Andyrews Progress Thread, 1/16/22 A Trip to The Red Barn - Lets fab a Firewall! Options

[Andyrew]

Welcome to my Audi Turbo 914 build thread! This first post has been highly edited for your(and my) ease of navigation.
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(IMG:http://www.914world.com/bbs2/uploads/post-172-1428991066.jpg)
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The car 1973 Porsche 914 1.7 w/ appearance group package
(IMG:http://www.914world.com/bbs2/uploads/post-172-1429499049.jpg)
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The Story:
I purchased this car when I was 14years old and had bought 2 other 914s with it for a measly $1100, The other 2 914’s were basket cases and one had been in a roll over. The previous owner put the 2.0 from the roll over car in this car. I parted out the other two cars and DID A V8 CONVERSION on mine after I couldn’t figure out how to adjust the valves (It seemed easier..). I do a 5 lug conversion as well as put some fiberglass flares on the car and many other things before I decide to paint the car. That is the start of this thread.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i1210.photobucket.com-172-1295463716.1.jpg)
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Next I decide that I don’t like how the v8 drives and how I could never keep it cool so I decide to embark on a journey with an engine I was already more familiar with. The Audi 1.8T.
To start at the 1.8T engine conversion click below.
http://www.914world.com/bbs2/index.php?sho...4780&st=309

Details on the car:
Engine: Audi AEB 1.8t Engine, Fully rebuilt, balanced rotating assembly and blueprinted, balanced and clearanced Intermediate shaft.
Crankshaft: Stock/polished
Rods: Scat Forged I beam rods
Pistons: Stock
Cams: Stock
Valves: Stock intake, Stainless nitrite coated Supertech exhaust AEVN-1103
Valve springs: Supertech high rpm valves SPRK-AUDI18
Piston rings: Goetze 08-502900-00 (Factory stock)
Head gasket: Elring Stock head gasket
Rod bearings: 034 Dry film coated bearings 034-202-1008
Crank bearings: 034 Dry film coated bearings 034-202-1000
Intake Manifold: Stock
Throttle Body: Stock AWM
Exhaust Manifold: APR Iconel Stage 3 manifold
Exhaust: 3" turbo back stainless steel w/ 2 stainless resonators
Intercooler: 700hp air to water core.
Turbo: Comp Turbo triple ball bearing CTB5356
Injectors: Bosch 550CC injectors ported and flow matched to 1300CC
Fuel Pump: Bosch 044 inside 034 Surge tank
Fuel rail: Stock fed with AN10 line
Water pump: Davies Craig EWP150 w/ LCD controller
MAF: PMAS HPX MAF in 3" housing
Boost controller: Cortex EBC

Transmission: Audi A4 1.8 5 speed code EHV FWD unit
100mm stub axles from boxster transmission
eBay sprung type LSD


Wiring: Strip all Porsche wiring, Replace with Audi wiring 100%
Engine Management: Modified OEM Audi Ecu
Power brakes: Not yet
ABS integration: Not yet
Traction control integration: Not yet
Launch control: Not yet
Cruise control: Yes
Climate control/AC: Yes
OBD2 full control: Yes
Check engine light: No smile.gif
Front trunk and rear trunk: YES!


8psi: 240whp (Canyon and autox setting)
14psi: 280whp (Street)
17PSI: 300whp (Track and Street driving) (Estimated power goal)
30psi(E85): 400whp (Full tilt mode)


Suspension:
Raised 911 spindals up front with Koni yellows
Mueller Roller Needle Bearings front and rear in leu of all bushings
Turbo tie rods
22mm Torsion bars
Nascar front sway bar
Koni yellows rear
911 rear hubs with 100mm studs
Ground control coil over kit in rear
225lb springs

Brakes:
911 A calipers front
Stock 914 rear calipers
Vented rotors front and rear
Porterfield semi race pads
19mm M/C
Proportioning valve replaced with T

Wheels:
Boxter rear 17 x 8.5 twists up front with 245 40 17
911 turbo 18 x 10 turbo twists in back with 285 35 18

Body:
Rich Bontempi HPH Flares Front and Rear, Molded
916 front and rear bumpers (front bumper to be reworked completely)
6" ducktail spoiler with supports
Engman long stiffening kit
Seam welded rear
Camp 914 hood shocks rear
Camp 914 Euro front turn signals
Bike rack (IMG:style_emoticons/default/biggrin.gif)

Interior(In Progress):

Fully custom interior (Still in design phase)
Harness Bar
5 point Cam lock harnesses
Pepboys Corbeau style seats





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Now that the intro is done, here is my checklist of things that I want to get done with it.

