Tim's '86 BLAZE 4kq EPIC PROGESS!!!!

Document and share your build!
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq TALL DECK STROKER this

Post by my2000apb »

UPDATE TIME!!!!
Ok so I’ve been back from working on the road for a few weeks and have been tearing into the car big time, major progress!!!!

I have been working on a way to integrate the handbrake into the trans tunnel to keep things nice and clean and DD looking.

I got the urS4/4kq linkage to work well in my car, had all the gears, reverse pushdown worked well, everything shifted fine. BUT, it still didn’t feel like my old b5 s4 did, that shifting just felt so much more defined and refined. The old small chassis stuff just feels vague in comparison. So what do we do when we don’t like something? CUT IT OUT!!! So I went ahead and cut the oem shifter pedestal out of the trans tunnel!!!
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So I started off by building a base for the b5 box for mounting in the tunnel. The box is basically 16 gauge square stock and skinned in 16 gauge sheet. I had thought of framing in the shifter box with some round or small square tube, but ended up just skinning it in with 16 gauge sheet and that seems quite strong enough. It’s stronger than the rest of the uber flexible b2 chassis.
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I also made a small 4x4” wooden tunnel brace to keep things from collapsing as they were cut out/apart.
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Top of the shifter box/ pedestal in its general area, getting laid out with the center console, window switches and ashtray to make as clean of an install as possible.

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Last edited by my2000apb on Tue Apr 02, 2013 10:45 am, edited 1 time in total.
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq TALL DECK STROKER this

Post by my2000apb »

UPDATE!! With the shifter box properly located for clearances, it was time to skin the pedestal box and integrate it back into the trans tunnel. Its not framed in, but all 16 gauge and stronger than the rest of the tunnel already so I didn’t think it needed more reinforcement.
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It’s now all primed and seam-sealed up top, and primed, seam-sealed, painted and undercoated on the tunnel side. I’m just waiting on a new b5 s4 shifter linkage bushing rebuild kit and it’s all getting reinstalled.

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and a sweet bead, im getting a lot better with thinnner sheet
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and as it sits now
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Last edited by my2000apb on Tue Apr 02, 2013 10:38 am, edited 1 time in total.
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq TALL DECK STROKER this

Post by my2000apb »

UPDATE!!!

With most of the new tunnel/shifter done and sorted it’s time to move on to a lot of other smaller things on the list.

I had a nasty lil rust spot on the rear driver side door sill, under the clip in plastic sills that the 4kq has. So I popped the plastic sill cover off and cut the rustiness out. Toph dove right in and hammered out a small patch piece that fits quite well. Got it welded in there and primed.
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I also got my front tie rods rebuilt with new adjuster barrels and coated hardware, thanks Kev, (Bambridge) on S2 forum. And they look great, as well as being adjustable now ahhaha
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And the passenger fender vent has been cut and is mid prep for welding.
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I also got a chance to beadblast and clearcoat my serpentine tensioner/ alternator bracket. And I put on a new full metal spring tensioner from a later ABA. She’s ready for install!
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And with all my heatshields off I decided to do a semi-ghetto rebuild on them. They got rewrapped in several layers of extreme conditions aluminum tape, and daaaaaayum do they look good!
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And when I installed my clutch MC I swapped the pin out for the new one, def needed it!!
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Last edited by my2000apb on Tue Apr 02, 2013 10:35 am, edited 1 time in total.
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq TALL DECK STROKER this

Post by my2000apb »

UPDATE!!!

O1E time, fluids, seals, 4kq output cups and a custom center locker.
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I got it up on the bench, drained the fluid, and popped the rear end cap to get the center diff out. Its actually a very easy swap, off with the back cover, center diff slides out, slide other center diff in and close er up. DONE
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Custom center locker next to unmodded o1e center diff
It should have no problem staying “locked” after three passes with a 350A three phase mega-welder.
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Also swapped out the 108mm output cups for the 100mm 4kq units. Also replaced the output cups seals 016 409 399A

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Last edited by my2000apb on Tue Apr 02, 2013 10:33 am, edited 1 time in total.
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq TALL DECK STROKER this

Post by my2000apb »

UPDATE!!!

Ok more updatage, I got some time to get the rear sub frame, diff, sway bar, etc. all put together. I added some more grease zerks to the sway bar mounts on the sub frame. And even found some cool little OEM covers for them as well.
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Heat shields have all been ‘rebuilt” with extreme conditions aluminum tape. And they are now hung back on the bottom of the car.
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And I really love putting all new hardware on stuff, its so much more enjoyable
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Sub frame spacers back from hard black anodizing and installed.
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And finally the rear sub frame, diff, c-arms, sway bar etc all installed and looking pretty.

