Another 8L Track Car - Lets get ready to 'Ruuuuuuuumble'!

[Welly]

Still want the seats?

Dude, sorry I meant to PM you. Budget is a bit tight to stretch to getting seats just yet. I've spent mostly all of what I have on the engine.

I'll have to leave them for now.

 

[Andrew@A.L.D]

I will most likely still have them when you have the cash anyway lol

 

[Welly]

I will most likely still have them when you have the cash anyway lol

OK mate, I'll bear that in mind.

 

[Welly]

OK then.... did a few bits and bobs whilst having 3 days off this week.

Firstly, removed most of the air con pipework from the A3's engine bay. A PITA frankly, but does give much more working room so worth doing.

The rods turned up from China at my office whilst I was off - so I went and grabbed them!

They just are the same as the IE rods to be fair, or at least as close as damnit. Here are my old IE 20mm Non RD rods:

Anyway, very happy with them for the money to be fair. Would have been better had they been EDM Rifle Drilled - but I didn't have the dosh and am aware of the potential consequences...

Fitted up to the pistons nicely - a nice tight fit onto the wrist pin I must say...

Also started mocking up the manifold and turbo for fitment. Started by giving the head a cleanup to remove all the old skanky bits of gasket etc. Looking good now it's clean:

Nice large inlet ports is what we want... (Yellow cover has to go though...)

Adjusted the manifold flange to make it actually fit the head correctly. It has also now been ground flat as it was a few mm out of square as most Chinese manifolds are! Then fitted up the 38mm wastegate to get an idea.

So that fits then.

Next on went the turbo to try and get an idea of sizes. Lots of measurements taken of the dimensions for the whole assembly together. It's Big. VERY big and it is going to be a tight fit.

However based on measurements it looks like it physically will fit into the engine bay which is a bonus...

More to come this weekend...

 

[burns3]

Coming along nicely mate, i'm sure it will be a tool when it's all up and running.

 

[badger5]

tight fit into wrist pin = bad wellyboots

How tight were they to push in??

it should slide thru easily by light touch else splash lube wont get there and they will wear rapidly and do this>

 

[Welly]

tight fit into wrist pin = bad wellyboots

How tight were they to push in??

Reasonably tight dude, didn't push in easily. Not mental tight though - thoughts? They weren't that bad...

 

[Welly]

Reasonably tight dude, didn't push in easily. Not mental tight though - thoughts? They weren't that bad...

Very close to what I remember the IE ones being to fit on the first rods I bought back in the Jurassic period.

 

[badger5]

Reasonably tight dude, didn't push in easily. Not mental tight though - thoughts? They weren't that bad...

I bought a small honing tool to get the pin fits "nice" as the variance on rod bushes and pin (used) often made for some being tighter than others, then a customer brought some used rods, pistons in for fitting into his new block, and looking at them (the video) they were shagged completely... Explanation being they were too tigh, unsifficient lube able to splash in there (which is the RD point which I wont labour any more).. The pins were ribbed.. oh err, such was the consequent wear, and so much friction had picked up and spun a bush in a rod.

I hone them so you can easily push the pin thru with light touch.. slide in and out.. no effort required.

the finishing diameters on all rods seems to vary compared to pins... new and used..

IE rods often on the tight side..

 

[Maz]

I'm impressed, not just by the speed in which you are tackling this but how Mrs Welly is cool with you using the dining table as a work bench.

 

[badger5]

lol @ mrs welly comment.


shhhhhh
its hush hush

 

[Welly]

I'm impressed, not just by the speed in which you are tackling this but how Mrs Welly is cool with you using the dining table as a work bench.

What they don't know won't hurt them....

Also, the top is made of glass so I have to go a bit steady....

 

[kwistof]

shagged completely... Explanation being they were too tigh, unsifficient lube able to splash in there (which is the RD point which I wont labour any more).. The pins were ribbed.. oh err, such was the consequent wear, and so much friction had picked up and spun a bush in a rod.

It's Friday and yes I'm being childish
(I'll get my coat)

 

[coatesy]

It's Friday and yes I'm being childish
(I'll get my coat)

ahahaha quality its good to see some one out there has the same humor as me lol.


looking good welly dude!

 

[Welly]

I bought a small honing tool to get the pin fits "nice" as the variance on rod bushes and pin (used) often made for some being tighter than others

Just for reference, I have borrowed the aforementioned honing tool...

 

[ReDBull]

I know what you mean about AGU cylinders heads being hard to find! I've been looking for one for a while now. I think I may have to buy a complet engine. The builds looking good so far and good luck when your Mum finds out.

 

[Westy]

I know what you mean about AGU cylinders heads being hard to find! I've been looking for one for a while now. I think I may have to buy a complet engine. The builds looking good so far and good luck when your Mum finds out.

AEB heads seem to be so much easier to get an they're just as good.

 

[Jason.s]

Yeah sold mine for 70quid!

 

[s33nyboy12]

I am impressed too, very speedy looking good.

