The Project Pad

MORE!!!
I also got started on the hanger braces for the turbo/ex mani and the downpipe as well.
Just a few sneak peeks of the mounts for the braces, those will likely get finished this week as well.




I also made up a heatshield for the front passenger CV boot/joint, its ultra thin alu for now and ease of mockup, I’ll be making it out of 0.125” aluminum sheet for the final version.


I also started making a heatshield for the upper radiator hose. I will anodize and then wrap it in gold foil. the upper radiator hose is 20AN earl's with FlameGuard sleeving as well. I'm more concerned with keeping the hose itself from extreme heat vs. coolant heating up just a tad. between the heatshield and the sleeving, I'm sure it'll be fine.

very much coolness goes on here.

Keep it up Tim, and you might just have this running in time for carlisle next year!

speeding-g60 wrote:very much coolness goes on here.

thank you sir, you've made some pretty epic stuff too.

this shall be the summer of badass vrt cq, minimal work until mid august, so its gametime!!!!

DE80q wrote:Keep it up Tim, and you might just have this running in time for carlisle next year!

yeah itll be damn close mechanically, but its paint,cage, eng mgt that's my big huddles financially

getting more done every day. if all goes well by the end of this month, intake manifold will be done, downpipe and w/g dumps, all boost/inlet plumbing complete, custom axles and spacers, custom subframes and rear tie rods.

I also have a batch im prepping to go and get clear and black anodized, so a lot of the aluminum work will wrap up this month.

back to the garage, more updates to come!

wheres the pic dump? i know youve been doing stuff!

glibobbo21 wrote:wheres the pic dump? i know youve been doing stuff!

well I had been making epic progress, down pipe done, WG reroute all done except the hole in DP and the v-band flanges welded on, and , I guess, in my progress I totally spaced putting my tube SF back. so I located the lower v-band for the downpipe properly for an OEM SF vs. my custom SF. so I'm back out to cut a chunk of DP off, relocate the v-band connection and finish up the WG re-route.

ill get an update done here shortly, but no more exhaust pics until the WG and DP are DONE!!!
but I've finished up plenty of other stuff to still have a meaty update. check back late tonight


and a single teaser pic!!!

With all the GTR talk lately I can't help wondering where this is at...?

All_Euro wrote:With all the GTR talk lately I can't help wondering where this is at...?

Exhaust is done from head to tailpipes except for some EGT and 02 bungs.
wastegate merge and dump back into DP is done
Turbo hanger brace is nearly done

BIG thanks to Shawn, vt10vt, for coming down and giving me a hand for the day!!!
we got the oil cooler mounting nearly finished, cv boot heatshield final ed. made. also worked on my upper radiator hose heatshield,
epic progress, ill get an update loaded tonight

UPDATE TIME!!!!!
Ok let’s get caught up. I got 3X 10AN male bungs welded on my valve cover for the catch can lines.


I got a TON of AN plumbing supplies for the oil system, trans and dif coolers and pumps, catch can lines, vacuum and boost reference lines, blah blah.


Last fall Jim and myself stopped by a scrap yard a few towns over and I found a few of these!!! They are from electric pole turnbuckles. They shoduld make for some good, strong, removable tow hooks. The longer one goes in the front, so it can stick out through the bumper and the rear is a bit shorter and even thicker ahahah.



I welded a plate on either side of the reciever threaded part. The plates are slide up through a hole in the bottom of the frame rail, up into slots cut for the upper edges of the plates and seam welded on either side.


They are a tad recessed and only need a little bit of flapper disc to make them smooth. I then welded a 2x3” plate around the entire area. It had qty. 8, 3/8” holes in it along the weld seams of the reciever’s plates. And again plated and seamed below the framerail. I just need to drill a hold in the front aluminum cross member for the tow hook. I knew I was going to do this when I built the front cross member and there is a ¼” wall thickness 1.75” tube going through the mounting plates for just this purpose.

UPDATE!!!
The catch can will be mounted under the strut tower bar just like the coolant tank. I will make it out of some round stock and a cap, as well as a box for the upper.

Here it is as a template



I am using dual K&N 1” breather filters on the catch can outlet. I went a tad over the top and beadrolled the ends of tubing where the filters attach. If there is any real pressure buildup to the point of needing the beadroll, I’d be screwed. So its more of a fit and finish thing.


And taped together.

MORE!!!
Catch can ready to weld.



I drilled a ton of holes in a thin plate and will be using that as a separator layer for the media.



And here is the catch can all finish welded and mounted up. I still need to clean it up a bit near some welds,( thin thin material) caused a few blisters. Give it a good sandblast and some clear powdercoat.



