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

[Mike Bellis]

All that work and your running a stock fuel rail?

[Andyrew]

Exhaust parts came in (IMG:style_emoticons/default/evilgrin.gif)

3" Stainless mandrel bent tubing, Vband clamp, 3" Stainless resonators.







Pretty happy with the way it turned out. I still need to weld in a hanger. System only weighs a couple pounds so right now the Vband clamp is holding it pretty good.

[Andyrew]

All that work and your running a stock fuel rail?

I was told it would not be the restriction until about 600hp, and with my AN10 supply lines probably not till way after that. Ill change it if I need to but right now I didnt want to deal with it. Assuming it doesnt leak...

[Andyrew]

Last one for tonight

[Andyrew]

Alternator bracket came in yesterday.


Quickly Karate chopped it in half. Only the top half is needed, the lower half has a idler pulley and the power steering pump. Both not being used.


With the alternator mounted under the intake manifold you can see the gutted water pump sticking out.


The pulley mount looks like it could interfere so off with its head!

This nets us with about a 26 1/2" belt, I have a 27.3" belt on order, and I think it'll work just fine.


I also got the extended oil tube for my S4 oil cooler (Going to run this till I decide to run the external oil cooler...). But it requires the little cat ears to be ground off the oil cooler mount. Couple minutes with the grinder and they were off. Oil cooler is installed and the oil filter installed as well, but I will probably pull it and fill it prior to starting the engine.

[Andyrew]

Got some work done this weekend.
Made a heat shield for the manifold to protect the coils and the oil feed line. New 3AN oil feed line also came in.


Got the remainder of my AN lines in. So I mounted up the fuel pump. I hate having to reach both sides to get to bolts so I welded the backsides of the bolts to the firewall (IMG:style_emoticons/default/smile.gif)


Located and clocked the water pump. This will actually be "free floating" but the outlet on the engine and the flange on the water pump are literally touching so it really doesnt move at all.


I experimented with aluminum welding.. Sometimes experiments fail... This one did (IMG:style_emoticons/default/barf.gif)
Had I actually preheated this and used pure Argon this might not have been so bad.
I am going to see if a local weld shop can clean up my welds with a tig so it'll hold pressure. If not I'll go by a members place and try my hand at it with his Tig.

[Andyrew]

Mounted the W/A IC radiator. Just one bolt right now. Trying to figure out the rest still.


I'll route the hoses behind the radiator and through the firewall.


Speaking of hoses... How about some stainless joiners? (IMG:style_emoticons/default/biggrin.gif)


And How about some more stainless joiners? A little explanations as well. This took quite a bit of research.. (IMG:style_emoticons/default/dry.gif)


A little explination for the intercooler



Truth be told this is all just me delaying getting back into the electronics (IMG:style_emoticons/default/barf.gif) ... The wiring is really whats going to hold me back from getting the car running. I know about 50% of the critical electrical components and I cant read the factory manuals so I really have no idea what to do next... Im slowly working through it though (IMG:style_emoticons/default/unsure.gif)

[jd74914]

I like the intercooler water cooler location. Nice and clean. (IMG:style_emoticons/default/smile.gif) Are you going to shroud and run a fan?

If you didn't shield with 100% argon I would cut all of those welds out; depending on the alloys aluminum aluminum welds can be brittle as-is so they really need to be done correctly. If you do end up TIGing them yourself, I've found the trick to aluminum is going relatively hot and fast; almost the opposite of welding steel. If you are fortunate enough to have access to a nice high frequency inverter machine, then you can set it up so it's more like welding steel and go slower.

[Chris H.]

Truth be told this is all just me delaying getting back into the electronics (IMG:style_emoticons/default/barf.gif) ... The wiring is really whats going to hold me back from getting the car running. I know about 50% of the critical electrical components and I cant read the factory manuals so I really have no idea what to do next... Im slowly working through it though (IMG:style_emoticons/default/unsure.gif)

Manual is in German? What year? I'll look around for you.

[Andyrew]

Truth be told this is all just me delaying getting back into the electronics (IMG:style_emoticons/default/barf.gif) ... The wiring is really whats going to hold me back from getting the car running. I know about 50% of the critical electrical components and I cant read the factory manuals so I really have no idea what to do next... Im slowly working through it though (IMG:style_emoticons/default/unsure.gif)

Manual is in German? What year? I'll look around for you.

