The Project Pad

PRY4SNO wrote: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!

Thanks, I'll definitely take you up on that. So far, I think I just need the lines that run to/from the compressor (to the evaporator and dryer). I've already got the compressor and mount.

For reference, you need to use the return fuel line from the 20v as the 20v has a larger fitting. 20v screws right into the 20v FPR. The inlet fuel pressure line fits just fine, once you remove the banjo adapter.

Injectors (Bosch 0280155759) and adapters installed. $88 for a set of 5 that were cleaned/tested and come with a 5yr warranty!

IMG_20150527_201530788 by Vex Art, on Flickr

Mounted in the fuel rail. I think I want to find some clips to hold the injector adapters into the fuel rail. I'm guessing that with the car N/A, the fuel rail bolts will be plenty, but it's just an extra safety factor. I think most people don't even use the lower injector clips like i did.

IMG_20150527_203817159 by Vex Art, on Flickr

New to me radiator installed and shroud painted.

IMG_20150527_203845117 by Vex Art, on Flickr

Starting to look more like an engine!

IMG_20150527_203832815 by Vex Art, on Flickr

HPR poly subframe bushings installed.

IMG_20150531_185920753 by Vex Art, on Flickr

20v brake booster line didn't reach the 20v intake port and the 20v didn't come with a vacuum booster, so....found one off a 1.8T New Beetle at the junkyard that worked perfect! Also got some new OEM-style cloth braided vacuum hose.

IMG_20150530_145727055 by Vex Art, on Flickr

More goodies to install. Brass distributor gear and silicone crankcase breather hose.

IMG_20150529_202217280 by Vex Art, on Flickr

The cardboard radiator ducting was deteriorated so I made some new ones out of thin aluminum.

IMG_20150531_213533323 by Vex Art, on Flickr

IMG_20150602_203651172 by Vex Art, on Flickr

Got the breaker and terminal lugs to build my battery cables, still waiting on the 1/0 SGX cable to arrive. Also ordered some 4AWG SGT cable for smaller stuff.

IMG_20150531_221444724 by Vex Art, on Flickr

Started work on the front coilovers and got the lower perch off. The fronts need new Koni struts, which won't arrive in time for Audi Expo so I'm going to reassemble with the stock struts for now.

IMG_20150602_210546190 by Vex Art, on Flickr

IMG_20150602_212201109 by Vex Art, on Flickr

Are you planning on running cruise control?

PRY4SNO wrote:Are you planning on running cruise control?

Hoping to. I've got the 20v CC pump installed and it's pretty much identical to the 20v pump I also have, minus the mounting due to the brake booster. Should work!

Well the marathon to get the car ready for Audi Expo is over and it won't be there :( Attempted to start it tonight, but it looks like I've still got some wiring to troubleshoot as it's not triggering the fuel pump. The final nail in the coffin came when I jumpered the fuel pump relay and found a leaking fuel line. I won't be able to get a replacement or build one before next Saturday. The 20v fuel inlet line is leaking at the crimp going to the fuel rail and it's also not sealing correctly with the 20v body fuel line.

So some updates on the progress thus far...

A thread restorer kit has been invaluable for this build. The car is super clean since it's been a PNW car it's entire life, but there's still some crust on nuts/bolts so this tool has been great for cleaning them up.
IMG_20150610_193656628 by Vex Art, on Flickr

Front coilovers installed
IMG_20150608_210852191 by Vex Art, on Flickr

Rears installed
IMG_20150610_212601162 by Vex Art, on Flickr

16x7.5 TSW Hock's, tires need replaced so I'll run my ABT's for now
IMG_20150608_214511994 by Vex Art, on Flickr

IMG_20150610_212609949 by Vex Art, on Flickr

NAPA sent me the wrong driver's side axle so only the passenger was replaced. Going to order a rebuild kit for the driver side since it seems to be in pretty good shape minus the boots.
Undercarriage shot:
IMG_20150610_215729994 by Vex Art, on Flickr

Brass distro gear installed with roll-pin:
IMG_20150613_162142062 by Vex Art, on Flickr

1/0 SGX battery cables
IMG_20150610_223014699 by Vex Art, on Flickr

IMG_20150613_225532453 by Vex Art, on Flickr

Battery box temp mounted in trunk
IMG_20150614_242111010 by Vex Art, on Flickr

Got a 7A throttle cable since the 20v was too long. Sadly, the firewall and gas pedal connections of the B3 chassis are completely different from B2. So, I modified the 7A cable with the B2 firewall and gas pedal connections. Use some thin aluminum tubing to crimp the two together; tested it with quite a bit of weight and it held.
B3 top, B2 bottom:
IMG_20150613_142609083 by Vex Art, on Flickr

Crimped modified cable
IMG_20150613_173632270 by Vex Art, on Flickr

Cable was still a little long (I think I need to shorten it on the pedal side), but for the time being I flipped the intake bracket and it works great:
IMG_20150613_185123077 by Vex Art, on Flickr

Intake with a simple sheet metal heatshield
IMG_20150614_242031270 by Vex Art, on Flickr

Wow Super clean and great work. Love that intake , i didnt think that "Engine Cover" could look that cool.