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Last edited by my2000apb on Tue Apr 02, 2013 10:31 am, edited 1 time in total.
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq TALL DECK STROKER this

Post by my2000apb »

More update!!

Just a bunch of smaller random things I’m making progress on

I’m going to be using qty 2, oem 4kq rad shroud flaps, going to mount them sideways on my front mount radiator shroud I made up. They should fit quite nicely.
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Toph is making a VERY SWEET ecu/relay mounting panel for the car. The hinge mounts about halfway up the firewall and hinges downward for wiring access. It will be covered in OEM black carpet. And is VERRRY CLEAN of an install. All the relays and ecu will be tucked up into the old AC area. Here’s a pic, much more to come.
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Shifter pedestal all sealed up and painted
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O1e shifter linkage rebuild kit
PN 8D0798151
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I decided that I should heat shield the passenger side engine mount as its pretty close to the exhaust manifold. I used alu/fiber backed tape all the way around and 2 small 1/8” rivets to hold it in place and keep it from peeling back.

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glibobbo21
Posts: 659
Joined: Wed Feb 27, 2013 11:51 am

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by glibobbo21 »

no heat will get to any of you guys' parts.
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

Update!!!
Ok I got a little bit more garage time this week.
The clutch, pilot bearing, throw out bearing and bell housing shield all in place and mounted up.
Also dropped the motor/trans into the bay.
The manual steering rack adaptation happens tonight, then the steering rack goes in, and assembly time!!!!

I wrapped up the starter in heat shielding, and got it mounted up to the trans and engine.
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So I started putting everything together and just wasn’t quite happy with the amount of clearance between the radiator fan and the serpentine tensioner. I wanted MORE!! So I made more haha. I took the shroud off the radiator and cut it down and re-flanged it. Now it sits closer to the radiator and gives me additional clearance around the tensioner that I wanted.
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I also mod'd some threaded clips to use on the lower shroud mounts
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I also marked and cut out the holes for the shroud flappers, one side done, one to go.
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Also got a list of parts that came in Thursday and more due in Friday
Rear ball joints
Front strut mounts
Water outlet gasket
Genuine ABF timing belt
Oem sway bar bushings
And more stuff I prob forgot


Mega weekend progress to come, check back Monday for updatage!!!!
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

UPDATE!!!
I spent most of the weekend out in the garage and got a lot done but never as much as I want to! Radiator/shroud/flaps/ fan etc is all done primed and painted waiting for install.

Prepping to cut the flapper holes out
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Flapper holes cut
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Shroud, fan, flappers etc. all together and ready for install
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I also made up some very “new England” ABS sensor plugs to keep grime out until I utilize wheel speed / ecu functions. Made out of some hardwood dowel, with a pilot and set screw. All stainless hardware yay
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my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

MORE UPDATE
I also got a few of the smaller tasks done that I had been putting off.

With the new intake manifold / alternator / serpentine bracket and mounting I had to remake my post IC boost pipe. It was pretty easy and the only part that took a little time, was placing the BOV and making the hole for that. BOV will be jsut behind the drivers headlight.
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I also refreshed my tie-rod / engine bay boots.
Cleaned them up with some simple green and steel wool, new rivets and back in the car they went
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my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

And a little more, Toph and myself have been working on this ecu / relay mounting tray for a little while now. The tray will hold all of the new vehicle electronics that are going to be installed. The VEMS ecu and a number of aux. relays will also be mounted here. The tray pivots on a hinge near the front upper of the passenger footwell. It mostly takes up all the space where the A/C used to reside. It hinges up and mounts under the glovebox. Very tidy

Ill get some installed pics tongiht
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my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

well I guess ill work on this one today
User avatar
vt10vt
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Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by vt10vt »

my2000apb wrote:well I guess ill work on this one today

Life must be real hard having to choose which badass project to work on especially on a Monday.
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

well sometimes it is!!! id still rather mount my tilton dif and trans pumps/coolers in the vrt cq than do 4kq body work :/ but I digress, both are still better than most options out there to occupy myself

theres about 50 pics from the last round of work that ill post up tonight

its down to cabin wiring(engine bay wiring done!!!!) interior reassembly and PAINT!!!
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

UPDATE!!!

Ok after a break, I’m back to the 4kq. Lets get caught up with all the pre-carlisle stuff.

Im running a larger 2.7t aux water pump, the 16v/aba combo, longitudinally mounted etc. most of the coolant hoses needed to be modified for everything to fit well.