I have the full (Were talking FULL) workshop manual. Problem is they look like this.

The body harness is a 2001 S4, the engine/dash is a 2001 A4 AWM engine.


Intercooler will have a fan, and probably a shroud in the future. I'll control the fan with the temp controller I posted a couple pages ago.


I think I am going to get a Steel flange for my MAP sensor. Then I can weld up the pipe no problem... Avoid all this aluminum BS.

[jimkelly]

if anyone NEEDS a TIG its andyrew. especially for aluminum, and steel. wish i lived nearby, i'd love to observe his activities while drinking beer and eating jujyfruits (IMG:style_emoticons/default/biggrin.gif)

[Chris H.]

I have the full (Were talking FULL) workshop manual. Problem is they look like this.

The body harness is a 2001 S4, the engine/dash is a 2001 A4 AWM engine.

Oh Lord...that's painful man. I'll see if I can find anything. Somehow my browser seems to be tuned to locate obscure manuals or supplemental materials. It's a gift (IMG:style_emoticons/default/screwy.gif) .

[dan10101]

Did you see this?

http://www.audizine.com/forum/showthread.p...rness-Explained

[Andyrew]

Yup. Its incorrect (IMG:style_emoticons/default/dry.gif)

[Andyrew]

At this point my biggest concern is in regarding how the starter, alternator and battery wire up. They are my most difficult to pinpoint items. I would imagine it would be obvious, but its really not.

I'll figure out the engine itself when I physically throw the harness in.


In reality I am saving wiring for last and just doing the other stuff I HAVE to do until I run out and then I'll tackle the wiring till its good and done.

[76-914]

I would work on wiring till I looked like this (IMG:style_emoticons/default/wacko.gif) . I found medication and cursing soothed my brain but did little to complete the task. I would work on anything except wiring until the guilt set in at which time I would attack it once again. This cycle repeated itself at least 15 times before I worked my way thru it. Have fun and try to stay sane. Kent (IMG:style_emoticons/default/beerchug.gif)

[JRust]

I'd consider relocating that fuel pump. Or at least add some rubber to dampen the sound. Right by your head you are going to hear that pump. Maybe it won't be heard over your killer motor setup though. I guess you get to try it & find out. I can hear mine which is down low on the firewall & behind the passenger seat. Maybe my Walpro is just loud (IMG:style_emoticons/default/dry.gif)

[Andyrew]

I'd consider relocating that fuel pump. Or at least add some rubber to dampen the sound. Right by your head you are going to hear that pump. Maybe it won't be heard over your killer motor setup though. I guess you get to try it & find out. I can hear mine which is down low on the firewall & behind the passenger seat. Maybe my Walpro is just loud (IMG:style_emoticons/default/dry.gif)

The pump inside the surge tank should basically be unheard. I do plan on adding some rubber isolators at some point. Just dont have any at this point.

The 044 is a pretty quiet powerhouse anyways. What I will likely hear is the carb fuel pump that will prime the 044.

For right NOW Im going to leave it but yes at some point noise isolation will be extremely important as I finalize the interior and try to maximize the proper sound.


Small update for tonight. My belt and plugs came in. Belt fits great! So I'll grab a spare to keep in the car. I have 2 spare plugs to keep in the car. They are copper core so I'll probably change them out every oil change, but it'll have a stronger spark with them.

Belt is a 5 rib 37" 5PK940, but anywhere from 36.5 to 37.5 should work. But it should be an over the counter belt (IMG:style_emoticons/default/piratenanner.gif)

[Chris H.]

I would work on wiring till I looked like this (IMG:style_emoticons/default/wacko.gif) . I found medication and cursing soothed my brain but did little to complete the task. I would work on anything except wiring until the guilt set in at which time I would attack it once again. This cycle repeated itself at least 15 times before I worked my way thru it. Have fun and try to stay sane. Kent (IMG:style_emoticons/default/beerchug.gif)

Dude...you have to look at those Audi wiring diagrams. They'll make you want to break stuff. Still haven't found anyone who has transcribed them with pics and stuff. Wonder if the Passat has a fairly similar layout. Probably more swaps on those.

[Mike Bellis]

The electrical diagrams look simple to me... (IMG:style_emoticons/default/biggrin.gif)
I actually overlaid striped color lines on the wires to make it easy to read.

My ECU did crazy stuff on copper plugs so 034 switched them out to get rid of the misfire.