B3 Coupe quattro 32V V8

[bluequattro]

B4 bonnet and slam panels

[Kieron20V]

Both heads built now, cams timed and fitted new water pump, thermostat and tensioner pulleys with new belt. Given the Belt covers a quick refresh with some matt black too as they were a bit tatty.

Thrown the alternator back on after giving the idler bearing a clean and regrease as it sounded rough as ****holes and audi want £80 for one as its part of the housing too, cant just press it out and fit a new one.

My engine stand is looking a little strained, got some serious lean going on. Bought an engine crane so I can get it off the stand and get the flywheel off to do the rear seal and start knocking the exhaust together.
Need to refit oil filter plumbing today to see what room ive got to work with then I can begin.

Picture dump for anyone that cares.

[Error404]

Very tidy, I like the red cam covers
Is that alternator water cooled? Whats the rough weight on the V8 then mate?

[andy10v]

Timing belt looks fun!

Picture dump for anyone that cares.

Keep them coming, I am enjoying reading/looking, just dont really have anything to contribute.

[Kieron20V]

Not sure on weight exactly, think someone posted on motorgeek a while back that it was roughly the same as a 5 cylinder including turbo and manifold etc. Not sure how far from the truth that is.

Got my engine crane today, so its come off the stand now and ive taken the flywheel off and changed the rear crank seal. For refit I need to make sure the runout is ok as there is no centring between the crank and flexplate. To do this ive had to rig up the starter on some jump leads to turn it over and will adjust it by eye tomorrow when the battery has recovered. Had it turned over today for a bit until I could see oil pressure, or rather the low old pressure switch went off, so im happy now at least the engine is primed a bit and lubed up inside.

Also made a start on the turbo oil fittings, done the return flange and need to finish the supply and find some suitable gaskets. Also going to make a start on the downpipe, just joining the flange to a v-band.

[Kieron20V]

Alex, no alternator isnt water cooled, its from an A8 and I also ran it on an A4 I had for a while after it packed up. It did have a duct and shroud for an air guide on the A8 but I had to cut it off to fit.


Since last update:

Changed rear crank seal.



Installed flywheel/flexplate adaptor and trued it up checking run-out.



Started some welding,

Turbo oil drain flange -10AN



I put the box and engine together too just to make sure there wasnt any issues there and to check out what I need to do to get a working crank sensor. The Allroad one that came with the box doesnt have enough depth strangely, and the butchered 7A one I was running on the CBL box is too long. So need to make an adaptor to get something to work or find a universal one to fit.



I'm also going to try and use the stock S2 shift linkage, this later 01E doesnt have all the bolting provisions for the top cradle part of the linkage to bolt onto, It will need 1 hole drilling and tapping in the gearbox and some sort of bracket to join up another but should be doable. I was going to get the newer style b5/b6 linkage and adapt that, but going to try this first for simplicity sake. If I dont like it it wont be hard to sell it on anyway and the A6 linkage is cheap.

I was hoping to have a lot more welding done by now, Ive borrowed my old mans Tig but it keeps crapping out on me, the trigger keeps inverting and sometimes wont arc up at all. Really annoying when it decided the trigger is an off switch as your pulling away, made some right mess. Probably going to splash out an an AC/DC Tig set, investment for the future, got an inlet manifold to make later...

Ive made the bits to do the turbine inlet merge keeping it divided.

Tubing is 2", crushed and then cut at an angle to meet the divide and sits pretty good over the inlets, will just tidy up the ports to smooth it out when its finished.

Its not quite symmetrical I know, but it'll work.







All for now, until I have a working welder again. I can fit the clutch in the meantime, and I need to go back to the car and put the front subframe and suspension back on to get the car moved.

[V6quattro]

Is that a flywheel insert from 034? How do you like it?

[Kieron20V]

Is that a flywheel insert from 034? How do you like it?

It does what it needs to so cant grumble on that and its fairly cheap, easier to source than a manual S8 flywheel and cheaper than having one made, but like most things 034 it needed some machining to fit properly.


Ive just splashed out and bought an R-tech 160 AC/DC set. So ill probably be in the garage all weekend now.

[Error404]

[RS2]

How is the project coming along?

MG

[Kieron20V]

How is the project coming along?

MG

Funnily enough I was going to update the thread tonight, just uploading some photos.

Clutch refitted, and gearbox now back on.



Found a solution for the crank sensor, with the spacer the allroad box came with on the sensor removed and a little trimming on the sensor body itself (plastic ring for an oring) the allroad sensor ends up with around a 40thou air gap which is pretty much spot on.

Only issue is the sensor uses a newer style 3 pin plug so ill have to modify my engine harness, but no biggies as the pins should just swap into the new style housing. I'll post a pic when I get it later in the week to show what I mean.


Ive taken a bit of a gamble and started working on the turbo pipework. Studies lots of photos ive taken and I hope I can get away with this placement. Nothings more than tacked for now anyway, and i'm just playing with the bits ive got to see what I can do.


Turbo flange is braced directly to the passenger side manifold and i'll add a brace to the valve cover when I've ordered some rod ends.







Started welding the downpipe flange too but ive run out of gas.



Gonna pick up some more argon tomorrow hopefully and get some more done, but its all happening now.

Welds arent too pretty as im getting used to my new machine but getting better each time.

[Kieron20V]

So, ive welded in the outlet from the passenger side manifold and tacked up the run to the turbo flange from there. Its only tacked for now as I need to get it in the car to make sure it clears, but ive looked at as many photos as I can find of around there and it should be ok, its the rear inlet thats going to be tricky to miss the engine mount, will be pretty tight round there.








So next job is to get everything back up to the barn where my car is and see how it all fits together. I think clearance above the gearbox will be tight to due to the steering rack and arms, but should be okay provided I can get the plumbing routed high enough, but still need to keep some space for the downpipe which will be 3.5".


Next update wont be for a while as i'm working and wont have chance to move the engine up there for a few weeks.


Kieron.

[K Simmonds]

Much like Andy I enjoy reading your updates but don't have a lot of use to contribute, your TIG work looks pretty bloody good mate, perfection is a worthy goal though.

This thing is going to be wild once you getting it running and mapped up!

[Kieron20V]

Bad news, won't fit there. Good job it's only tacked for now.

I've chucked front subrsme back on along with the suspension and wheels so I can get it back on the deck and on my driveway sometime soon so no more guesswork.

[my2000apb]

who makes the double boxed/ratcheting wrenchs?
thanks