Register *5-15-11*
Fix ignition **5-30-11**
Tune (again) ecu ** Converted back to Carbs after ECU died 5-30-11**
Clean goo in trunk (pic)
Install Dr window crank *5-30-11*
Change oil ****Finished 1-29-11****
Change water pump *Received Remanufactured pump from Slits 1-26-11****Finished Install w/ hangups 1-29-11****
Flush coolant
Finish targa bar S *Started progress on the bar*
Dr front 1/4 *Sand day 1 1-29-11* *Bondo Day 2-1-11**Primer Day 2-19-11*
Dr door *Sand day 1 1-29-11**Bondo Day 2-1-11*[/url]*Primer Day 2-19-11*
Rocker pannels *5-7-11*
Dr rear 1/4 *Sand day 1 1-29-11**Bondo Day 2-1-11*[/url]*Primer Day 2-19-11*
Trunk *Removed spoiler, Plugged old spoiler holes, Long board sanded trunk*
Rear bumper *Page 8*
Pass rear 1/4 *4-17-11*
Pass door *4-17-11*
Pass front 1/4 *4-17-11*
Front bumper *5-5-11*
Hood *Primer 5-2-11* *Paint 5-15-11*
Top *5-4-11[url=http://www.914world.com/bbs2/index.php?showtopic=114780&st=120#]
Primer sealer *5-15-11*
Paint *5-15-11*
Radiator cutouts in wheel well (And replace hood with stock) ***Completed 1-26-11***
Fix headlights *6-8-11*
Fix horn
Finish seat install ****Progress 1-19-11**** ***Finished 1-26-11***
Finish carpet *6-8-11*
Finish front sway bar
Fix Dr Door handle

This post has been edited by Andyrew: Jan 15 2022, 09:16 PM

[Andyrew]

They were Yummy!


Today I didnt get near as far as I had hoped... Did about 1.5 hours of sanding and then spent the rest of the day trying to fix the washing machine... New machine, Old house... Overflow issue. Still isnt resoved but it works..

Ill put about 2 hours in tomorrow and post of pictures then.

[Andyrew]

Got a little progress today before the game started.
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Finished the filler for the rear fender. From here its final sanding prior to primer filler. Still have some more work to do to get the front fender ready for primer filler.

Ran out of filler so I decided to get working on the targa bar as I could make noise without worry. I still had to finish grinding and rewelding the lip on the targa bar to eliminate it and make the bar smooth (no chrome pieces on the bar)

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Wanted to protect the bondo from the welding. 1/8" MDF board works pretty well.

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Tack welded it up to test it out.

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Stitchwelded it.
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All welded up.

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Highest points of the weld. The top portion is the lip all ground down and welded solid. I'll finish grind it later when I apply some filler.

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Started work on the other side. I think I might finish it tonight depending on how late this football game goes.

[Andyrew]

Finished up sanding the LR fender tonight. I was afraid the area around the tail light would need some more filler and I was right... darn it I knew I should have laid it more evenly.. BUT the rest of the fender is DONE with filler. Needs primer filler and final sanding.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1210.photobucket.com-172-1297060351.1.jpg)

Front fender got some sanding as well, then I got tired of the dust kicking back at me (I typically have the fan on and door open, but it was night and cold..) so I called it a night.

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[Andyrew]

Made some progress yesteday and today. Not enough yesterday to post... (Mixed and laid some small batches of filler)

But I bought some filler. Supposed to be better than the other stuff.
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Put the front bumper on and made some tape and marks for myself. Still need to put it on again and redo it. both the bumper and the body are going to take quite a bit of work to look right together (yay fiberglass bumpers...) I think im going to get the body where I like it and just match the bumper.

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Noticed a low spot on the door. Filled it in some. (This is the stuff i'll notice when I actually throw some primer filler and guide coat on...)

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This is prior to 2 more applications of filler... Last application I said "fudge it" and laid it on thick.. Took 20 mins of my lunch to sand it today.. Arg..

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I was done with working on the fenders (for now) so I decided I would pull the supports off the spoiler. took some finessing, but I got them loose.

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And I then removed the rivets holding it on.

