Sasquatch Part III Audi 1.8t transplant..., PCV upgrades finally... Options

[euro911]

Wow, Mike. I can't believe I missed this until now. Took me two evenings to go through the entire thread, but enjoyed every minute. Pretty awesome engineering you've done there (IMG:style_emoticons/default/thumb3d.gif)

Question - Will a T4 mount up to an Audi 5-speed or a Boxter 6-speed trans? (I could use an extra high gear, or two). If not, what other options are there for us old-school air-cooled lackeys? (IMG:style_emoticons/default/laugh.gif)

[Mike Bellis]

Wow, Mike. I can't believe I missed this until now. Took me two evenings to go through the entire thread, but enjoyed every minute. Pretty awesome engineering you've done there (IMG:style_emoticons/default/thumb3d.gif)

Question - Will a T4 mount up to an Audi 5-speed or a Boxter 6-speed trans? (I could use an extra high gear, or two). If not, what other options are there for us old-school air-cooled lackeys? (IMG:style_emoticons/default/laugh.gif)

The problem is the starter location. The 914 and 911's have the starter mounted on the transmission backside. Ie: 901, 915, 930, etc... The later model cars have the starter mounted in front of the tranny next to the engine.

If you can machine and weld, it would be possible to mount the starter on the backside but this is not for the beginner. If you remember the automatic 914 that used an Audi 5000 transmission. This had a starter machined into the rear bell housing.


On a side note... The car is going to the dyno tuner today. a full update and pictures later... (IMG:style_emoticons/default/smile.gif)

[gryphon68]

[quote name='Andyrew' date='Sep 22 2012, 11:10 PM' post='1743052']
sway away custom axles? So 914 outer cv and boxster inner cv?

Why did you switch to boxster stub axles then instead of just going with the audi units? (I assume since they are custom axles they can make it for any cv...)
[/quote]

[quote name='kg6dxn' date='Aug 4 2013, 11:40 AM' post='1904219']
[quote name='76-914' post='1904212' date='Aug 4 2013, 08:21 AM']
If it weren't for the fact that my axle angle was too severe, I would have left the 5 speed in there for a while. I needed the 108mm flanges from the 6 speed to use 930 CV's. I tried to buy just the axle flanges but none of the Porsche dismantlers would sell me just the parts. Now I have all the parts, I just have to make it work...
[/quote]

Very interesting build thread. Interesting alternative to the Subi-swap for those looking for modern liquid-cooled power and smooth shifting.

My apologies if I missed the answers somewhere, but was curious about the two comments above.

First, why the Boxster axle stubs instead of the Audi's if you were doing custom axles?

Second, what was the issue with the axle angle? Was it due to the height or the length of the engine? Are the axles on the 6-speed in a different location relative to Rear face of Block compared to the 5-speed? Or did the 6-speed just allow the use of 930 CV's which should be more tolerant of the large axle angle (which is unchanged from the 5-spd?).

Thanks,

[Mike Bellis]

Very interesting build thread. Interesting alternative to the Subi-swap for those looking for modern liquid-cooled power and smooth shifting.

My apologies if I missed the answers somewhere, but was curious about the two comments above.

First, why the Boxster axle stubs instead of the Audi's if you were doing custom axles?

Second, what was the issue with the axle angle? Was it due to the height or the length of the engine? Are the axles on the 6-speed in a different location relative to Rear face of Block compared to the 5-speed? Or did the 6-speed just allow the use of 930 CV's which should be more tolerant of the large axle angle (which is unchanged from the 5-spd?).

Thanks,

I mounted the engine and trans as far forward and as low as possible in the chassis. This was to maintain the F/R balance of the car. By doing this, the transmission output flange is no longer lined up with the center of the swing arm axle stub. The tranny is forward. Additionally, the car is lowered and the transmission is lower, This raises the swing arm stub center while lowering the tranny center. Thus creating a compound angle on the CV's.

