Alex's 7A Swapped CGT - New Wheels

[the german]

looking gooooooood!

[DE80q]

Just for reference, I'm running 1g cable from the trunk of my B3 to a distribution block under the hood. After all the ground were sorted, there was negligible voltage drop. I'm using cable designed for high voltage electric motors though.

As for welding cable, the mane reason it is not a good choice is the insulation. It doesn't take kindly to oil and other chemicals. Most people that have used it saw it cracking up pretty badly after a year of 2.

Other wise, I love this project! Keep at it, should be a fun car to drive in the end.

[the german]

I used these on the coupe- works great, no problem cranking the v8 off the small odyssey battery in the trunk.

http://m.harborfreight.com/6-ft-300-amp ... -8816.html

[alxdgr8]

Primered and rattle canned the spots where the battery tray was ground off and some other scratches. Got rid of the surface rust spot on the hood too. Paint matched pretty well with a small test area, but with the large area it obviously doesn't. The engine bay itself is about 10 shades of white since a lot of it has yellowed, so I'm not sure there's anything I can do about it. Maybe it'll look better with the engine in it, or maybe I should spray the whole engine bay.

IMG_20150418_220845638 by alxdgr8, on Flickr

IMG_20150418_222256307 by alxdgr8, on Flickr

IMG_20150418_231451552 by alxdgr8, on Flickr

IMG_20150418_234356457 by alxdgr8, on Flickr

[alxdgr8]

As I was warned, it's pretty much impossible to ceramic coat the 'bag-o-snakes' header. So knowing that it was going to turn out shitty, I sprayed it extra heavy to reach all of the nooks and crannies which lead to it turning out shitty. Oh well, it'll do for now and I'm sure it'll start flaking off after a few miles.
Also hacked up the heatshield to show off the not-so-beautiful header.

IMG_20150425_214513840 by Vex Art, on Flickr

IMG_20150425_214439275 by Vex Art, on Flickr

Rattle canned the belt cover and I think I'm going to redo it in matte. The gloss black is just a bit too much and doesn't match the valve cover very well.

IMG_20150425_214645439 by Vex Art, on Flickr

Iroz Motorsport billet goodness in the form of a power steering adapter.

IMG_20150425_224830931 by Vex Art, on Flickr

More shiny parts. Decided I should try and mount the 20v AC stuff on the 20v engine in case I can get it working again. Don't have it all together yet, but I think it'll work just fine.

IMG_20150425_214831301 by Vex Art, on Flickr

Difference between the B2/20v snub mount and the B3/20v snub. I'm told I need to use the 20v one to fit the chassis correctly. 20v is on top, 20v on bottom; 20v is about 1/4" longer.

IMG_20150425_224638644 by Vex Art, on Flickr

[alxdgr8]

20v AC compressor and lines are mounted on the engine now. It's missing the lower rear bracket as the 20v doesn't fit due to the oil filter housing and the 20v one sits an inch or two too low. Should be fine with the other 3 attachment points though. If not, I'll fab up a bracket down the road.

IMG_20150426_172726361 by Vex Art, on Flickr

Lines clear everything just fine. Probably going to fab up a heat shield or wrap them in fire sleeve.

IMG_20150426_185028700 by Vex Art, on Flickr

20v doesn't have the mount for the AC line 'hook', but it fit perfectly at the end of the alternator adjustment bracket.

IMG_20150426_185048311 by Vex Art, on Flickr

The 20v PS pump adapter doesn't allow you to run the 20v engine hook. Chopped off a small bit and drilled a new hole and it fits just fine. It's a little taller now, but hopefully it clears the hood.

IMG_20150426_175448979 by Vex Art, on Flickr

Painted the PS and crank pulley so they didn't look so crusty.

IMG_20150426_221513570 by Vex Art, on Flickr

Installed one side of the Jamex strut bar with Mance solid strut mounts. Looking at it now since I deleted the battery box, I could actually run a straight rod between the strut towers. This would allow me to have a much more effective strut bar than the curved Jamex piece. I might just install as is and then change it later.

IMG_20150426_224951504 by Vex Art, on Flickr

[alxdgr8]

Got the other strut mount drilled and the brace mounted.

IMG_20150427_231209726 by Vex Art, on Flickr

Also pulled the dash and heatercore in prep for the wiring.

IMG_20150427_232739988 by Vex Art, on Flickr

[alxdgr8]

Fresh 3B flywheel, still need to order a clutch. Also waiting on my 1.8T rear main seal to come in before this will go on.

IMG_20150428_210613856 by Vex Art, on Flickr

My new toy for $100 complimentary of an Ebay auction (cosigned by my company). Sun/Snap-On DGA1000 exhaust gas analyzer. Auction listings said it had a keyboard error so I figured I might need a new one. Silly idiots didn't plug it in that's why! Plugged it in and it powers up and operates perfectly. Hell even the IR remote and printer works! Should work great for troubleshooting CIS on the Merc and for getting VEMS to pass emissions on the 90 (so I don't have to keep getting re-tested every few days until it passes).

IMG_20150428_211437401 by Vex Art, on Flickr

IMG_20150428_211839363 by Vex Art, on Flickr

[DE80q]

Now that little toy will come in handy!

