300bhp motor goes in....
Discussion
These are extracts of a thread on Classic Audi Forum, the RallyRep's getting an AAN (300bhp 20V Turbo 5 pot, sport quattro'esque motor) grafted in.
The posts here are in date order...
P1 - Sunday 6th...
Well there is this...
http://www.youtube.com/user/Isimmorallyrep?feature...
The last start up and run we'll witness as a KV... Today, it ran over for it's heart transplant... The KV had a suitable run up to temperature, run up to full power and cool down...
Andrea followed us over with the newly rebuilt WR and this evening we've sat here talking about how sad we'll be to see the demise of the 'mad-as-a-box-of-frogs-107db-rallyrep'...
When she comes home, she will be so much quicker, but somehow.......
Different...... And different will be hard to accept after such an incredible engine.:cryin:
Here are a few videos for old times sakes... It'll never sound like this again...
http://www.youtube.com/user/Isimmorallyrep?feature...
http://www.youtube.com/user/Isimmorallyrep?feature...
http://www.youtube.com/user/Isimmorallyrep?feature...
http://www.youtube.com/user/Isimmorallyrep?feature...
Monday 7th -
Well, the KV's on a pallet...
And the RallyRep looked like this at 4pm
By 6:30pm we'd got the AAN offered up and seated, but John's got to sort out the Needle bearing on the Crank. So it's back on the stand again tonight.:tup:
8th Feb
KV engine's gone off to it's new home...:sad:
The PAS rack has been mated with the S6 pump pipes.
The servo plumbing and one way valve has been modified.
The ECU position finalised
Fuel lines moved
S6 crank plug removed and Roller needle bearing ordered.
Sachs clutch aligned
14" Kenlow twin speed fan mounted, and wiring sorted. (it's a tornado of a thing!)
New S6 engine mounts fitted...
Numerous other bits and bobs sorted, whilst we wait on the Roller needle bearing.
John's had a good day... Bless him.:nod:
Oh, and my Crash-helmet's arrived...
09th Feb
I'll keep this short and sweet, been a busy day, early start tomorrow... But we are here...
We planned to run the existing Rad, but it's just not going to work, so there's a custom built Aluminum rad set for delivery on Wednesday 16th...
- - - - - -
[quote]No photos again, sorry... But, the ECU's located, wiring's all through the bulkhead... Front end panel is modified and fitting, but removed again, awaiting the Intercooler arrival tomorrow. Radiator also now 'in the post'... POS's mounted, as are several other 'bits' like the Altitude Sensor. Other bits and bobs of plumbing done too... So, getting there.
[/quote]
- - - - - -
Got some photos now -
Front end panel back in - You get an idea where the intercooler's going. (incidentally, it arrived this afternoon).
ECU and Wiring brought through to cabin, ECU has got a location, but was unclipped here.
Overall view of the build, Radiator arrives tomorrow hopefully.
Ford Focus RS Ceramic heatshield will be used to protect the wiring (neither the 'shied or the wiring are in their final position here), there will additionally be shielding between the hot side and the air intake side. Air filter design not confirmed yet.
That's where we're at, the car must be running for Sunseeker Rally in Bournemouth, 26th Feb... So the heat is on... But... Unforeseen event aside, it's looking very achievable... (famous last words, is that!).
The posts here are in date order...
P1 - Sunday 6th...
Well there is this...
http://www.youtube.com/user/Isimmorallyrep?feature...
The last start up and run we'll witness as a KV... Today, it ran over for it's heart transplant... The KV had a suitable run up to temperature, run up to full power and cool down...
Andrea followed us over with the newly rebuilt WR and this evening we've sat here talking about how sad we'll be to see the demise of the 'mad-as-a-box-of-frogs-107db-rallyrep'...
When she comes home, she will be so much quicker, but somehow.......
Different...... And different will be hard to accept after such an incredible engine.:cryin:
Here are a few videos for old times sakes... It'll never sound like this again...
http://www.youtube.com/user/Isimmorallyrep?feature...
http://www.youtube.com/user/Isimmorallyrep?feature...
http://www.youtube.com/user/Isimmorallyrep?feature...
http://www.youtube.com/user/Isimmorallyrep?feature...
Monday 7th -
Well, the KV's on a pallet...
