Diy S2

[Ruffiano]

Some Motivation for me to get to work

[saltinot]

Very nice, sounds like my plan. Do you still have that RS2 Airbox kicking around? I saw you list it on audifans, I wanted to pick it up but didn't (don't) have the cash until I sell some of my other parts.

I sold the airbox, but the the fellow I sold it to says he didn't think it was going to fit on his car. I can get you his email if you are interested.

[Ruffiano]

Thanks tom, I figured out who it was. We'll see what his plans are...

So my wife has been working on her thesis, so the last couple nights I have had some free time... Made some progress on the project...

Cleaned up the head a bit, put on the water mani

Got the 7A free


Engine bay needs a serious scrub down


Also got the ABY intake manifold back, sent it to a local "shop" to have the Service Channels removed... people say it is easy to wrinkle coat...

turned out like hell... oh well. whatever.

Mock up.

[Error404]

Looking good

Whats involved in having the service channels removed in the ABY IM?

[lind4hl]

you need to cut up the manifold, cut out the piping that goes thru the manifold, weld the holes and then weld the manifold back togheter

[Error404]

Cheers - don't think i'll be doing that then, sounds like a PITA!

[lind4hl]

yep its a pita, i would rather save money for an wagner reverse or AAN..

[Error404]

my thoughts exactly

[Acidburn]

Cheers - don't think i'll be doing that then, sounds like a PITA!

Plus for the time being stick with the 3b manifold it flows better than an aby one

[Ruffiano]

you need to cut up the manifold, cut out the piping that goes thru the manifold, weld the holes and then weld the manifold back togheter

Manifold doesn't need to be "Cut", they holes are just Drilled out (large bit), it is cleaned out inside and then the holes are welded shut.

[Ruffiano]

So Today (friday) I was planning on running my car out at the salt flats however due to many things beyond my control (including my basement flooding and having to completely gut it and rebuild it) i wont make it. Last weekend I made a very diligent effort to get things wrapped up, but it just wasn't in the cards. Here are some pictures of the way it stands, it now has all four wheels on the ground and is fully converted to s2 hubs. Needs a good detail after this is all over.



Engine bay, new motor mounts from 034, street density, new s2 wiring harness, removed battery tray, 3b s2 downpipe waiting for engine...


Engine getting ready for the transplant, I need to change the front pulley, however I don't trust the engine stand with that kind of force, so we'll wait till it is in the car before wrenching on it.


Ran into problems with the Water line to the turbo, and the PS pump bracket, apparently the AAN line and ABY lines are different, now I need to figure out the solution.


Also need to figure out the vacuum lines, I found Pauls stuff on s2central, but i'm more of a picture guy... I know the ISV needs to be hooked up, not sure about the other lines, i know one is for the PVC valve...


I also scored some goodies for super good prices... Ronal R38s, mint condition, 17x8 $100!



Went to a local junkyard, and AMAZINGLY found a MINT set of Ellipsoid Headlights, now maybe this is something that is often found in Europe, however to find a set of European only headlights in a random junkyard in America... very slim chances of that...

I probably shouldn't mention the fact that I paid $30!


That is everything for now, hopefully I'll have more progress this weekend.

[H_man]

It is realy coming along now !!!! keep up the good work!!!!!

[s2_bo]

Picked up some bargains there then!! The head lights look perfect and should have cost more like $500

You can connect the water line to the turbo by using a piece of silicone hose, i think its 8mm ID. just cut a length long enough to connect one end to the banjo on the water manifold and the other to your metal pipe that leads to the turbo (not the one that goes to the DV though )

The vacuum lines connect to the following:

The one thats connected on your picture with a 'T' goes to the FPR one end and to the ECU / via moisture trap on the other end.
The large hole is for the ISV and the other gold nipple goes to the rear diff and air con via a one way valve / 'T' piece.

The one at the front of the manifold goes to the DV
The one on the angle thats slightly bigger goes to the PVC valve.

The above is from memory so i could be wrong about it but should give you an idea.

Nice project!

[Ruffiano]

Thanks for the advice on the water line, sounds like a good option, i find a flaring tool so the hoes stays where it should. Thanks for the vacuum help as well, clears it up nicely.

Where do most people tap for a boost gauge? Seems like most "t" the line that goes to the ECU.

[Ruffiano]