1992 AUDI S2 Project - Keep it British with a twist.

[Wizard-of-OD]

Hi Issam,

Thanks for replying, tbh reading your reply I feel a bit guilty about bumping up the thread and putting pressure on you so to speak.

It was pretty compulsive reading though.

Hopefully the future ride is smoother going forward.

Kind regards.

No worries at all!
We got off to a bumpy start but the ride since has been amazing.

[macspring]

Hi Issam,

Thanks for replying, tbh reading your reply I feel a bit guilty about bumping up the thread and putting pressure on you so to speak.

It was pretty compulsive reading though.

Hopefully the future ride is smoother going forward.

Kind regards.

[Wizard-of-OD]

Any updates to this roller coaster thread ?

Totally forgot about updates!
As of right now the S2 is under a car cover awaiting the body shop to start the process. In the mean time time I have been collecting more parts.

So far I have the following:
- KW V3 Coilovers
- FTM Gearbox - this is the European B6 A4 2.5 TDI with the additional gearbox oil cooler pump
- FYF Gearbox - North American B6 A4 3.0 N/A . The last of the 01E's offered in North America and it has all the improvements plus it is a 4.11 F/D so I don't need to convert my rear differential again (back to 3.89)
- Wavetrac LSD's for front and rear

Basically the project has come to a halt while I plan out my brake system , the wheel and hopefully get my downpipe from Iroz before the spring.

[macspring]

Any updates to this roller coaster thread ?

[orignalS60]

It would be cool to have an aluminum thermostat housing with provision for -AN fittings for
the AAN engine.

[Wizard-of-OD]

The uk ones are aluminium of some description. Maybe world war 2 coke cans and ration packs. They are you cant really weld to them. I would be in for one or two for sure

The way I usually do coolant flanges (1.8T and 16V for e.g.) is we provide enough thickness in the model so that it can be tapped for AN-20 fittings. That way if you want to use OEM hose :
- AN-20 to 1.25" barb male union
If you want to run AN connections between the radiator & the flange , AN-20 male union + AN-20 push lock fitting and voila never have to worry about coolant hoses again.
Of course I could CNC machine them as well but now we are talking -$200-300 a part.

No sorry I meant getting alloy parts/prototypes made, using laser melting for example? A mate of mine uses a local firm for this, for reproducing castings for historic race cars etc. Not cheap but cheaper than tooling for conventional casting. He rates the quality of the material

Metal 3D printing needs to come down in price first before I can even begin to look at one. I will tell you , the day a machine comes under $10K is the day I sell my $80K CNC! Sell CNC for $60K....buy 6 Metal 3D printers

These are some of the links for the guys trying to make them affordable:

http://3dprintingindustry.com/2014/09/23/sub-4000-metal-3d-printer/

http://3dprintingindustry.com/2014/07/21/matterfab-launches-affordable-3d-metal-printing-2/

I have heard talks about machines becoming more affordable but have not seen any as yet. Food for though , when I first looked @ 3D printers in 2009 , the one I wanted was 35,000 CAD and could only print an 8 x 6 x 6" part. That would mean for an intake manifold I would have to print it in 3-4 sections so roughly 40-45 hours of printing. The printer I got was just under 8K and can print a 10 x 12 x 12 part but I want bigger.

[Error404]

No sorry I meant getting alloy parts/prototypes made, using laser melting for example? A mate of mine uses a local firm for this, for reproducing castings for historic race cars etc. Not cheap but cheaper than tooling for conventional casting. He rates the quality of the material

[terrybullwon]

Yes , the plastic ones seem to follow the same issues as the later vehicles so would like to recreate them in aluminum. Should we start a GB?

.

The uk ones are aluminium of some description. Maybe world war 2 coke cans and ration packs. They are you cant really weld to them. I would be in for one or two for sure

[Wizard-of-OD]

Good info.
Have you ever used additive manufacturing for alloy parts?

Once yes . I mostly use them for fitment though , never for long term as I really do not know how the coolant will react with the material or heat for that matter even if I changed the fill density to 50+%.
I use PLA (Polylactic acid / polylactide) for reference.

[Error404]

Good info.
Have you ever used additive manufacturing for alloy parts?

[Wizard-of-OD]

Yup, 3B, ABY & ADU all the same as 7A
80 is a lot for our market for sure

Actually I mis-spoke earlier. Called another dealership and even though the 3B is NLA , the 7A is still available. There are actually 4 in North America and 11 in Germany

OEM Part # for 7A/3B/ADU/ABY Thermostat Housing : 034121121C

http://trshop.audi.de/konakart/SelectProd.do?prodId=49194&manufacturer=manufacturer&category=Engine%2C+clutch&name=COVER&model=0001

MSRP = $286.13
Cost = $167.84

The reason I use 80 as an example is we sell the thermostat covers for the 1.8T for $119 USD.
The mold costs - approx $6000 CAD
and once casted , the casted parts machined work out to around $26 each.
So for 100 pieces cost works out to around $86 each.

The 3B unit is roughly the same size so if we did 80 it would work out to about $101 each. Not exactly a huge savings compared to something that is available now but just thought Id give some inside information for those considering it.
Issam

[Error404]

Yup, 3B, ABY & ADU all the same as 7A
80 is a lot for our market for sure

[Wizard-of-OD]

Excellent, looking forward to seeing the results then

BTW, only AAN thermostat outlet is plastic, 3B, ABY & ADU are alloy
They do corrode quite badly though, so these are the water rail would be good to reproduce

The only aluminum ones we got over here were for the 7A (no ADU/ABY here) and the part is now NLA in North America (not sure about Europe)
Ideally I would like to recreate all the housings again but it boils down to supply and demand. Break even point on coolant flanges is 80 pieces. Easy to do with the 1.8T and 2.0 TFSI crowd. Not so much with the 2.0 16V & 2.2 I5 community...

[Error404]

Excellent, looking forward to seeing the results then

BTW, only AAN thermostat outlet is plastic, 3B, ABY & ADU are alloy
They do corrode quite badly though, so these are the water rail would be good to reproduce

[Wizard-of-OD]

Assembled the 3D printed part this morning and realized I made an error with respect to the linkage spring cup .
Now onto REV_07:

Everything else worked and I am trying to see if I can get away with the 3.15mm additional on the housing otherwise I will have to make a new shaft

Will find out in 14 hours as it will start to print in a few minutes. (takes approx 14 hours to print)