And the RallyRep looked like this at 4pm
By 6:30pm we'd got the AAN offered up and seated, but John's got to sort out the Needle bearing on the Crank. So it's back on the stand again tonight.:tup:
8th Feb
KV engine's gone off to it's new home...:sad:
The PAS rack has been mated with the S6 pump pipes.
The servo plumbing and one way valve has been modified.
The ECU position finalised
Fuel lines moved
S6 crank plug removed and Roller needle bearing ordered.
Sachs clutch aligned
14" Kenlow twin speed fan mounted, and wiring sorted. (it's a tornado of a thing!)
New S6 engine mounts fitted...
Numerous other bits and bobs sorted, whilst we wait on the Roller needle bearing.
John's had a good day... Bless him.:nod:
Oh, and my Crash-helmet's arrived...
09th Feb
I'll keep this short and sweet, been a busy day, early start tomorrow... But we are here...
We planned to run the existing Rad, but it's just not going to work, so there's a custom built Aluminum rad set for delivery on Wednesday 16th...
- - - - - -
[quote]No photos again, sorry... But, the ECU's located, wiring's all through the bulkhead... Front end panel is modified and fitting, but removed again, awaiting the Intercooler arrival tomorrow. Radiator also now 'in the post'... POS's mounted, as are several other 'bits' like the Altitude Sensor. Other bits and bobs of plumbing done too... So, getting there.
[/quote]
- - - - - -
Got some photos now -
Front end panel back in - You get an idea where the intercooler's going. (incidentally, it arrived this afternoon).
ECU and Wiring brought through to cabin, ECU has got a location, but was unclipped here.
Overall view of the build, Radiator arrives tomorrow hopefully.
Ford Focus RS Ceramic heatshield will be used to protect the wiring (neither the 'shied or the wiring are in their final position here), there will additionally be shielding between the hot side and the air intake side. Air filter design not confirmed yet.
That's where we're at, the car must be running for Sunseeker Rally in Bournemouth, 26th Feb... So the heat is on... But... Unforeseen event aside, it's looking very achievable... (famous last words, is that!).
Edited by Isimmo on Tuesday 15th February 20:54
ecain63 said:
Looking bloody great mate! I do miss my rally rep builds, had much fun with my old Pug 205's. If I get down to Sunseeker I'll keep my eyes peeled. Great build there lad!
Fingers crossed, it'll be doing the Demo runs over the Somerly House stage on Saturday with several other Rally and Hillclimb quattros... Gawd, I do hope it makes it...
Followed this on CA as well, good luck with the noise department. If at al possible the stromung system on my urs4 was a lot throatier than normal without being obscene, but they are a tad expensive plus would need modifying to fit.
A great project indeed, although only 300bhp, you are nto trying near hard enough!
A great project indeed, although only 300bhp, you are nto trying near hard enough!
So how are things coming along? are you going to make it in time for the demo run at sunseeker?? I look forward to seeing the Audi with the new lump and more grunt!
I'll be there with Lanciasport again. We have a few Grales doing the demo's if we can get confirmation of the regs we need to meet?
I'll be there with Lanciasport again. We have a few Grales doing the demo's if we can get confirmation of the regs we need to meet?
DumpTruck said:
So how are things coming along? are you going to make it in time for the demo run at sunseeker?? I look forward to seeing the Audi with the new lump and more grunt!
I'll be there with Lanciasport again. We have a few Grales doing the demo's if we can get confirmation of the regs we need to meet?
The regs are a mistery to us too, I think the only major thing last year was the 2005Snell spec crash helmets. They let our old girl run as was, and that's a mismatch of Rally and Road bits without battery cut-outs etc.I'll be there with Lanciasport again. We have a few Grales doing the demo's if we can get confirmation of the regs we need to meet?
Hopefully it'll be there... Be gutted if we don't make it. There should be 6 Rally quattros again.
Well, the Radiator arrived yesterday, it's now fitted and the fan attached, tomorrow it's the big push for the ECU and wiring, it's all in place, but just needs connecting, there's the additional matches into the CQ loom, such as the feeds to the gauges, warning lights etc, then there are the feeds (perm live, ign live, earth etc) to power up the ECU and engine-bay loom. There's still plenty to do, but it's getting close.
