The 20vt Quantum Syncro Wagon - The Group B Grocery Getter

[dougkehl]

I've been thinking about it for a while and finally decided it was time to move this thread hear from Motorgeek. The thread here will outline the final plans for this car and how it went from something that wasn't supposed to be a big project to me letting all the bad ideas I have for this car take over for better.. or maybe worse.

The final engine plans have changed compared to the plans on Motorgeek. For the moment the final engine formula for this car is as follows:
AAN block
AAN ported and polished cylinder head
WN/WH 77.4mm stroke crank
Custom made intake manifold with 42mm ITBs
Iroz Equal length exhaust manifold or custom made
BorgWarner 7163 EFR with .85 a/r v-band non-wastegate turbine housing from an indy car
3" downpipe and exhaust
Stock AAN wastegate, may change to a Tial 44mm
Pauter rods
Either a Treadstone vertical flow intercooler or maybe I'll get my own core and make one.
I plan to make all the intake charge tubes out of carbon-kevlar and realistically I plan to make a ton of other carbon-kevlar stuff

Bottom line I want this car to look just like a regular QSW minus being a little lower and having white Azev type A's. But I want to open the hood and just have it remind me of a Group B Quattro to some extent and 100% go like a bat out of hell. This engine is going to take a long time to get together because I'm also in the process of buying a house which will take some funds away, but for the better!

Here is the progress on the chassis so far for those of you who haven't seen it on Motorgeek

When I bought the car like two years ago
IMG_20150906_112522_713 by dougkehl1, on Flickr
IMG_20150906_112355_564 by dougkehl1, on Flickr
IMG_20160128_165836_643 by dougkehl1, on Flickr

Tried pulling out that smashed back end..
IMG_20160410_125411_933 by dougkehl1, on Flickr
IMG_20160413_161434_597 by dougkehl1, on Flickr

But I cut it out anyway... Drove from NJ to Cape Cod, MA to get some parts.
IMG_20160521_140801_931 by dougkehl1, on Flickr
IMG_20160522_131025_430 by dougkehl1, on Flickr
IMG_20160529_123650_558 by dougkehl1, on Flickr
IMG_20160531_121554_187 by dougkehl1, on Flickr
IMG_20160531_121607_861 by dougkehl1, on Flickr
IMG_20160601_211745_050 by dougkehl1, on Flickr
IMG_20160607_115547_221 by dougkehl1, on Flickr

Then I started stripping it down to fix the remainder of the rust and prepare for paint.

IMG_8179 by dougkehl1, on Flickr
IMG_8184 by dougkehl1, on Flickr
IMG_8198 by dougkehl1, on Flickr
IMG_8204 by dougkehl1, on Flickr
IMG_8259 by dougkehl1, on Flickr

Rotted floor.
IMG_8306 by dougkehl1, on Flickr
IMG_8295 by dougkehl1, on Flickr

New floor.
IMG_8381 by dougkehl1, on Flickr

Crap floor out!
IMG_8405 by dougkehl1, on Flickr
IMG_8406 by dougkehl1, on Flickr

My dad gave me a hand and prepped the floor.
IMG_8401 by dougkehl1, on Flickr

New floor in!
IMG_8409 by dougkehl1, on Flickr

Finish floors.
IMG_8419 by dougkehl1, on Flickr
IMG_8420 by dougkehl1, on Flickr
IMG_8422 by dougkehl1, on Flickr

Fender replacement.
IMG_8350 by dougkehl1, on Flickr
IMG_8354 by dougkehl1, on Flickr

Currently I just finished the body filler smoothing and I'm just about done masking it off in preparation for primer. Hopefully by weeks end I'll have it primed.

And here are some of the engine parts acquired to this point in time..

AAN with an 01E that I bought about two months after I bought the car. Paid $500 for the engine and trans. I'll be keeping the locker 016 in this car though.
IMG_8207 by dougkehl1, on Flickr

Set of ITB's I put together and the intake plenum
IMG_8338 by dougkehl1, on Flickr

And the BorgWarner 7163 EFR.




Sorry for the mega post, but everything is covered up to date. It will just be one update at a time now haha

[pilihp2]

this.
is.
amazeballs.

[dougkehl]

this.
is.
amazeballs.

Thanks man! I hope it all works out how I'm planning.

One more update from yesterday on MG. The guy I bought the turbo from runs his own company that makes prototypes of basically what ever you want.. He was offering to help make an inlet for the compressor housing for the Indy Car EFR compressor housing. Two nights ago he sent me pictures of the finished 3D printed model mocked up on his 7163. So now we're working on either 3D printing it in aluminum or just turning the inlet on a lathe and machining the flange and then I can weld the two together. Really just comes down to cost at this point.

inlet 1 by dougkehl1, on Flickr
inlet 2 by dougkehl1, on Flickr

Also started working on the turbine housing inlet v-band flange design. Because of course the turbine inlet v-band flange on an Indy Car is way different than on a regular EFR v-band turbine housing.. And I don't want to weld another flange to this turbine housing.. So I'm considering turning this on my friend's lathe out of 304 stainless steel, but if he doesn't have the tooling necessary I'll just have a machine shop do it for me for the sake of saving time even if it means spending a bit more money.

Indy EFR V-band by dougkehl1, on Flickr

[the german]

I like where this is going.

[Foscora]

Alright, I'll follow this thread then.

[pilihp2]

What is your plan for exhaust manifold?

[dougkehl]

What is your plan for exhaust manifold?

Either an Iroz equal length manifold with the v-band flange I'm making for this turbo, or it will be something similar to the Prospeed manifold below and I'll do all the fab work myself.




