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Im so looking forward to see this animal coming together, great to see this kind of enthusiasm still exists. Wont get to say hello this year mate not going to make it down. Next year for sure. Ill be keeping an eye on this one
Cheers
Jmac
Alba European
Service, Diagnostics and repairs. Mobile Diag available on request
Audi/VW/Porsche Factory trained tech 25+ yrs exp
For people who value experience call 0423965341
Cheers J mac, i have some big plans for this project that will come to light in time...
I got stuck into dynamically balancing the crank, front pulley, flywheel and clutch last night.
Once i had machined the knife edge on the factory forged 92.8mm stroke 2 litre crank i linished the main and big end bearings. Then i balanced the crank by itself. It was out of balance by 23.4 grams at the flywheel end and 18.6 grams at the front. By linishing the weight off in the correct positions i brought it back to 0.1 grams at either end. I added the front pulleys, flywheel and clutch pressure plate to the crank and balanced them together. The ultralite 4340 flywheel and clutch were 16.2 grams out and the front pulleys were 4.8 grams out, after carefully linishing off the unbalanced areas the assembly was within 0.1 of a gram balance in all 360 degrees of rotation. The total weight of this assembly would be far less than a standard setup though i do not know by how much.. Forgot to bring my camera into the workshop though to get some picks on the balancer... You can see in the photos where i have removed weight on the flywheel though.
Most standard factory crank shafts are within 4-5 grams of balance, the best i have seen was a BMW M3 crank 1.4 grams out and the worst was an aftermarket 355stroker crank for a bommadore that was 487.3 grams out and through itself off the dynamic balancer!
Thanks Richo! Some pics of the bodywork... A lot of hours have gone into it and its far from ready for paint yet! I cut and filed this vent into the bonnet on the drivers side.
Here is the drivers side front guard with the original bodykit pumped out 15mm bolted and fibreglassed into the guard along with the side skirt and those who know roccos will spot the bottom corner of the door has an additional steel strip welded on to remove the step in it and blend it into the same profile.
Heres the rear wing, it has the original 83 model steel frame of the wing inside it beneath the fibreglass and aluminium tube frame work.
The side mirrors have been modified also with aluminium sheet giving the basic profile and approximately 4mm of fibreglass over the top.
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Mk2 GTI 2 door 1.9l 8v turbo 1st mk2 1st engineered water vw nats 09
Mk1 twin eng twin turb
scirocco gti 2.1l 16v turb 6spd
Audi A4 B5 1.8t
I am trying to decide how to do the S3 driveline and would like everyones opinion on the setup of the rear suspension with the haldex and differential. I have quite a few options really though i aim to have it handle as well as i can and keep the car as light as possible... Please post up pics and or links to awesome builds threads
Option #1: Original rear trailing arm with stub axles cut off and hubs mounted to it, suspension struts mounted offset to clear drive shafts and haldex / differential on fabricated mounts.. probably the lightest option..
Option #2: Use the complete S3 suspension setup i have and rear subframe for mounting the haldex / differential. Fabricate mounts for it, custom coilovers and modified trailing arms.. Heaviest option..
Option #3: Purchase Mk2 syncro rear subframe and hubs and modifiy it to suit haldex setup and fabricate mounts..
Option #4: The cool option.. fabricate a complete independant suspension setup and haldex / differential mounts from aluminium and polish it all up. The most expensive and time consuming option for sure...
Option #5: Leave it FWD and don't try and pull so much HP out of it!
Sorry bro, couldn't help myself
your boring
VW: it aint just a car, its a way of life There are few things more satisfying in life than finding a solution to a problem and implementing it
My Blog: tinkererstales.blogspot.com.au
ha true, but i've been seeing this thing unfinished for 12 years and reckon the less delays the better
HA! Just for that bro Option 4 has it cheers GoLfMan.
I made something today that i think may be a totally original performance modification... I havn't seen anyone else make a hollow steel intermediate shaft before, though i may be wrong? Weight of original VAG shaft 1256 grams, weight of custom shaft 693 grams. Stainless Steel tubing with 2mm wall thickness is used for the main body with drilled out lengths of 4340 steel tig welded on the ends and machined between centres to original dimensions. I made one of these for my MK2 turbo 8v a couple of years back aswell.
sigpic
Mk2 GTI 2 door 1.9l 8v turbo 1st mk2 1st engineered water vw nats 09
Mk1 twin eng twin turb
scirocco gti 2.1l 16v turb 6spd
Audi A4 B5 1.8t
I've never seen one on the web - i'm sure it would at least be original in so far as you can't buy one - but as you know, there are a lot of golf tuners out there, someone might have done it before.
Needless to say, good job anyhow. Can I ask - where/how/what did you do for the gear end? Is it bolted on?
'07 Touareg V6 TDI with air suspension
'98 Mk3 Cabriolet 2.0 8V
'99 A4 Quattro 1.8T
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