express.

I also had a second ABY engine I picked up locally from another forum member stored in the garage with the intention of rebuilding myself.

After looking at it for a year on the engine stand and moving it around the garage.
I gave Danny at DNA a call when I seen his I5 builds and crated up engine to send for a rebuild.

Then Andy10v was selling a rolling shell and I thought I should rescue it.

With money spent and all these parts doing nothing it was time to formulate a plan.
Originally my plan was to rebuild the engine for my S2 to go for a 450hp goal but with the purchase of the 3b shell the plan changed.
I was thinking to install rebuilt engine from DNA into the 3b shell but with no MOT and history of wiring gremlins I decided it would be better to fit into ABY so I could run the engine in properly without risk of starting problems.
I started to assemble rebuilt engine with reverse manifold and EFR turbo, but with parts missing for ISV, power steering pump issues and downpipe fabrication I was going no where fast.

I decided to assemble rebuilt engine with my original RS2 Hybrid setup until run in.

So plan B
Fit new engine to ABY with Hybrid RS2 setup and run in.
Fit Vacuum brake setup to 3b
Clean up original removed ABY engine
Paint block and fit to 3b with Wagner reverse setup with EFR Turbo.
Fabricate downpipe.


Spare ABY



S2s face to face



Now with prices on the increase and the Coupe becoming a rare beast I am keen to return the ABY to OEM as I have the 3b to go crazy on.
Thinking over time I will be removing solid bushings from ABY and keeping as OEM+ comfortable cruiser.

3b cage



S2s Stacked



Posters and billy bass





Rs2/Wagner intercooler comparison



Engine Crate for DNA



Engine Build at DNA











Original ABY Engine ready to remove



Engine coming oot
Lift was really handy just lifted up and pushed car back.



Mul engine oot



Crusty block
Its only once you get an engine out of a quite respectable car you can see over the years how crusty its becomes down there and around the back.




Rebuilt ABY engine from DNA



New engine removed from crate







Having some fun throwing parts together







AnLe Gearbox mount



Vidar Skotheim Oil cooler AnLe engine mount



Machined ABY coil cover and K24R catchtanks

[sjw185]

Yea hopefully see big change when I get it back on the road.
Got to clean up the brakes and fit DS2500 pads not impressed with my brakes even after fluid change. going to get braided lines on rear as well.

[andy10v]

That should tighten the front end up nicely.

[sjw185]

Front Subframe Refurb

S2 Back on stands.
Front subframe time, Been putting it off for a while.
Collected a lot of parts have had forged wishbones for years.
Going for a clean up and paint with POR15 then solid subframe mounts and poly wishbones bushes.
Need to get this done before i can renew MOT.





I found removal was a lot easier that the rear subframe all bolts came out ok, wishbone and subframe bushes looked pretty bad so I'm hoping for a rear improvement.




Used the blowtorch method then pushed the centres out with the puller.
Used a socket to knock the sleeves out.





Some wire brushing and chipping its starting to look better.
Using blue steel as a primer to kill the rust.
Going to have a go with the wire cup next to finished it off.

[andy10v]

That would be nice, would you try and get a non sunroof head liner or make one?

I did look at that carbon panel, it is a lot for glue on patch though.

Flocked trims would look tidy, Andyp sprayed his black and that was a big improvement over the stock cream.

[sjw185]

Was thinking to go to hard lines and a good quality short flexible line just to try and get best from my brake setup. I know they can be a pain but when i bought my long flexible lines they came without stainless steel ends so was going to change them out as they are looking a bit corroded now.

Will start with fabricating a low subframe but if I take out the sunroof I quite fancy doing a proper job with carbon roof panel that Paul s2 central was looking at.
Think it would look quite cool with the carbon B pillars.
I would then fit a new head liner and maybe flocked pillar trims for a nice finish

http://www.lwsdesign.co.uk/product.php?product_id=171

[andy10v]

Sounds like that should sharpen things up a fair bit.

RS2 solid pipes to the calipers are a pain when you want to work on stuff, I am going to switch from hardlines to flexis.

Seat down and sunroof out is the way forward! Is your car not a bit nice for ripping the sunroof out though?

You could get a cheap recaro or similar from ebay or gumtree, a bit of box section and flat bar on a spare seat subframe or make from scratch will really improve the headroom.

[sjw185]

So whats next on the mod list

Dont know how I missed this post?
Going to remove front subframe and refurb.
I have solid subframe mounts and forged arms with powerflex to fit.
Got some DS2500 pads to fit on the front brakes, Im thinking to replace my aging flexible lines to the front calipers with solid pipes and small flexy hose as RS2.
Gotta do something about my seating position, going to get a subframe knocked up to get me a lower seating position.
Also think im gonna launch the sunroof mechanism
Buy some new tyres for the RXs and get back to Knockhill

[andy10v]

So whats next on the mod list

Another couple of pictures;

[sjw185]

Looks like you had fun, did the car behave?

Car was good but fitted old tyres that didn't give be much confidence.
Had the back end coming round to meet me a few times
Good learning experience though
Got some passenger laps in Martins 90 very impressed by the car and grip in the pouring rain

cheers

Steve