My AAN 2.2 20v Turbo B5 A4 Avant build

[djh]

cool get it fitted

[Sleeper_Avant]

need welding gas etc

just sold a galaxy tab so the cash is going into a grinder, drill, extension lead and some Argon hopefuly!

then i can get the engine and box mounts fab`d up too, taking far far to long now, not happy!

[Sleeper_Avant]

right, still got no gas.......................... DOH!

but,
tidied up garage so i can move, much better.

Wiring, DONE!!
eventually got it all chopped out that isnt used (looms are still in doors but will just unclip, no big deal as i will sell these)
look at how much isnt used, weighs a lot too, hopefully scrap man give me a few quids for it



wiring hidden behind support brace, needs a bit more tidying once i have spliced my loom got the 6 gauges (no instrument cluster or dash being used)







rear section of loom all done, loom taped up and put in a bag out of harms way





Tomorow, i think i will get some conduit, finish the inside of the wiring altogether and mount my gauges on the support brace, will get some pics of them all lit up.

still using my Greddy 270degree sweep gauges, white faced......... like this


More thrilling installments tomorow kids!

[djh]

looking good

[Sleeper_Avant]

Right then, this is how today went.............

was up early (6am) so went to my garage before work to fiddle with my gauges and see what wiring i needed.

i have:
boost
exh temp
water temp
oil pressure
fuel pressure

need a few little bulbs for them, not faulty wiring which is good. (will try to get super bright blue LED`s and see if they light up like mk4 golfs/passats!)
oh and they are HKS ones not Greddy! that was my old boost gauge, DOH!!

**incidently, these came out of a very famous record breaking R33GTR skyline i broke for parts, as did the 12mm INTERNAL ID fuel lines and a few carbon fiber odds and sods on my A4 if you look hard........ **




then i thaught id push the car outside, spin it round 180degrees and push it back in to dummy mount the engine and gearbox for space...........

one of the wheels snapped off! FFFFFFFFFFFFFF%^&%$




so i had to literaly drag it round with a tow rope, nudging it with the Quattro like a fork truck lol
then dragged it backwards with the quattro into the garage, so now i cant get it back out untill the A4 can be rolled out, damn, but makes me hurry up lol!




so i finished swearing and sweating from manhandling the sodding A4 and broken dolly,
got the car up on stands on the super-level floor



then i set about putting the dummy block, and gearbox on pallets to see what the fit was like how i wanted it.........

the reason i used pallets as i want it as low as possible, and the pallets touch the floor, flush, so the engine/box are level with the floor!
easy and simple, fits perfectly (just hope the subframe fits the engine, will find out when i make the mountings at the end of the month)

lots of pics now





then i remembered the I5`s sit on an angle, so decided to build it up from a few "spares" i have lying arround now!



























looks like an off the shelf manifold wont fit now either, neither will a standard AAN one!




this is difference between 7a, AAN and 3b can cover heights, theres a lot of height in an AAN one!




driveshaft angle is far too harsh to even consider keeping at a Quattro, **** yeah! RWD all the way lol

[Acidburn]

getting there, when do you reckon it will be running next?

[Sleeper_Avant]

this was the engine while i ran quattro the 1st time,
cam cover was touching the bonnet and i had to bend the grille/bonnet up to clear the cam pulley, thats how close it all was!!!!!!

before:





after:






you can see where i had to cut the bonnet support, look how much room i have now!

[Sleeper_Avant]

this also means, i can fit a standard front pannel, and do away with the race look bonnet catches.............

might be able to fit STD radiator, this would be excelent also!

much more plans hatching in my head seeing how much room i have freed up

chuffed to bits i really am!

[Sleeper_Avant]

i MUST have the car running under its own steam in 4 or 5 months as im not renewing the lease on the workshop or my flat.

will be looking for a house or bungalow with a single garage, the 80 quattro is gonna have to go before then too

spec will be:

cheap pikey GT40 turbo
440cc injectors
minimal boost, probebly just 1bar ( honestly!)
funky exhaust manifold to fit the chassis
3 or 3.5inch turbo back side exit exhaust
100% standard engine and AAN ECU

do a few trackdays and next year fit the "phase 2" spec JNL Racing engine

[Sleeper_Avant]

todays thrilling installment....................

not a great deal,

trapped my thumb nail so left in a huff lol!

anyway,

mocked up subframe and antiroll bars on the front.......... does NOT fit, i remember why i mounted it the way i did last time round........

so im chopping the centre of the subframe right out, you cant see my pen marks so i made the line with a brush handle lol

basicaly in line with the 2 gearbox mount holes

started mocking templates up to get the engine mount to chassis plates laser cut,

and a little sketch on the windscreen so old goldfish upstairs dont forget lol







this is what i will be making the engine and gearbox mounts look like:

engine:
(basicaly mk1/2 escort WC X/member bushes and mounts, mounted to chassis)


gearbox:
will TRY to build something like this, again mounted from chassis/floor.


more at the weekend, cant do a lot untill i get gas next weekend ££££££

[Acidburn]

mocked up subframe and antiroll bars on the front.......... does NOT fit, i remember why i mounted it the way i did last time round........

What catches on there? engine or something else?

Is it because you've dropped the engine down and back?

When I was looking at this I was going to get some mounts done like you have in the above post and go from there.

[Sleeper_Avant]

yep, this is going to be a propper ball ache, and i might end up not fitting a front antiroll bar, and using a type of compression strut affair

even if it was dry sumped, theres no clearance

but chin up, i will sort it!

[Acidburn]

There must be a way around it quite easily, would be surprised a lot of the ford boys couldn't come up with a solution.

What about notching (spl) the subframe or is it totally in the way?

s2_bo on here was running coilovers without a front arb from what I remember. Would you brace the subframe, weld in a new section in front of the engine then cut out the offending bit?

I think this is a good time for you to switch to a tubular subframe

[Sleeper_Avant]

i cant peter, the subframe takes the 2x lower arms, at funny angles!

i will brace the 2 halfs when i chop the centre out, but from underneath and maby a bolt in section that goes between the front mounting bolts, if you get what i mean........

[Acidburn]

yeah same setup as the pissrats, a removeable bolt in section could work, its just trying to keep clearance considering knowing you it will be on the floor