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]

Extended the wires to the brake and clutch switches.



Redid the mounts for the sensors, this should get me a bit more foot room aftwr I make a new cover for it. It also keeps it on the pedal cluster.


I need to grab a couple relays and wire up the fuel pumps.

[Andyrew]

Got a little bit of progress done,



Hooked up the ECU and got proper readings! Which means that the wiring job seems to be correct.

Pulled the spark plugs and put a little bit of oil down them as well as filled the engine up with oil and tightened the oil line.

I tried to crank the starter but it wouldnt do anything. After discussing it with my Audi buddies, its because I do not have the central locking system hooked up. I just need to ground the wire going to the central locking system.


So in the meantime I hooked up a test wire to the starter and then set it on the battery post to test to make sure the starter worked. Yup! So I gave it a good couple of 30 second cranks to start to prime the oil system and get the lubrication of the engine going good and ensure there was no strange noises. Everything seemed good!

Next step is getting the fuel working, a couple more little things and start this mama jama (IMG:style_emoticons/default/smile.gif)

[Chris H.]

Awesome. Nothing more exciting than when it fires up. If you have the electrical right it will (IMG:style_emoticons/default/beerchug.gif) .

[76-914]

Awesome. Nothing more exciting than when it fires up. If you have the electrical right it will (IMG:style_emoticons/default/beerchug.gif) .

Uh, that's #2 on the list, Chris. Numero uno es when the ECU Fires and goes up in smoke. Andy, I'd be interested in your pre start diagnosis of your wiring job. In detail if you've time. I don't mind telling you that when I powered up mine the first time I was so nervous you couldn't have driven a ten penny nail up my ass with a sledge hammer. Kent

[Andyrew]

Well, I double checked to make sure there were no loose /exposed wires, I read and re read how the system gets its power, and I hooked up my power wire accordingly.

I grounded all the grounds and installed all the relays per the manuals and what I found on the cars in pick n pull.

I left the key off and hooked up power to the system and inspected everything for hot or melting wires, then I hooked up the ECU and turned the key to the on position. Since I dont have the ABS hooked up the dash cluster beeped at me three times (The tuner said he turned that off.... but alas..) I then plugged in my ecu logging software and pulled up the ecu as well as any parameters that it could read at the moment. I also checked fault codes, but my software being the free version basically wouldnt let me check everything, so I left it at that.

[Chris H.]

What usually causes a melted wire is accidentally electrifying a ground wire. I did it. Luckily it wasn't connected to anything important so I just replaced it. The melting started IMMEDIATELY. Within about 10 seconds the garage was full of magic smoke. I think you're clear of that hurdle.

I think you're in really good shape. You're getting readings from the ECU, everything powered up so its grounded correctly. Time to button up the fuel stuff and fire it up!

[Mike Bellis]

I had to open the dash cluster and de-solder the buzzer. Otherwise it will keep beeping 3 times over and over...

The starter relay is interrupted by the clutch switch and central locking. Just remove the central locking interrupt wire/ bypass it. And if the clutch is not pushed in, it won't start.

I removed both of these and have the key control the starter relay directly. very easy to do.

[r_towle]

When you figure all of this out, will you do my 4.2 conversion?

[Andyrew]

I had to open the dash cluster and de-solder the buzzer. Otherwise it will keep beeping 3 times over and over...

The starter relay is interrupted by the clutch switch and central locking. Just remove the central locking interrupt wire/ bypass it. And if the clutch is not pushed in, it won't start.

I removed both of these and have the key control the starter relay directly. very easy to do.

I may have to kill the buzzer, but my tuner said he would tune that out... Hopefully the new guy can.

Starter has been taken care of. I grounded the central locking wire and the engine cranks over with the key (IMG:style_emoticons/default/smile.gif)


Next on the list is the fuel pump wiring, throw fuel in and fix what is likely a very leaky system. (IMG:style_emoticons/default/dry.gif)

[Andyrew]

When you figure all of this out, will you do my 4.2 conversion?

Wiring would probably be similar, but no.. I have probably 3-500 hours into this conversion so far, and a good 50 of it in wiring alone with what is likely another 20 to go before the chassis is all wired.


In the future if this conversion gets popular I might entertain making kits or doing all the wiring mods, but its so much custom stuff it just doesnt make sense. You pretty much have to just fabricate everything.

[Andyrew]

Ill fill in details later. Still issues, but this did happen.

https://www.youtube.com/watch?v=qSrB9kXreM4

[Chris H.]

Congrats! That's a big payoff moment for hours of tracing wires, cross-referencing diagrams, fabricating, welding, etc, etc. Nice work.

[914forme]

Huge step, congratulations (IMG:style_emoticons/default/piratenanner.gif)

[mgp4591]

Hell yeah! Congratulations! (IMG:style_emoticons/default/aktion035.gif)

[Mueller]

Sounds good, I like!

[Mike Bellis]

Awesome! (IMG:style_emoticons/default/piratenanner.gif)

Now all you need to do is finish... (IMG:style_emoticons/default/poke.gif)

[dan10101]

I like the tune it plays wish I could have been there to hear it. But, I'd rather have it happen without me than not happen with me.

Is is it loud, 11 of 10 or 9 of 10?
I like it either way!

[Andyrew]

Its louder than I expected. Its basically 3" straight pipe..

I dont think the mufflers do much at all (IMG:style_emoticons/default/smile.gif) I might need to put a chambered muffler in there somewhere. Cruising on the freeway may be a bit.. loud.

[76-914]

Ill fill in details later. Still issues, but this did happen.

https://www.youtube.com/watch?v=qSrB9kXreM4

Congrats Andrew. (IMG:style_emoticons/default/piratenanner.gif) We need a Gene Wilder avatar that screams "It's alive". (IMG:style_emoticons/default/beerchug.gif)

[matthepcat]

You might try some exhaust inserts. I used a brand called "car chemistry" on my old V8 and was able to reduce some drone. Not sure on a turbo car though.

Sounds great

Its louder than I expected. Its basically 3" straight pipe..

I dont think the mufflers do much at all (IMG:style_emoticons/default/smile.gif) I might need to put a chambered muffler in there somewhere. Cruising on the freeway may be a bit.. loud.