I then made up the valve cover to catch can lines in Earl’s black Pro-Lite 350 Hose, 3X 10AN 90’s to straight’s, into the can.
they are just threaded on and not correctly aligned.

UPDATE!!!
I finally got back into exhaust work after taking a short break from stainless. Here is the downpipe, nearly ready except for adding a small wedge.


Lower portion of the downpipe tacked together.


Here is the front Wastegate outlet that needs to be finished. It’s a bit tight up front with the Wastegate outlet, airbox intlet, headlight, radiator and shroud, but it fits!




Start of the tight radius outlet for the front Wastegate.

MORE!!!
Completed front Wastegate outlet

MORE!!!
In order to make the Wastegate outlet “Y” removable without taking everything apart, I will be adding an additional Tial v-band connection for the front gate, just before the “Y” junction.

I purchased two additional MVR 44mm Wastegate inlet flanges that would normally belong on an exhaust manifold. I put these on the lathe at Ryan’s and cut them down to fit and recess perfectly with my 2.0”, 304SS 16ga. Tubing that is used on the Wastegate outlets.


And another shot of the rear WG outlet.


And a few pics of the Wastegate outlets merging



And the Wastegate merge back into the downpipe, its dual 2.0” to 2.5” v-band and flex-joint and then back into the downpipe.


NOTE: the sizeable hole between the downpipe and the Wastegate outlet Y , flex, v-band etc. the steering rod has to fit through there!!! With the HTMS steering arms on my strut tubes and upper ground control plates, the steering rod has been run through full droop and compression at full steering range of motion, and it clears!!!

UPDATE!!!
I got started building a turbo hanger brace. The main vertical is ½” stainless rod and the side supports are 3/8”. It attaches up front to two spare m8 bosses in the head, just forward of the exhaust manifold flange.

The rear mount is on an upper boss on the cylinder head and a studded boss located very high up on the exhaust manifold.

The lower center mount is a stainless, extra large diameter shoulder bolt, so the machined should part of the bolt goes though the mount arm and in shear. It is very strong


Im just waiting on a 1” punch and flare, sheetmetal tool and I’ll be adding one small, punched sheet brace to the turbo hanger brace to finish it off.

I’m awaiting some machined SS adjusters with LH and RH threads, those are just welded bolts for mockup






And a few pics of the oil cooler mount that Shawn, (vt10vt) helped me make up when he was down here a few weeks ago.

I just need to add another leg to a silicone isolater mount tab under the frame rail, to triangulate it, and it’s done, and time for plumbing.

Fvcking love updates to this thread.

UPDATE!!!
I got a 16AN bung and elbow, welded up to the oil pan for the turbo oil drain return. The hose is made up with Earl’s pro-lite and wrapped in FlameGuard insulation, as it runs close to the Wastegate outlet tube.



I also got a spare rear diff modded up for the pump/cooler return line. It sprays right on the rear differential ring gear.


I just need to make the pump and cooler brackets, more on that later.
I also had Ryan replace the plate on my valve cover with something a bit thicker so some engravings, more on that later

MORE!!!
I sent some drawings to a machinist buddy of mine and got the these beautiful pieces back!!!

The first is a receiver for a 3/8” rod end. I am also having a threaded RH/LH adjuster made to tension/adjust the serpentine belt. The rod end fits in snugly with washers and Seals-It rod end seals.



The second piece is the water/methanol manifold. It has an 1/8” NPT outlet for a 4AN adapter for each cylinder and an add’l outlet for a nozzle at intercooler outlet. It will be mounted on threaded bosses on the intake manifold for nice short lines to each cylinder’s nozzle.
It will also get anodized black when all the parts go out.

UPDATE!!!
So the engine and trans has been pulled so I can get some work done in the engine bay. Here it is on the engine stand.

UPDATE!!!
I picked up these ‘70-78 Z car flares online somewhere and will be doing a bit of work to get them to flow well with the CQ, like it or not, I’m doing it, I need/want all the tire I can get under there. 265/40/17 yup no prob, will go 275/35 at some point once its dialed in.




And just screwing around with a 245 on a 17x8” fat five




I also picked up a SEAT Cupra R lip spoiler to put on the bottom of my S2 front bumper.

Now back to it!!

HOLY SHIT! Now that's an update. This thing is going to scream!

NICE update tim!!

how much do those flares stick out? the ones im using are universal ebay fiberglass ones, $180 shipped. 3" height on em.

I'm about to put a set if those flares on a buddies b5 passat. Your fab work and attention to detail is completely over the top!


Old Audi's rule all.

Wow, blown away by the fab. Do you own a shop? Amazing stuff.