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Threw the light in to get a look at what I was dealing with. I love the spoiler, but I love a clean rear end as well... Thoughts anyone?

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Since the trunk was clear, I figured it was a good time to plug the holes from the previous ducktail spoiler. They were good sized holes, but nothing some welding cant fix (I actually couldnt get a block behind it because of the double layers, but it filled just fine) The spoiler actually hides all but 1/2 of these holes, but I figured I would clean it up anyways in-case water got in.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1210.photobucket.com-172-1297322847.18.jpg)
I then decided to work on the targa bar some. ground down and welded @6" intervals, then i'll grind all of it down and weld it. (6" intervals was to keep the targa bar from splitting.

I need to get me a bigger grinder... This is tedious... A big 9" with 36 grit pads would be wonderful... My 4.5" works, but the grinding stones are only good when they are really fresh... Meh, maybe i'll just buy a bunch of stones...

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Finally I decided to longboard sand the trunk.... Whoooo eeee I got a lot of work to do.... Im debating a bunch of primer filler, or just skim it with glazing puddy and flat board it... Tough decisions... Maybe i'll hammer and dolly it (However most of the area's I WOULD do that in have the trunk reinforcing behind it... I do have my Map/Oxygen tanks... I could shrink them (and risk some oil canning..). Im looking for suggestions here as well..

[orange914]

Got a little progress
(IMG:http://www.914world.com/bbs2/uploads_offsite/i1210.photobucket.com-172-1297046387.4.jpg)
Wanted to protect the bondo from the welding. 1/8" MDF board works pretty well.

OH... thats not the new fender flair template!? (IMG:style_emoticons/default/biggrin.gif)

[Andyrew]

Haha! Nah, that wouldnt be over the top now would it?

[Beach914]

Yup, You need to do a dually rear set up to get tires wide enough. Maybe from a chevy pick up.....just kidding. Looks really good.

[Hontec]

Man, that's a lot of work going into filling/sanding!! (IMG:style_emoticons/default/pray.gif)

[Andyrew]

Yup, Bodywork is always extremely laborous... Especially something like this where I have to create my own body lines.. There is a lot of "That looks like shit, what if I do this", And certainly plenty of "Well, I could do this, but Eh Its good enough". Those kind of lines are what makes the difference in the final sanding.. Its rediculous how much more work I have to do, but its what you have to do for a decent paint job..

I have been pushing a lot of time lately towards my new washer/dryer... It works fine, but the drain for it @ the house can not keep up with the pump.. I've been doing some serious engineering to get this stupid thing to work and its costing a lot of money just to get it to work..


I just keep pushing for the day when I can finally lay down some Phoenix Red... Mmmm that color is sooo pretty.

[pt_700]

i prefer my 914's rather unadorned (in response to your question about rear spoilers). after reading the thread and link about the low pressure area behind the targa bar, it's likely there's not much airflow back there to push on a spoiler anyway. looks like you'd have to use a big wing to have much effect.

by the way, there's some really good stuff in that thread and link (http://www.914world.com/bbs2/index.php?showtopic=115467&hl=targa). surprised so little was studied about the aerodynamics of these cars.

thanks for the posts and pics! keep 'em coming!

paul

 2008_poster.pdf ( 276.51k ) Number of downloads: 637

[Andyrew]

Well the biggest problem is this car can actually USE the spoiler.. Without a spoiler the rear end gets REALLY unstable at speeds much over 100mph. I've been at 145 with just the small ducktail spoiler and that was just a bit scary.. This spoiler is a larger spoiler and should have better downforce at lower speeds. I was also considering the "vortex generators" on one of my spare tops, which should help get wind to the spoiler.

I think i'll just get another trunk as a spare and have it flush... For now i'll paint this hood with the spoiler.

[Lennies914]

It's good to see the progress you're making. I personally enjoy the body work more than the mechanical work. I'm looking forward to starting my next project. You are inspiring me.
Keep it up, it's looking great. (IMG:style_emoticons/default/beer.gif)

[computers4kids]

Andrew,
If you ever want to tow your car down here I'll be glad to give up a Sat or Sunday and help you. I have a 60 gallon compressor, DA, simple air tools, air block & hammer body tools...nothing special but works. I only have a cheapo HF wire fed...not worth the trouble.