I'm still undecided though, because I would prefer the Iroz manifold for the benefit of it being equal length, and Hank does a realllyyyy nice job making them from what I've seen. I don't really think it's possible to go wrong with one of them. But there is something about the Prospeed manifold I like, probably the fact that it's a replica of the Audi Sport manifold found in S1 E2 cars.

[dougkehl]

The lighting in this picture is terrible, but it's finally primed. It needs another coat I think on the roof, but the rest of it is pretty good.

IMG_8473 by dougkehl1, on Flickr

[maverick]

I freaking love this project!!

[dougkehl]

I freaking love this project!!

Hey, thanks man!

I'm starting to actually like it again now that the car is set up to go to the spray booth next weekend for paint!

Finished block sanding the chassis last night, it needs a few touch up spots with primer. And today I'll get the hood prepped for the Aerocatch hood pin latches and then I'll finished up the body filler on two doors and by Thursday I should be able to start priming the hood, the hatch, all 4 doors, front fenders, sunroof, and the two stupid rain gutter pieces that Volkwagen decided to rivet on instead of just making it part of the car haha. I also got in touch with Ground Control to put together a coilover kit for this thing. So hopefully I can scrounge the funds together to get those ordered as well.

IMG_8491 by dougkehl1, on Flickr

[zephyrj]

Can't wait to see this thing ripping around. I still look out for a decent qsw.

[loxxrider]

Awesome, glad you made it over. I'd save yourself the headache and get one of hanks manifolds. Hell, if you aren't using a k26 flange, why not sell the indy housing to someone who needs it like me and get yourself a regular vband one so you don't even need adapters?? I'd pay handsomely for that housing so I can use it on an rs2 Evo manifold for my avant.

[dougkehl]

It's all going to come down to time. I want to build a manifold so I can say, "yeah I made that", but I know realistically even IF I spent less money to make my own the time could be worth more than the money spent on one of Hanks manifolds.

And you're tempting me to pull the hotside off the turbo. It really would make everything easier, but I really kinda want to use it. I'm just going to have a flange made and get the correct clamp assembly from Reid Washbon and weld it onto whatever manifold I get. Oddly enough they supply clamps for Indy Car turbos, but not the corresponding flanges.

[loxxrider]

Interesting on the clamp/flange situation. Well, if you decide want to make yourself some money on that housing, do send me a message! There's really no reason to use that hotside from a performance standpoint. It's a packaging thing if you have a stock manifold and are running one of hanks kits.

[dougkehl]

Update time..

Chris and I made a deal and he now has the turbine housing from my 7163 for his Avant. I'm very grateful for that because it works out for both of us. A new v-band in/out .85 A/R non-wastegate housing is now on the way from Jeff at FRP!!

Also, I got the remaining parts primed over the weekend and the car will be going to paint either this weekend or next depending on the weather.
IMG_8518 by dougkehl1, on Flickr
IMG_8520 by dougkehl1, on Flickr
IMG_8523 by dougkehl1, on Flickr

Also, these showed up today! Ground Control really hooked it up because this car is a bastard child of suspension parts thrown together and it works well enough. Originally they didn't want to supply me a kit because it would have been a one-off thing and I guess they don't like to do that. After talking with Donovan for a bit we got all the parts worked out. The kit consists of 50mm Audi 4000 front perches, sleeves, springs and top mounts and the rear is first gen Mitsubishi Eclipse GSX rear perches, sleeves and springs with Mk1 Rabbit top hats and bushings. I can't wait to get these in.. I'm mostly excited to do work on the car I find enjoyable instead of body work.
IMG_8526 by dougkehl1, on Flickr

[dougkehl]

Got the new turbine housing yesterday. It's quite nice. Hopefully within the next month or so I can get the engine up on a stand and start fiddling around with it and this lovely turbo.

IMG_8531 by dougkehl1, on Flickr

[the german]

That is the most dramatic picture of a turbo on a washing machine I have ever seen.




But seriously, looking great.

[dougkehl]

That is the most dramatic picture of a turbo on a washing machine I have ever seen.

Haha It's funny you mention the washing machine because my one friend always busts my chops about taking pictures of car parts on the washing machine.. But it's the perfect place because of the light that's directly above it lol.

But hopefully it'll be painted this weekend. It's just about ready to go. I've got just a few more things to block sand, like the sun roof and hood and then it goes on the car trailer and off to the booth!

[ringbearer]

Where are you located?
Car is looking great!

[dougkehl]

Where are you located?
Car is looking great!

Thank you! It's getting there slowly. But I'm currently located in northern New Jersey, soon to be northern NY just north of Lake Placid.

[ringbearer]

I thought you were out west for some reason, keep up the good work!

[dougkehl]

Got some parts ordered today to reassemble the car when it comes back from paint next week. New door handle seals, a new antenna, new wiper shaft seals, new washer jets front and rear, new seals for the switch that controls the interior light when you open the doors and a new horn.. Oh and I got a hold of the guy that's going to supply me the camber and toe adjustment plates and bolts for the rear subframe so I can correct both once I install the coilovers.

And a little off topic, but it's something I'm super pumped on and some people here might think it's cool. I traded a set of wheels I had for my Mk1 to my friend for his Mk1 in exchange for this sweet CB450 chopper roller.. I'll probably post about this here along the way too lol
IMG9526341 by dougkehl1, on Flickr
IMG9526351 by dougkehl1, on Flickr

[mrdeye]

Nice! At one point in time that chopper use to be Zed's!

[loxxrider]

That new turbine housing looks super nice. Glad it worked out to both of our benefits!

[chaloux]

This thread is awesome. This project is awesome. That ground control kit is a hilarious mix, nice job.