The small F hose out of the water pump was plastic oem shite, so I made one out of 16 ga. Steel and tached on a few small beads to help keep the hoses on.
F hose in progress.jpg
F hose in progress.jpg (1.55 MiB) Viewed 35062 times

new F hose.jpg
new F hose.jpg (1.71 MiB) Viewed 35062 times




The other larger coolant hose is an AEB unit modified to fit the 16v head outlet.

coolant hardline mockup.jpg
coolant hardline mockup.jpg (1.26 MiB) Viewed 35062 times

coolant hardline welded.jpg
coolant hardline welded.jpg (1.09 MiB) Viewed 35062 times

coolant hardline welded, rear head.jpg
coolant hardline welded, rear head.jpg (1.13 MiB) Viewed 35062 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

Once finish welded I got them blasted and powder coated black texture.

And here they are reinstalled.
coolant F hose pc'd and installed.jpg
coolant F hose pc'd and installed.jpg (1.35 MiB) Viewed 35063 times

coolant hardline pc'd and installed.jpg
coolant hardline pc'd and installed.jpg (1.77 MiB) Viewed 35063 times

coolant lines installed.jpg
coolant lines installed.jpg (1.98 MiB) Viewed 35063 times



I also got some replacement heater core hoses, and a fresh heater core hose grommet(scirocco fitment), and here it is installed.

new heater core hoses and grommet.jpg
new heater core hoses and grommet.jpg (1.26 MiB) Viewed 35063 times

new heater core hoses and grommet2.jpg
new heater core hoses and grommet2.jpg (1.39 MiB) Viewed 35063 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

UPDATE!
I also finally got around to making the spacer for the ABZ alternator mounted on the ABA oem bracket/tensioner. Its about 9mm thick and, 0.009” oversized vs the alt. shaft, so it fits pretty well.

Here it is
alt pulley spacer.jpg
alt pulley spacer.jpg (1.22 MiB) Viewed 35063 times


alt pulley spacer upclose.jpg
alt pulley spacer upclose.jpg (1.19 MiB) Viewed 35063 times



And how ironically the 6 rib serp belt I need, 975mm is not available in the USA!!! WTF!!! It’s a basic length 6 rib!!! Im sure I could have found something a tad shorter or longer, but 975 is perfect, oh and its from a ABF haha lmao! A mk3, euro 16v talldeck hahaha

So here is the belt installed in its euro-only glory!
abf belt w spacer fits perfect.jpg
abf belt w spacer fits perfect.jpg (1.13 MiB) Viewed 35063 times

ABF serp belt installed.jpg
ABF serp belt installed.jpg (1.31 MiB) Viewed 35063 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

UPDATE!!!
I’m running a Stebro rear muffler from a CQ. There is a small difference where it mates to the midsection, but as I was building it all from scratch that was a non-issue, well nothing a v-banding can’t fix

BUT! There was a larger issue at hand. The bumper cutout for the exhaust tip on a b3 is much more inboard compared to a b2 chassis car. So the muffler got some corrective surgery.
I welded the tips together, right where they attach to the exhaust tubing, out of site, inside the bumper. Above and below, with a short piece of 3/8” rod. This will help keep them aligned with each other as we extend the tips.

lining up exhaust tips.jpg
lining up exhaust tips.jpg (1.41 MiB) Viewed 35060 times

b3 to b2 exh tip relocation.jpg
b3 to b2 exh tip relocation.jpg (1.42 MiB) Viewed 35060 times


And here is the tip extension all welded up
exh tip relocation welded up.jpg
exh tip relocation welded up.jpg (1.7 MiB) Viewed 35060 times



And the complete exhaust, FINISHED!!! Turbo to tips, well damn I need an o2 bung but that’s easy.
exh finished, turbo to tips.jpg
exh finished, turbo to tips.jpg (1.22 MiB) Viewed 35060 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

UPDATE!!!
With the re-modified intake manifold I needed to change my post IC boost piping around a bit. I also got all the pipes bead rolled to keep the couplers on.
beadrolled boost piping installed.jpg
beadrolled boost piping installed.jpg (1.18 MiB) Viewed 35060 times

post IC piping and BOV installed.jpg
post IC piping and BOV installed.jpg (1.57 MiB) Viewed 35060 times



I’ve also seen enough compressor outlet silicone couplers fail to know the following was a great idea! I completely wrapped the couplers with Thermotec insulated wrap. This will keep a lot of the manifold heat off the coupler and ensure its longevity.
insulated compressor outlet silicone.jpg
insulated compressor outlet silicone.jpg (1.2 MiB) Viewed 35060 times


I also ran my starter lead and sleeved it in OEM fire sleeve. It’s also attached to the bell housing shield to keep it from moving around/chaffing etc.
starter cable mounted.jpg
starter cable mounted.jpg (1.11 MiB) Viewed 35060 times


I rebuild my rear tie-rods with new boots and grease. The joints themselves were in good shape but the boots were all cracked and dry. So I replaced the boots and packed them back up with grease. While they were apart, I cleaned them up and chased the threads. Reassembled with anti-seize, they adjust nice and smooth.
fully rebuilt rear tie rods.jpg
fully rebuilt rear tie rods.jpg (1.74 MiB) Viewed 35060 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

UPDATE!!!
Almost back up to date. So I am using a oem cv heat shield on the passenger front. It’s obviously on there to keep the boot from melting, but the added light impact/road grime protection is a nice addition. I wanted the same protection for my driver’s side.