[PRY4SNO]

So much jelly...

[alxdgr8]

Got both of the old wiring harnesses out, time to put the new one in!

IMG_20150503_201954101 by Vex Art, on Flickr

Copper exhaust manifold nuts

IMG_20150503_172830930 by Vex Art, on Flickr

New pilot bearing and 1.8t rear main seal installed (oil pan doesn't have to come off like I've seen mentioned)

IMG_20150503_184517740 by Vex Art, on Flickr

New PS reservoir filter vs old one

IMG_20150503_175916316 by Vex Art, on Flickr

[PRY4SNO]

Nice work. I didn't have to pull the oil pan either, when I did the 7a RMS on my black coupe.

[alxdgr8]

New engine harness is routed through the firewall (what a pain!). Also found some cracking around the clutch master cylinder, going to order the firewall brace from 034. Still working on figuring out where everything hooks up and what isn't used.

IMG_20150506_215424059 by Vex Art, on Flickr

New clutch master and slave

IMG_20150506_220748271 by Vex Art, on Flickr

Didn't like the gloss black on the timing belt cover, so I redid it in a gunmetal. PS pump cover and fuel rail are done in the same.

IMG_20150506_214941497 by Vex Art, on Flickr

With the 093 trans, you have to modify the bellhousing to accept the timing/reference sensors. The 016 trans in 4kq apparently has this, but not the 093 on the CGT. Easy fix with the angle grinder.

IMG_20150506_172916172 by Vex Art, on Flickr

Clearanced

IMG_20150506_175821700 by Vex Art, on Flickr

Sensor clear just fine

IMG_20150506_175955783 by Vex Art, on Flickr

The horror of trying to integrate two different wiring harnesses. I may be overdoing it trying to get all of the dash warning lights to still function. The wiper motor and spray pump definitely need integrated, possibly more.

IMG_20150505_230029368 by Vex Art, on Flickr

[the german]

Loving it! It's going to be worth it when it's all done and everything works like it should.

[alxdgr8]

Painted the fuel rail and the timing cover in a gunmetal that looks much nicer than the gloss black.

IMG_20150509_202630235 by Vex Art, on Flickr

IMG_20150509_202212132 by Vex Art, on Flickr

New clutch. Ordered a Luk for a 200 20v on the recommendation that it was just a rebadged Sach for $100 less. Looks like the clutch disc is indeed Sachs, but the pressure plate is Luk. Still should do the job just nicely. Had to use the Coupe GT throwout bearing due to the differences in the transmissions. The CGT TOB is slighly different from the AWD 016 trans TOB, but it should work. The 016 version has a slight cup in the mating surface, but it's also plastic where the CGT one is metal.

IMG_20150512_205438072 by Vex Art, on Flickr

IMG_20150512_190503982 by Vex Art, on Flickr

IMG_20150512_201342087 by Vex Art, on Flickr

[alxdgr8]

And some fun with work lights and a dark garage

P1010088 by Vex Art, on Flickr

[the german]

If you make the engine bay any nicer you are going to have to strip and repaint the rest of the car to match

[alxdgr8]

Don't give me any ideas!

[alxdgr8]

Box of goodies from Hersh Performance and Racing. Poly engine/trans/subframe mounts.

IMG_20150517_183243166 by Vex Art, on Flickr

Engine mounts are in

IMG_20150517_202528850 by Vex Art, on Flickr

Trans mount

IMG_20150517_202519332 by Vex Art, on Flickr

034 firewall brace to stop the cracking

IMG_20150517_183049273 by Vex Art, on Flickr

Installed

IMG_20150517_191500316 by Vex Art, on Flickr

And the engine is in!

IMG_20150517_210318423 by Vex Art, on Flickr

Need a 20v throttle cable as the 20v one is too long

IMG_20150517_210448012 by Vex Art, on Flickr

[chaloux]

Whoa, this is the first time I've looked through this. Super clean! Excellent work

[40v4kq]

Yeah, great job for sure Alex! My only gripe (and its a small one lol) is that oil filler cap. I had one of those and it leaked like crazy, it was horrible. Do yourself a big favor and get a proper black plastic cap (autohauseAZ has them) and keep that Purdy engine clean

[alxdgr8]

Yeah, great job for sure Alex! My only gripe (and its a small one lol) is that oil filler cap. I had one of those and it leaked like crazy, it was horrible. Do yourself a big favor and get a proper black plastic cap (autohauseAZ has them) and keep that Purdy engine clean

Thanks for the heads up, I think I have a few plastic ones sitting around that I'll throw on.

[alxdgr8]

My plans to retrofit the 20v AC system have been thwarted after reading the R134a conversion TSB. The 20v uses a York compressor which can't be converted, therefore I'll have to use the 20v one (a Denso). Need to find some B3 AC lines then since they are different and then convert the compressor o-rings and accumulator/drier. But that'll be done down the road, more important things right now than AC!

[the german]

Woohoo!! Getting close. Gotta get it finished up so you can cruise around now that it's nice out

[PRY4SNO]

I'm in the process of moving all my hoarded Audi parts to my new home.

When I do so, any spare AC/7A parts are yours for the picking if you like.

I'll even be in Seattle come late August... nothing beats free parts, delivered free!