Looking great...you are definitely motivated. (IMG:style_emoticons/default/beerchug.gif)

[J P Stein]

Not many lunatics have the urge to modify the targa bar.....but I'm one. (IMG:style_emoticons/default/biggrin.gif)
Here is an old thread with my run at it mixed in.....there are a few items covered in it. I don't think it made the car any faster....... (IMG:style_emoticons/default/confused24.gif)

http://forums.pelicanparts.com/porsche-aut...-we-got-em.html

[J P Stein]

Spoiler?.....yeah, that's the ticket.
If a little is good, max per rules is better. (IMG:style_emoticons/default/biggrin.gif)

[Andyrew]

I'll update this thread tomorrow. Not much to post but the pics will be uploaded to the Photobucket account if you want a sneak peak.

[Andyrew]

Vday weekend I didnt do much like I said.

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Started off with my new favorite beer.

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Friday I picked up some glazing puddy and some grey primer filler(not pictured)

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I basically laid down a bunch of filler/ glazing puddy mix over the trunk as I decided it would be easier just to sand it smooth.

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Laid it about 1/8" over the whole trunk. Lots of filler...




Fast forward to tonight.

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Lots and LOTS of sanding over the trunk. It got really boring so I went down to 60 grit from 80 grit (I dont have that much 60 grit... so i save it, I have about 100 feet of 80 grit..)

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Laid down a layer of glaze, then sanded, and laid another layer of glaze down. I still have maybe one or two more layers of glaze to get all the low spots/ pinholes, but the bondo/glaze combo worked really well and was very easy to spread.. I just wish i had more practice in technique. Oh well.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1210.photobucket.com-172-1297844738.13.jpg)
I enlisted some help of Orange914's son, a good friend of mine.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1210.photobucket.com-172-1297844738.14.jpg)
He was very happy for some reason... I told him I would "make him a star"
If I could get more help like this from more local friends, this would possibly go by faster..

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Sanded the spoiler most way with a course block.
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Some primer filler and a bit more sanding and this spoiler will be ready for paint!

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My friends accomplishments. Took off a couple layers of primer and commented on the poor overall shape of the bumper. He is very much adiment that I shouldnt change the bumper in design... maybe he's right... We'll see what I end up doing.

Thats all for tonight! BIG weekend ahead, should be BIG progress! I got my hands on a compressor so let the priming commence!!!!

[Mike Bellis]

(IMG:style_emoticons/default/smilie_pokal.gif)

[Andyrew]

Lets start with Friday.

I didnt get near as much done as I wanted, Particularly because it was raining and I was dealing with a multitude of other issues.. Arg.

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I did get my garden started (IMG:style_emoticons/default/tongue.gif)

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I picked up a longboard air sander... Oh I wish I did this prior to doing the rear trunk.. Arg.

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More progress on the damn targa bar. This is a project and a half... Finally figured out that a cutoff blade attached to my grinder works pretty damn good. Grinding blades just make heat, cutoff blades just slice through the welds.

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Found my window crank! yay! No vice grip!

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Took the plundge and cutoff the excess from the flare.


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Then I took a step back and said "Wait a minute, I actually like this! A built in brake cooker (or similar) scoop! I can shape my rocker pannel if I want to later, but for now this allows me to progress.

[Andyrew]

PRIMER DAY!!!

I should have done some more bodywork, but in reality I needed to see where I was. Lots of little pinholes from the bondo and a couple of areas that are a tad low or the bondo wasnt sanded. Overall I am REALLY happy with the progress so far, It looks REALLY GOOD!
The sprayer needs to be adjusted properly.. This was simply a bit of a test to see how it all went down. I could have laid it more evenly, but so far I didnt notice any issues.

I'll have to get my black primer stirred and mixed if they can do it as its pretty hard, we'll see what the paint shop says, but ya. Im curious now if my old Phoenix Red paint will still be good.

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Put the air board sander to use. Worked great! Need a bigger compressor..

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Removed door panel so I could remove the outer door handle. Pic is for my reference for speakers. This is Dr. side speaker.


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Forgot to take pics of bondo and sanding of the targa bar... Oh well.


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Heres dad putting a regulator on the gun. (IMG:style_emoticons/default/smile.gif)

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Taping job.

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Work station.. The glass jar is to hold the spray gun, I dont have a vice yet so this had to work.


THE PRIMER!!
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Still wet

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Hours later, All dry!

A Happy Me!
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Tomorrow is guide coat and we go down in grit, 120? 220? Not sure, We'll see!