I got ahold of another cv shield and set to mounting it up. The bolt hole provisions aren’t on the drivers side, well kinda. There are a few bolt holes. Some of the 6 speeds have the bolt holes as they have dual dp’s(2.7tt, 4.2, etc.) I’m running a five speed o1e from an urS4/6.

drv side o1e.jpg
drv side o1e.jpg (1.23 MiB) Viewed 35011 times

drv side 01e cv shield.jpg
drv side 01e cv shield.jpg (1.31 MiB) Viewed 35011 times



So I made an adapter plate to mount to the transmission and I will mount the cv shield to the adapter plate.
dr side cv shield bracket.jpg
dr side cv shield bracket.jpg (908.89 KiB) Viewed 35011 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

Here is the bracket and cv shield installed.

dr cv shield installed.jpg
dr cv shield installed.jpg (1.17 MiB) Viewed 35009 times


dr cv shield installed 2.jpg
dr cv shield installed 2.jpg (1.45 MiB) Viewed 35009 times



And the adapter bracket up close

dr cv shield adapter upclose.jpg
dr cv shield adapter upclose.jpg (2.02 MiB) Viewed 35009 times


and here's a pic of the passenger side, slightly modified for DP v-band clearance
modified axle shield for DP vband clearance.jpg
modified axle shield for DP vband clearance.jpg (1.54 MiB) Viewed 35009 times
Last edited by my2000apb on Sun Aug 18, 2013 11:46 am, edited 1 time in total.
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

Update!
Earlier I built a rugged/removable mega fog light bar. I have 6 Hella 500 or 550’s. the lower two will have an “arm” switch on the dash and will be actuated by the high beam switch. The upper four will also have an “arm” switch and be actuated by a small push button switch on top of the shifter knob.

Having previously run several different fog light switch setups, I was always unhappy trying to find the switch on the dash mid-corner/oncoming cars etc. The switch placement on the shifter knob makes it soooo much easier to turn off/on, while maintaining “hands on” controls the whole time. This is a much better solution.

Mocking up the fog light harness.
building megafoglight harness.jpg
building megafoglight harness.jpg (1.34 MiB) Viewed 35009 times

building megafoglight harness2.jpg
building megafoglight harness2.jpg (1.1 MiB) Viewed 35009 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

Here is the fog light harness finished on the bar. I just need to get the plug for the connections into the chassis harness and wire it in.


foglight harness finished.jpg
foglight harness finished.jpg (948.89 KiB) Viewed 35009 times

foglight harness finished2.jpg
foglight harness finished2.jpg (1.28 MiB) Viewed 35009 times

foglight harness finished3.jpg
foglight harness finished3.jpg (1.15 MiB) Viewed 35009 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

Update!!!
I made up some adapters to go from the k24 > AN fittings. They are some factory flare ends and bends, mostly from a 2.7t partout, tig’d together. Then sleeved with Earl’s Flameguard, and earl’s flameproof tape.

k24 oil and water adapters done and installed.jpg
k24 oil and water adapters done and installed.jpg (1.87 MiB) Viewed 35015 times



I also ran the alternator cable and sleeved it in Tech-Flex. I had a few mk4 wire clips and fit nicely to hold the cable from moving around.
alt cable run.jpg
alt cable run.jpg (1.39 MiB) Viewed 35015 times

alt cable mounted on new mk4 clips.jpg
alt cable mounted on new mk4 clips.jpg (1.57 MiB) Viewed 35015 times



I also ran my new fuel pump wiring. I just need to put the terminals on and reinstall the fuel tray.
new fuel pump wiring.jpg
new fuel pump wiring.jpg (1.22 MiB) Viewed 35015 times
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: Tim's '86 BLAZE 4kq uploading pics +update

Post by my2000apb »

Update!!!

I’ve made ALL NEW brake lines. New tube, fittings, soft lines, adapters etc. oh and new 2 piece strut nuts and bolts.
Here is a rundown with pics, and the part numbers in the background.

new strut bolts and nuts.jpg
new strut bolts and nuts.jpg (1.66 MiB) Viewed 35015 times

new strut nuts.jpg
new strut nuts.jpg (1.02 MiB) Viewed 35015 times


new brake line T.jpg
new brake line T.jpg (1.02 MiB) Viewed 35015 times


brake line clip.jpg
brake line clip.jpg (1 MiB) Viewed 35015 times

brake line clip2.jpg
brake line clip2.jpg (1.44 MiB) Viewed 35015 times
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