Well i hope you make it in time! i'm also planning to go up to Race Retro the following day if your up for that? http://www.raceretro.com/
The next event for the lancia crowd is the Rally Show at cornbury (Nr Oxford) which i guess you will be going to ??
http://www.therallyshow.org/
There will be demo runs here too , but you get to drive the entire stage not just a short few hundred metres like sunseeker! See the link below for a guide to the stage! looks like it could be fun??
http://www.youtube.com/user/TheRallyShow?feature=m...
The next event for the lancia crowd is the Rally Show at cornbury (Nr Oxford) which i guess you will be going to ??
http://www.therallyshow.org/
There will be demo runs here too , but you get to drive the entire stage not just a short few hundred metres like sunseeker! See the link below for a guide to the stage! looks like it could be fun??
http://www.youtube.com/user/TheRallyShow?feature=m...
Oh boy, what a day, all the ECU wiring connectivity has been completed, and the front has been rebuilt to fit... We're knackered though!
It was later altered after this photo so it sits like the top photo, but with the lamps.
The front end is back off again now, if only to give easier access to the last of the plumbing to be done.... Battle recommences tomorrow.
It was later altered after this photo so it sits like the top photo, but with the lamps.
The front end is back off again now, if only to give easier access to the last of the plumbing to be done.... Battle recommences tomorrow.
Gawd, that was a hard days work, very good progress really, but even so...
Basically it's all been the fabricating and the plumbing, the brackets and 'air management' across the front of the car.
From left to right across the front we've got, oil cooler and air duct, air filter cold air trunking, intercooler, air access space for radiator...
Internally (topside of the engine bay) this reads as...
Air filter with shield and direct cold air trunking, Focus RS turbo heat shield, then turbo, manifold etc...
Front end wise, pretty much all air onto the front end is now used/managed to aid cooling, it's necessitated an unbelievable amount of metal and plastic removal, there really is not a lot left.
Fan wise, the 3 speed 14" Kenlowe now has a Kenlowe fan controller, so it's a stand alone system, afterrun for turbo, fuel rail and rad fan have also been wired up. The VAGCOM data ports are in place, the wiring is pretty much there, just the tacho and Aux gauges, then put the dash clocks back in, wiring needs 'finishing', as in securing around the bottom of the relay plate.
There's loads more been done over the last couple of days but I'm too knackered to think about it...
Basically it's all been the fabricating and the plumbing, the brackets and 'air management' across the front of the car.
From left to right across the front we've got, oil cooler and air duct, air filter cold air trunking, intercooler, air access space for radiator...
Internally (topside of the engine bay) this reads as...
Air filter with shield and direct cold air trunking, Focus RS turbo heat shield, then turbo, manifold etc...
Front end wise, pretty much all air onto the front end is now used/managed to aid cooling, it's necessitated an unbelievable amount of metal and plastic removal, there really is not a lot left.
Fan wise, the 3 speed 14" Kenlowe now has a Kenlowe fan controller, so it's a stand alone system, afterrun for turbo, fuel rail and rad fan have also been wired up. The VAGCOM data ports are in place, the wiring is pretty much there, just the tacho and Aux gauges, then put the dash clocks back in, wiring needs 'finishing', as in securing around the bottom of the relay plate.
There's loads more been done over the last couple of days but I'm too knackered to think about it...
DumpTruck said:
Excellent Well done! Will you make it at the weekend?
We'll be out and running tomorrow with it, get some mileage up... If it's okay through that and Friday (and there's no reason to suspect why it shouldn't), then yep, the old girl will be there...
It'll be a lot quieter than last year, but a lot quicker... 'Ying-and-Yang'.
Sh!te we are sailing close to the wind with this one, after about three hours of 'final prep' we went into the 'final test'... Which snagged a few 'b@stards' we weren't expecting. First off, the oil pressure warning systems were 'errant' and needing managing, then we had a brand new Kenlowe rad fan controller go feral, luckily, we had a new one in the workshop. The basic stuff, like the indicators, side lights and the (rear)fog-light went nuts, but the big stuff, 520watt rally lamps worked fine... Then, on the first test run, the old girl was awesome, right up until it popped the high pressure feed blank off the Power steering hydraulic system pump... So we're over-pressuring the system.... The cure MUST come tomorrow, with a new PAS reservoir, cooling coil and balance return...
Why do I do it????
Why do I do it????
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