Urq project

[AndyP]

Des - rear brakes to think about:

Phaeton rear disc - 310x22
B5 RS4 caliper carrier - machine 4mm off the mounting face (for stock S2 rear hubs)
URS4 rear calipers

Got a part number for those carriers?

[diesel des]

The more I build this car the more I see it as a track car with the odd play on the street. I agree 700 bhp seems like a lot. A good solid 600 bhp should be enough....

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[jsws3]

The more I build this car the more I see it as a track car with the odd play on the street. I agree 700 bhp seems like a lot. A good solid 600 bhp should be enough....

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My car is running 550.1 and I have driven plenty of fast cars gtr's and scoobys with big power but when mine comes on boost its a animal and 4 wheel drifts even with super sticky Dunlop track tyres so god knows what mine will be like when jonus maps it again with the early boost cams , however don't be put off with going for 700hp as I'll be there soon .

Ps you have my old manifold and waste gate set up glad it's going to be used .

[mac2226]

So I was thinking that I was going to need to map the engine with reduced boost through the mid range to save the stock rods. But then I thought **** it, build another stroker with forged bits. And a ported head. And a set of cams. So all those bits are on order and I have to pull a tdi engine from a a6 I bought years ago.

Then a gt30 and 500 bhp seems small. So a fancy tube manifold came up for sale with a water cooled tial wastegate.

Oh and a gt35r wearing a tial stainless back housing. Good for 625 bhp. It was the right money so... The turbo is boxed up again and going to my turbo man for a billet compressor wheel. There are options there. One is slightly bigger and he reckons will do 700bhp. The other spools up faster than the stock 35r and makes a bit more power. Decisions decisions.

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Hi des glad you got it early and safe, glad your going to make good use out of this turbo, tubular manifold and wastegate

[diesel des]

My car is running 550.1 and I have driven plenty of fast cars gtr's and scoobys with big power but when mine comes on boost its a animal and 4 wheel drifts even with super sticky Dunlop track tyres so god knows what mine will be like when jonus maps it again with the early boost cams , however don't be put off with going for 700hp as I'll be there soon .

Ps you have my old manifold and waste gate set up glad it's going to be used .

Your car is completely mint and looks better than stock. It must supprise people when you open the taps. I like the 4 wheel drifting comments that the sorta motivation I need!

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[diesel des]

Hi des glad you got it early and safe, glad your going to make good use out of this turbo, tubular manifold and wastegate

Cheers

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[Error404]

Got a part number for those carriers?

8D0615425A
You used to be able to get them from TRW, p/n was BDA514 but not sure they are available any more. You can find them listed online but they are the usual drop-shipping muppets who don't actually carry any stock and then can't get them. I got a used pair from a guy on SRS for £40.
New slider pin/boot kit from an A3 - TRW ST1160.
You need two kits as only two of the pins fit, but then you have a spare set of spare boots

[AndyP]

8D0615425A
You used to be able to get them from TRW, p/n was BDA514 but not sure they are available any more. You can find them listed online but they are the usual drop-shipping muppets who don't actually carry any stock and then can't get them. I got a used pair from a guy on SRS for £40.
New slider pin/boot kit from an A3 - TRW ST1160.
You need two kits as only two of the pins fit, but then you have a spare set of spare boots

Thanks! Another upgrade I don't really need, but I'm probabley going to do anyway!!

[Error404]

aren't they all?

I am using the B5 RS4 rear hub and 2pc rotor instead of Phaeton rotor & machining the carriers - all 100% bolt on and a bit lighter.
I believe Wolfie as the first to use this setup:

http://www.s2forum.com/forum/showthr...=B5+RS4+brakes

I found a pair of used RS rotors with very little wear, so avoided the big cost. Still fairly unnecessary

Sorry for the hijack Des

[diesel des]

aren't they all?

I am using the B5 RS4 rear hub and 2pc rotor instead of Phaeton rotor & machining the carriers - all 100% bolt on and a bit lighter.
I believe Wolfie as the first to use this setup:

http://www.s2forum.com/forum/showthr...=B5+RS4+brakes

I found a pair of used RS rotors with very little wear, so avoided the big cost. Still fairly unnecessary

Sorry for the hijack Des

No problems at all. It's all interesting stuff.

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[diesel des]

So the rods and pistons arrived. Rods are 159 mm long just like my last stroker build but these ones are x beam instead of h and also 22 mm small end compared to 20mm . They are rifle drilled.

The pistons are 82mm this time instead of 82.5 last time so I can use a stock head gasket. They have the same bore to piston clearance as the wossners I used last time. Compression to be confirmed but should be about 8.25:1.



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[diesel des]

Today I worked at the steering column and started fitting the corsa c electric system. I got a little magic box from eBay that connects to the control unit and gives it the right signals to work. There are a few different versions of these, some have a manual knob to adjust the assistance and some take a wheel speed signal and work with that. Mine takes a signal from the inbuilt torque sensor and adjusts the assistance as the force increases.

So I set it up in the bench and it works great! When turning the steering I put a spanner on the output shaft that I could load up the system with. Without trying to load it up much the steering had no assistance. As I started to hold the spanner tighter the assistance increased to a point I couldn't stop the spanner from moving. Very impressed.

Then i started measuring and cutting. Amazing thing is that the bottom of the corsa column has the same splines as the Audi rack! So that goes on no problems. I just need to join the Audi top to the top of the corsa shaft. I have it setup so that the corsa rod goes inside the Audi shaft. I will weld that and then drill and plug weld it too. Then I will grind the welds back and slide a sleave over it and weld again with some plug welds too. I need to get the sleave made up. Then I need to make some brackets to hold the lot up to the dash support.



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[Greg_S]

Result on the corsa steering column, how are you getting on with getting in mounted in place?

[SteveH]

Today I worked at the steering column and started fitting the corsa c electric system. I got a little magic box from eBay that connects to the control unit and gives it the right signals to work. There are a few different versions of these, some have a manual knob to adjust the assistance and some take a wheel speed signal and work with that. Mine takes a signal from the inbuilt torque sensor and adjusts the assistance as the force increases.

So I set it up in the bench and it works great! When turning the steering I put a spanner on the output shaft that I could load up the system with. Without trying to load it up much the steering had no assistance. As I started to hold the spanner tighter the assistance increased to a point I couldn't stop the spanner from moving. Very impressed.

Then i started measuring and cutting. Amazing thing is that the bottom of the corsa column has the same splines as the Audi rack! So that goes on no problems. I just need to join the Audi top to the top of the corsa shaft. I have it setup so that the corsa rod goes inside the Audi shaft. I will weld that and then drill and plug weld it too. Then I will grind the welds back and slide a sleave over it and weld again with some plug welds too. I need to get the sleave made up. Then I need to make some brackets to hold the lot up to the dash support.



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Lots of pics please as you do it

Could be a future standard S2 upgrade

[diesel des]

Cheers lads I will get some snaps. Tonight I welded the corsa column to the Audi column at the wheel end. I welded it, then used a sleave and welded that as well. Did a few plug welds too. It ain't shifting! I welded a bit at a time with the arc welder to get good penatration and used the air gun to blow on it as I didn't want too much heat getting into the corsa setup incase it cooked something.

So next up is the outer shell and i hope to do that tomorrow night.

Once that's done I will see what I need for brackets to mount it too the dash. The original Audi bracket that was on with shear bolts will still line up so that will secure it but I will be adding extra brackets to take the reaction force from the motor.



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