3b s2 coupe resurrection

[Error404]

Result!

[andy10v]

Glad you got it sorted

Result!

Thanks guys

Totally back in love with the car again, its soo much fun to drive!

New tyres, oil cooler and oil, sort the MFTS and then going to enjoy her for a bit before I start modifying again.

[irishs2]

I am smiling here to myself at the news. Good job.

[newsh]

Now drives beautifully, silky smooth, progressive and quite insanely fast

Awesome!

[newsh]

Damn, I want my coupe working properly again now

[K Simmonds]

Really please you've got her going properly, it a seriously rapid set up in a light weight car!

AFR's sound much the same as mine

What are the EGT's like? Mine are between 400 and 600 C on everything bar WOT where it creeps up to the low 700's.

[andy10v]

Damn, I want my coupe working properly again now

What are you planning on doing next?

[andy10v]

Really please you've got her going properly, it a seriously rapid set up in a light weight car!

AFR's sound much the same as mine

What are the EGT's like? Mine are between 400 and 600 C on everything bar WOT where it creeps up to the low 700's.

Cheers

Yup, its taking a bit of getting used to, after a rolly polly tdi

Need to check EGT on long boost pull, 400ish cruising at low speed, glanced at it a few times on boost, and it was climbing, but as per "normal", 600-700ish iirc.

[newsh]

Damn, I want my coupe working properly again now

What are you planning on doing next?

I need to get it mapped, the injectors are not fuelling as expected so it's not running right, lean on idle so it stalls when you dip the clutch, ok on boost up to a bar then going rich. So I'm going to fit RS2 injectors and software for the time being and be careful with the loud pedal. Then when Dmitri gets over here it can be mapped properly.

[andy10v]

Do you know when he is coming again?

[newsh]

Nope

[andy10v]

Managed to use 3/4 of a tank in the last two days without incident.

This morning blew another boost hose off on they way to Knockhill, Mikalor clamp onto the aluminium boost pipes. Drove to Knockhill with the MAF unplugged, and luckily there was a Turbosmart stall I could buy a clamp from, and borrow a ratchet (no tools in the car ).

Fancy jubilee type clamp, spring round the outside for tension, two pressure rings on the inside for clamping force, rather than spreading the load out like the wider Mikalor, so less likely to slip.



Also chucked on an old foglight I made into an air intake ages ago for a bit of fun



So I really need to add beads to the end of my intake pipes, or apply an adhesive to stop them slipping.

[newsh]

Untill you can get them swaged, rough the metal up with some coarse sandpaper and wash with brake cleaner before reassembling.

[andy10v]

Thanks for the tip.

Each time a hose blew off, it was never an OEM connection (swaged), always the silicone/alloy joints on the home made intake (straight).

So.... 1 pair of broken molegrips and two six inch nails later (plus the obligatory hammering, grinding, welding, filing, sawing and sanding)

DIY swaging tool



Filed the groove in the upper jaw first (teeth ground off so flat and does not mark pipe), then clamped the nail in the groove with the grips. Welded the nail into the lower jaw (that way it lines up perfectly). Cut off the ends of the nail, and tapered each side so only a small centre section was still full height. The long nail welded on is a depth stop so the swage is the same distance from the end of the pipe each time, nice and easy to go round. Sanded the contact points smooth so as not to mark the pipe.

Testing on an old intake pipe



Seems to work ok



So went onto my actual intake piping

Before



After



I had 8 pipes to do at each end, so got a good hand workout!

All washed inside and out with disc brake cleaner. Alos decided to try something we used to do with bike grips; sprayed with hair spray, slides on easily, and dries sticky for a bit of extra friction.

Took her out for a quick spin and she if flying again.

I think I had developed a slight boost leak before the hose blew off, she was not pulling as savagely as now, and had the occasional slight hesitation.

[irishs2]

Very clever. I like it