Interesting ideas/projects for this coming winter

[Josh-stateside]

I been getting alot of ideas lately. The motor is going in soon, and I will be running basically a stock Aby setup aside from the clutch setup.

Which for anyone curious:
I have a 4:11 stock 5 speed 7a tranny.
2000+ s4/rs4 clutch disc. ( had to be slightly modified to fit)
200 3b/7a sach sport pressure plate.
7a Single mass flywheel.

However once I get everything running, and once I put some miles on the motor I plan on doing a bunch of upgrades.

First, I am hesitant to drop the motor in because I am thinking of ditching AC. Most of the lines are allready off the car, and truthfully I would only be using it for maybe a 48 hours out of the whole year. I like the fresh air anyways.

So that being said.

I am a little bit worried about the transmission.
I am thinking I will have it tapped for oil lines and add a oil cooler in front of the radiator where the Ac refigerant condensor is now located.

I am also thinking of adding a thin 10 inch electric fan set on "pull" mode to the back of the intercooler. Not sure exactly how I would wire this in, But I have some ideas. Theromostatically controled?? I currently have an aby intercooler, possibly a custom intercooler will be made to match the Aby crossmember later down the road.

How nuts is it to think of adding a custom fan to the intercooler?
I have never seen a setup like so, but for the lack of space would it not be a decent idea? There are a ton of companies that make real nice slim line electric fans.


Turbo setup: something probably in the neighborhood of RS2 spec.

Opinions are appreciated.

Before I jump into anything, I will be doing alot of research to say the least.

I have to admit I am the DIY type person. I get alot of ideas.. Some rediculus, but some make sense.

I will be commenting on this furthure as time goes on.

Cheers
Josh

[Josh-stateside]

Update:

The AC parts have been pulled ;-)

I even swapped out the snub mount to the Non AC snub mount that I happen to have. Hopefully if all goes to plan I will have the motor in by late sunday night.

[porkkis]

You surely did get the crank balanced if you use the crank and flywheel as a different pair than original?! The crank of a 5 cyl audi is not in balance by itself but needs a flywheel as a pair.

[Josh-stateside]

Flywheel bolts have offset.

The flywheel itself is not perfectly (whats the right
terminology for this) Weighted? hub centric?

It's just a matter of matching up the 6 bolts and then it's all balanced again.

Good to know for two purposes.

It also makes lining up the engine speed (or is it reference?) sensor in the flywheel as simple as that. I can't remember everything.

[Josh-stateside]

Speaking of flywheel:

I was sent the wrong Pilot bearing. Which has ended my opportunity to put the motor in this weekend.

The 7a Pilot bearing side walls are thinner than the aan/aby.

Just a tidbit of knowledge.

Quite frustrated as of right now:

[Josh-stateside]

Well to furthure comment on this, lets get things noted.

1st: I don't know yet exactly how much space I have inbetween the motor and the intercooler, But I will hopefully know by the end of the week(if I get that pilot bearing by then).

2nd: I am considering Mounting it in front, Maybe two 8 inch high power fans( yes they make them and slim line too).

3rd: I like to get a S2 bumper later down the road, I am wondering how much space there is between the intercooler and the grills.

So on with finding info:


http://www.thermtrol.com/ThermtrolPD...esBulb&Cap.pdf

Quoted from the site:

"Thermtrol offers the versatile TS Series of adjustable thermostats suitable for applications requiring variable temperature setting ability and remote control. The TS Series design incorporates a changeover thermal switch and an auxiliary switch useful for fan control or alarm signal. A variety of available features, a large in-stock inventory, and a surprisingly low price combine to make the Thermtrol TS Series an excellent value."

The TS Series design incorporates a changeover thermal switch and an auxiliary switch useful for fan control or alarm signal

Could be just crazy thinking, But I have time.

[Josh-stateside]

More cool stuff:

http://www.spal-usa.com/html/pgtablel.htm

[Greg_S]

I had thought about mounting fans to suck through the IC but the pulley mounted on the crank has no where near enough clearance to fit a Fan infront of it, only other possibility is putting them on the front of the IC but even then think you have to chop a few little bits on the bumper.

Greg

[Josh-stateside]

another thought:

Water Spray.. Which I had in mind too..

But it could be theromostatically controlled too.

(homer)Hmmm....(/homer)

Thermostatically controled water spray for the intercooler


This is what happens when i am waiting for the battery to recharge so I can go here my 300+ watts of music (not including the sub) I just wired in.

I get ideas

[Vagsport]

" It's just a matter of matching up the 6 bolts and then it's all balanced again."

Josh, all 5 and 6 zyl. engines have 8 bolts, the 6 bolt flywheels are for 4 zyl engines. ops:

[Josh-stateside]

yah well the mind slips

I am working on too many projects.

I saw that the other day, I just didn't bother to reply nor fix it.

I hopefully will get my pilot bearing tomorrow, and by the end of the night have the motor dropped in!

[Martynf]

Hope the bearing goes in ok Josh, good luck with dropping he engine in, oh, and make sure your headlamps are NOT fitted to the car when putting the engine in.... , sorry, that was VAG Sports benefit!!!!

Good luck Martyn

[porkkis]

I guess it's not a big deal but what I ment with the balancing was that the crank itself is not in balance. Fiver does not have "counter weights" like 4cyl engines (1,4 and 2,3 with 180 degree offset).
So 5cyl engine is balanced externally with the flywheel. Crank in balancing machine without the flywheel tries to hop to ceiling at around 2000rpm.
I hope you get the picture despite my limited english.

And I do know because I just had my crank balanced (AAN block and crank, 3B flywheel). They drilled a few holes also...

Tiny off-balance just adds vibrations (and eats power) but shouldn't really break anything.

And yes, I knew about the bolt pattern. Always use new bolts btw!

[porkkis]

I forgot to mention an important detail:
Weights used to simulate conrods are 100% of conrod big ends plus 50% of upper end and piston (complete).

[Josh-stateside]

Well if you guys are curious this is the bearing going in:

SKF part number: 6002 2RS JEM

Specs:
O.D. 30mm
I.D. 15mm
Thickness: 9mm
Double sealed.

Cheaper than stock(alot cheaper), same size, and sapposely a much better product.

Hopefully I will be getting it tomorrow afternoon.

In reply to Porkkis:

Yes I do have new flywheel bolts

I am not too worried about the flywheel and crank. There are a bunch of guys running around with 3b motors and 7a flywheels here in the states. Mine is a little different but I will keep it in mind. Thanks for the replies thought. I am constantly trying to learn as much as I can and as fast as I can. Not to mention there are a bunch of people here in the states running s4 aan motors with Fidanza? single mass light weight flywheels. I think they are 11 pounds each.



P.S. How I work on the car:

Find instructions on Bently CD on the computer(s4 aan motor), Print, run to the garage, work on the motor, break, repeat.

I have a coupe quattro Bently book too.

Cheers
Josh