sledgehammer

225mm clutch disc won't hold much power and custom discs won't cost that much. I have Sachs race engineering 240m disc with suitable center part (National clutch UK made it for me) and it works very well with Audi RS4 B5 pressure plate and Howe T5 throwout bearing. It has even SAC mechanism which adjusts pressure plate when disc gets older and thinner. Clutchmasters have plug and play parts for this project but it's a bit pricey. Many ways to go but I'm happy with my setup.



This is how I managed to squeeze 3" downpipe in the engine bay. I had MWR style exhaust manifold but I wasn't happy with it. Collector is too far away from the turbo so the hot spot where all the exhaust pulses collects is in wrong place. Ideally you would like to get that spot near turbine housing. In dyno I saw that 4-1 part of the manifold was glowing red and further away closer to the turbo it wasn't.

V2Rocket

^^ that exhaust is beautiful!
i bet that was a lot of work and head scratching.

Van

Really nice fab work! I like what you've done with the intake manifold, too.

tempest411

I had one of these in a '00 Audi TT that ran perfect at 260k when it was rear ended. Except for basic maintenance I never had the engine apart.

sledgehammer

Lots of work yes but nothing impossible. I have very basic tools (Ryobi pipe cutter, angle grinder, belt sander and TIG) and with bought slip-on merge collector it was quite ok. Actually downpipe was harder to do than the exhaust manifold. There are so many curves which has to be just right. Can't wait to test-drive it

Have you ever opened Porsche 944 engine Quite a lot same kind of thoughts

Noahs944

Sledgehammer, please pat yourself on the back for an excellent job. Can we see the intake manifold please.
Tempest, My Audi 2.0 turbo has about 200 000 miles and works perfect/no burning oil, its been good after I replaced the accelerator pedal & throttle body. The gas pedal is the same as an R8 (sorry, that never gets old for me)!

sledgehammer

Apologies for terrible seams This was my first try to weld alloy The whole intake is still first prototype and looks like that too... Basically it is AEB intake with shorter runners and custom plenum. Throttle body is from boxster. At some point I'm going to make it again and probably with same recipe. There really is lack of space and nothing fits well. I had grams/skunk2 intake but it didn't fit at all.

This could be quite good. If it doesn't fit, cut runners until it'll do.
https://www.ebay.de/itm/Ansaugbrucke...43b7bbc57cae47

Noahs944

Sledge,
Yeah I see you did the best you could with the booster. I like it. Aluminum is finicky to weld, it seems like no two aluminums weld the same & cleanliness is paramount. Where did you get the piece the runners attach to (the "trumpets" in second photo)?

Van

That's the inside of the cast VW intake manifold.

Van

I'd really like to utilize the factory water pump and thermostat... so I spent some time working on it today. I made a prototype for an adapter that should give me enough clearance for a manual rack steering shaft - power steering rack shaft is an unknown right now (maybe I can test fit one in tomorrow.

I'd like to see what other people have done for water pumps.

Anyhow, here's little video showing my design and 3D printing process to test my prototype:

Its_Lobelt

Thats a really good solution. Amazing how technology allows for this kind of work.

sledgehammer

I have pierburg CWA400 with tiny PVM-controller. https://tecomotive.com/store/en/bund...mp-tinycwa-kit.

With that pump I've had zero problems with overheating. Radiator fans are almost useless because usually I don't need them at all.

Van

Not as fancy as Sledgehammer's... but I made the stock intake fit:

DSMblue

Very cool Van! Are you going to clean up the original casting marks and the welds to put some beauty into the manifold? Do you think that shortening the runners will cause any issues with reduced air velocity?

Van

Making it pretty is lower on the priority list than making it fit.

Yes, I think shortening the runners isn't ideal... but it was better to shorten all of them rather than cut it at an angle so they were different lengths. In a perfect world, you could put S bends in them (like a 951). Longer runners give you more mid-range torque/power (that's why some cars have dual-length intake plenums with an actuator to direct air flow). But it shouldn't hurt the top-end power much (if actually helping it), and, since this is a race car, I'm not in the slightest bit worried about changing the runner length.