Spent the last few weeks waiting on getting the correct adapter for the fuel line. Ordered the wrong one, then got sent the wrong one twice despite ordering the correct one, finally have the correct one on the way.

In the mean time I threw the fuel line on with a crush washer and wrong flare adapter and installed the 7A fuel pump relay and it fired right up.

IMG_20150722_203547307 by Vex Art, on Flickr

IMG_20150725_203054498 by Vex Art, on Flickr

[youtube]http://www.youtube.com/watch?v=26-ZB9bh7Zo[/youtube]

Glamour shots

P1160021 by Vex Art, on Flickr

P1010064 by Vex Art, on Flickr

P1010075 by Vex Art, on Flickr

YES!!! Well done.

Nice! A BBQ car finished early. Can't wait to see it

Very Nice.

Hawt. Nice work!

That engine bay looks clean! Love that silver vein intake.

That last pic is gold.

Very nice! That 7A looks right at home. Well done!

Looks fantastic man! I can't wait to see it in person this year!

Are you driving it yet!?

the german wrote:Are you driving it yet!?

Not yet, stupid work trips and vacation keep getting in the way!

Alright, finally made some progress! Was out of town for work for a few weeks, then some vacation, bought an UrS6 Avant, and a few other things. Countdown is on to BBQ '15....

Tachomter works. Used the tach signal from the 7A ecu, with a 220 Ohm voltage divider.
CLICK TO PLAY
VID_20150905_193037857 by Vex Art, on Flickr

Converted the gauges to LED. Lots of people haven't had success at this, but I think I figured out a selection that works great. Everything was purchased from superbrightleds.com I'll post up a DIY with all the details.

IMG_20150902_210406685 by Vex Art, on Flickr

IMG_20150902_225538347 by Vex Art, on Flickr

IMG_20150905_150324766 by Vex Art, on Flickr

Protizmo AILD-1 created by a fellow Porsche enthusiast on Rennlist. This is a high side LED PWD dimmer that auto learns the rheostat. Most of the current PWM dimmers employ a low-side driver that doesn't work with a common ground circuit like a car. To use these dimmers, you'd have to wire a dedicated circuit just for the LED's. This is the only high-side PWM dimmer I've found that allows you to use the OEM rheostat.
I built a simple wiring harness for it that plugs into the rheostat. Going to make a video of the dimming, but haven't yet.

IMG_20150905_184600269 by Vex Art, on Flickr

And the results.
LED on the left, incandescent on the right.

IMG_20150905_155319168 by Vex Art, on Flickr

Very bright, even in a lit shop.

IMG_20150906_220457022 by Vex Art, on Flickr

Messed around with fitting some Porsche Cup 1 17x7.5 for future reference. I won't be running these at BBQ. Looks like they'll clear the steering arm and fender.

IMG_20150906_141701603 by Vex Art, on Flickr

IMG_20150906_141546109 by Vex Art, on Flickr

Those rims will look awesome on the GT. Don't forget to clean up the inside of the lips. Looks like there is a lot of gunk buildup.

where did you get the alpine white in spray cans? Hope ill be needing some this week or next

Afterthought wrote:where did you get the alpine white in spray cans? Hope ill be needing some this week or next

Some Napa stores with paint centers do custom mix spray cans. I bought off the shelf colors that I kinda blended to match since my paint varies stages of yellowing depending where on the car. Best bet would be to bring in a panel for them to match.

T-minus 4 weeks until I leave for BBQ '15. Want at least a week of daily driving to make sure it's ready, so really t-minus 3 weeks.

New tires are on the way for the TSW Hock's, 205/45R16 BFG g-Force Sport Comp-2.
Other progress from this weekend:
-Aux gauges hooked up and working
-Dash warning lights mostly hooked up, not sure if I quite have the oil pressure buzzer/bulb circuit warning. Also need to figure out the CEL wiring. Parking brake, brake fluid, and coolant level lights are all functionging.
-Windshield wipers and washer are working.
-Windows fixed, faulty switches found AFTER I pulled the drivers side assembly to test it. Thankfully I had some spare good switches around.
-ECU mounted in the glovebox, didn't have enough length to run it over to the far side like the 20v ECU. Glovebox will have to do for now.

Still to do:
-Cleaup wiring, install drivers side lower dash
-Fill/flush powersteering
-Bleed clutch master/slave/brakes
-Fab up exhaust
-Hook up shifter
-Uninstall front suspension to install new Konis
-Uninstall/reinstall rear Konis to adjust them since I don't know what they're currently at
-Fill cooling system, warm up, check for leaks
-Mount front bumper
-Wire up and mount H1/H4 headlights
-Mount new tires when they get here later this week. Cleanup the wheels too; sadly won't have time to powdercoat them.
-Test drive and hope for the best!
-Get an alignment.

Nice! Not too bad, I think I'll make a BBQ list