An Alpine URQ in Utah - Knee deep in Swarf

[Wheeljack]

Thanks guys!

Dave, Just let me know and we can get a nice harness together for you. If you source the connectors (which I know you can do), it will be cheep cheep.

Martin, do you have a dark/chocolate brown dye in mind? I've looked around a bit, but didn't see anything that was a clear choice over the rest. The flash makes the carpet look worse than it is too, but there is some slight fading noticeable to the seasoned eyes. If it was worse, I would be more concerned, but this may be another shelved task.

That's some serious repair, Frank. Nice work. I know James did some similar work on his fenders, too. Ignorance is bliss.

[audifreakjim]

Damn Chris, that is looking awesome!

[Wheeljack]

Since today is the start of my weekend, I figured I would sneak a few hours in on the project...

I did the mods to the 7A valve cover to take the 2.0T tall coil packs. I opened up the top of the hole .030" on the diameter (from the original design mod dimensions) as it was too snug to really get the coils seated all the way.







Even now, it is pretty snug, but I'd rather creep in from the tight side than have coil packs flopping all over like a hotdog in a hallway.
I also wanted to shave the ribs and clean up/simplify the look a bit...





I have also picked up a urS6 parts car that is providing some critical final bits and pieces needed for the build. Most of the car is available, though, so PM if you need any parts.

http://www.motorgeek.com/viewtopic.php?f=4&t=47532

[audifreakjim]

That looks evil! Jimmy likely

[quattro87]

Nice Chris! It looks like that coil on plug setup would be better suited in a certain Urq with a red engine bay to me. I like the look, the simplicity, the room having 5 coils on the firewall takes up, and not having wires to arc and be another potential missfire. I like it.

[Wheeljack]

That looks evil! Jimmy likely

Send me a valve cover.

Nice Chris! It looks like that coil on plug setup would be better suited in a certain Urq with a red engine bay to me. I like the look, the simplicity, the room having 5 coils on the firewall takes up, and not having wires to arc and be another potential missfire. I like it.

It solves quite a few issues with space, cleanliness, and electrical noise...at least that was the idea...and they seem to support good power and can easily keep cheap spares (<$20/each) around.

Not to mention the weight savings if comparing to an AAN setup...



Yikes...But, there are so many places to cut 5 or 10 lbs. here and there with updating to later technology gear. The ignition system, the starter, the AC components, removing the bomb and associated hydraulics...All while keeping the heart of the engine intact...

[quattro87]

Speaking of heavy weight saving components, did I tell you that small carrier, as I seem to remember you referring to it as, of an A/C bracket and York compressor is now operational on Her Urq? It may be heavy, but is better than windows down. It's supposed to get 103 today and 107 by Sunday. I wish I still had a #30 jug of R-12 though. It could be better air, but isn't bad on the freeway.

[JonathanL]

Like that VC and coil setup!

[Dave]

i like the look!

[Wheeljack]

It was about time to start building up this engine. But to build one up, sometimes, you have to tear one down. So, here we go…

Lonely block in the shop…



Getting prepped for some paint…



If it didn’t weigh an extra 51 lbs, and have rust in the passages, I may think this was a shiny aluminum block…



Stock internals…



Stock I5 rods and shells…



AAN pistons…



Oh, what do we have here???



Some H-beams…







Putting in the pistons…



Bottom end assembled. Everything was plastigaged and radial clearances are .0015-.002 pretty much all around. Pretty typical for anything between new and 200K, lol…

[Dave]

love the first HDR shot of the work space! Glad to see progress is being made!

[quattro87]

:stupid: Those pics are awesome, but the shop looks too organized.

[Highlander]

Looking great Chris!!

Rather than painting the block silver, you should just machine us all up some billet aluminum ones.........

Looking forward to seeing more updates.

Cheers,

Craig

[nsimps]

Looking great Chris! Lots of progress going on here in Utah!

[ralleyquattro]

Very nice, love your work area. What are your plans for the package?

[Wheeljack]

Thanks guys. Slowly but surely. I've got some more updates soon...hoping to be 'sprung into action' by next weekend...

John: If I don't keep it clean, I'm out of room before lunchtime most days. Not much open work area if stuff doesn't find its home at the end of the day.

Craig: I *may* have a billet block partially modeled... We all know that availability isn't the only issue with the original alloy block. It is also not very strong, compared to its iron brother. But, light and strong...now that's a winning combination...and can be had with a billet block and iron liners.

Martin: I'm not sure what you mean...'...plans for the package?'...maybe I'm lost in translation, lol...

[ralleyquattro]

I am sure you mentioned it, I just stare at the pictures :slap: , just wondering what you are aiming for power wise etc.

[eurotuned_a4]

Nice work so far!

[Wheeljack]

The rough plan is something like...

Power: 500whp with maximum area under the curve...Turbo TBD, but something GTX3076R-ish
AC: Yes-modernized
Fuel: E85
Interior: Slightly updated, OEM-ish

This is replacing the eS2, so drivability and comfort are high priority...in addition to the Power/weight to put in some decent lap times and spank unsuspecting roadtools.

[ralleyquattro]

Nice, I have yet to figure out the A/C iussue... it would not bother me say 10 years ago... but now sitting in that brown leather interior and sweating my bag off in city traffic... not fun!

[Quattro v1.0]

This is replacing the eS2, so drivability and comfort are high priority...in addition to the Power/weight to put in some decent lap times and spank unsuspecting roadtools.

Chris, please expand on 'replacing' ;o]

[Mcstiff]

quattro v1.0 wrote:[/quote]

This is replacing the eS2, so drivability and comfort are high priority...in addition to the Power/weight to put in some decent lap times and spank unsuspecting roadtools.

Chris, please expand on 'replacing' ;o][/quote]

Lol, this was my first thought as well.

[Wheeljack]

quattro v1.0 wrote:[/quote]

This is replacing the eS2, so drivability and comfort are high priority...in addition to the Power/weight to put in some decent lap times and spank unsuspecting roadtools.

Chris, please expand on 'replacing' ;o][/quote]

Limited time and space means it will be for sale later this year, after I take care of a few things that didn't make it in the first time around. And I need to take it all apart to clean it again anyway. I mean, I've put like 3K miles on the thing...

Maybe I should go and post my 'feeler' thread in the swap meet. :tard:

[Quattro v1.0]

Could always leave one down here in Vegas :O}

[Wheeljack]

Had a few more hours this morning to work on the URQ...

I've decided to try deck cooling with this motor...plan is to do both the head and the block. From a heat transfer perspective, it is hard to argue the obvious benefits of getting a substantial water jacket around the upper portion of the combustion chamber.

So here is a SW model showing the block deck cooling modifications, which I will machine into both the head and block.



The other possible benefit I am hoping for is an increase in the strength of the head gasket interface. Most seals are a strong function of the pressure exerted on the seal in the static case, and this reduction in deck contact area should increase the static load on the gasket (comparing equal clamping forces). Of course, o-ringing is another option that works off the same principle. But I like the deck cooling because it is something Audi did on the works motors and I am interested to see if it offers increased detonation resistance and the ability to increase boost/timing with my configuration. I'm sure that the benefits won't be as apparent on e85 as it would be on the more knock limited fuels.

It's only time, I guess. What's a few more while I'm in there distractions?