The total angle was at the limit of the 100mm 944 CV joints (22°). So I switched to 108mm 930 turbo CV's. These have a max working angle of 30° and these are used by high power sand rails. A sand rail operates at severe angles all the time.

Audi makes a 100mm and a 130mm axle flange. The Boxster S/Cayman S 6-speed has 108mm flanges. Early 911 swing arm stub axles are 108mm and a direct bolt on for my 5 lug conversion.

I could have modified the Cayman S transmission stub axles to fit into the Audi tranny with a simple spacer but none of the dismantler's would sell them too me. They are $400 each from the Porsche dealer. I found a complete Cayman S transaxle in England and had it shipped to me for a total just under $1000.

The 6 speed has better gear ratios and the flanges I needed. Win, win for me.

The custom axles are off the shelf EMPI units from Pacific Customs. They cost $275 and each one is a different length. Both sides splined for 930 CV's. No custom machine work required and they can handle more HP than I will ever have.

To summarize, This was done with all bolt in parts. Even the shifter and cables are off the shelf units.

[Mike Bellis]

On a side note, The tuner called in sick today so no dyno tune until I return from the PCA Escape... (IMG:style_emoticons/default/sad.gif)

[Andyrew]

^ (IMG:style_emoticons/default/sad.gif)

[computers4kids]

If you remember the automatic 914 that used an Audi 5000 transmission. This had a starter machined into the rear bell housing.


(IMG:http://www.914world.com/bbs2/uploads/post-4253-1264391414.jpg)
(IMG:http://www.914world.com/bbs2/uploads/post-4253-1264391770.jpg)

[McMark]

I don't think that quite qualifies as 'machined' (IMG:style_emoticons/default/laugh.gif)

[euro911]

Well, it looks like they used some sort of machine to do that (IMG:style_emoticons/default/blink.gif)

[Andyrew]

How did the Retune @ 034 go?

[Mike Bellis]

How did the Retune @ 034 go?

They have had the car for 2 weeks and have spent 2.5 hours working on it. The tuner left for SEMA and my car awaits his return... (IMG:style_emoticons/default/sad.gif)

[Andyrew]

Ahh... Sema...

They must have been prepping their GTI,80Q,A4 for sema then..

That sucks.

[Mike Bellis]

Ahh... Sema...

They must have been prepping their GTI,80Q,A4 for sema then..

That sucks.

Looks like their GTI won the Grand Turismo award.

They did replace my: Silicone cobra head, MAF housing, coil pack & spark plugs.

I was a little pissed off at the service manager for not working on the car. Now I just want it to be done. I have no idea how much money I will owe when done. Right now it's $400 in parts and 2.5 hours... (IMG:style_emoticons/default/dry.gif)

[Andyrew]

.... They went and changed all the parts that they have their own name on....

[Mike Bellis]

.... They went and changed all the parts that they have their own name on....

I'm running an OBX fuel rail... (IMG:style_emoticons/default/poke.gif)

They're dyno tuning time is $250 per hour so I hope the finish quickly!

[Andyrew]

What did they replace the cobra with?

[Mike Bellis]

What did they replace the cobra with?

My aluminum cobra with their silicone "high flow" version.

[Mike Bellis]

Just for fun, here is a pic of my wife and me on the Mulholland Highway. This is a couple miles past the Rock Store, biker hangout...

[Andyrew]

What did they replace the cobra with?

My aluminum cobra with their silicone "high flow" version.

So their branded $60 version vs the universal rubber version they also sell for $30..

They change all the coil packs to the new version (The $15ea replacement version)?



A poor condition MAF could have been a real cause to your fuel issue. Also if your MAF is to close to your air inlet you'll get issues.. Changing out the coil packs could have been them ruling it out.. Its not a bad thing for the future..

I would really hope they give you some serious price breaks for all the stuff they are doing.

Nice pic BTW!

[Mike Bellis]

Cobra head was $60
Coil packs $30 each x4
MAF housing I had did not have the square mesh diffuser since it was aluminum. Their housing was $130.
Spark plugs were a deal at $4 each...