Lol at using your kitchen for the work! Love it

 

[Welly]

AEB heads seem to be so much easier to get an they're just as good.

AJH ones also work as far as I know - large port as well.

 

[Welly]

Not as much progress as I hoped over the weekend to be fair. In so much as there was none at all!

Was expecting head gasket and shells to turn up on Saturday morning and they sort of didn't. Rather annoying.

Anyway, they're here now so I can get on and fit the pistons and rods one night this week.

In other news I used the honing tool to give a bit more clearance to the small end bushings on the rods. Now they slide in and out very nicely indeed - much like warm apple pie. No photos of that sadly as I didn't have enough hands. My missus also came home and found me doing it on the glass hob in the kitchen - not impressed.

Popped up to the Dyno day at Bill's on Sunday - I couldn't stop long as I had to get to my daughter's birthday party... However I did get this from my crustacean friend... Prawny

Many many thanks again Prawn - much love.

Also here is today's deliveries...

Now need to get some gas for the tig welder and we'll be cooking.

 

[ReDBull]

AEB heads seem to be so much easier to get an they're just as good.

AJH ones also work as far as I know - large port as well.

Thanks for that I'll get searching! I've just been quoted £350 from a chap on eBay for a AGU head!

 

[ReDBull]

In other news I used the honing tool to give a bit more clearance to the small end bushings on the rods. Now they slide in and out very nicely indeed - much like warm apple pie. No photos of that sadly as I didn't have enough hands. My missus also came home and found me doing it on the glass job in the kitchen - not impressed.
cooking.

She cought you doing what the pie or the rods?

 

[Welly]

Thanks for that I'll get searching! I've just been quoted £350 from a chap on eBay for a AGU head!

I can't guarantee that as a fact as I've never seen one. What I do know however is that the AJH inlet manifold was the only large port OEM manifold that suited the S3 TT with the TB on the right hand side.

If the manifold is large port - then lets be fair, the head is going to be as well.

You can buy a whole engine for about £250 delivered - VW SHARAN SEAT ALHAMBRA 1.8 T TURBO 20 V ENGINE CODE AJH | eBay

For reference, the AJH engine came in the 1.8T Sharan and the 1.8T Seat Alhambra only as far as I know.

 

[Welly]

She cought you doing what the pie or the rods?

The rods. I don't do pies. I have a missus for that exact purpose.

 

[Speedy Steve]

I think rumble needs an even bigger cooler!
MASSIVE TURBO 4" THICK FRONT MOUNT INTERCOOLER SUBARU STI WRX 700x300x100mm | eBay

 

[scoobyra]

Just read this thread through and its funny as feck! Nicky said "Mike, our daughter's out, come upstairs"....I was like eff off, this is serious stuff on here and much more exciting

Good to see you at the weekend Welly and keep up the good work....at this rate, I won't have to shag the Missus for a good few weeks yet! LMFAO

 

[Welly]

Good to see you at the weekend Welly and keep up the good work

You too mate, always a pleasure. :thumbsup:

 

[Welly]

After giving it some thought I have decided I want to do something different this time.

Thus I shall be fitting the WellyCooler V2.

Which is this hossing beast of a thing.

MASSIVE TURBO 4" THICK FRONT MOUNT INTERCOOLER SUBARU STI WRX 700x300x100mm | eBay

I shall be cutting the bumper up literally to fit it so that the end result looks something like this:

Some of you may remember I considered doing this to Bumble. It's in my usual subtle, understated style...

 

[Westy]

You'll freeze the engine with that beast

 

[Welly]

You'll freeze the engine with that beast

Should be interesting to see how it performs vs the original core. I can't see there being much difference really. Same inlet size and outlet size, there is just more core.

 

[Speedy Steve]

Its going to look epic!

 

[ScottD3]

Mount a beer cooler in the back to cool the water down even more and spray it on the cooler.

To much?

 

[Speedy Steve]

na mount a beer cooler in the back and spray passangers with beer more like

 

[ScottD3]

na mount a beer cooler in the back and spray passangers with beer more like

Get a twin outlet one. lol

 

[s3dave]

Should be interesting to see how it performs vs the original core. I can't see there being much difference really. Same inlet size and outlet size, there is just more core.

Big is not always better of course ..then pressure drops..

 

[Welly]

Big is not always better of course ..then pressure drops..

Agreed there is more volume to physically fill, but in the grand scheme it's not a massive amount. However there is more cooling area.

Bigger certainly was better for the original type B core, I'm going to apply that principle again and keep my fingers crossed.

 

[badger5]

wonder what airflow manages to get to the water radiator after its passed thru the deep fmic
we will see in due course no doubt.

 

[Welly]

wonder what airflow manages to get to the water radiator after its passed thru the deep fmic
we will see in due course no doubt.

Yes, that is an interesting thought. I will also be removing the aircon rad from the A3 as I have now completely destroyed the pipework... That should allow additional flow the rad shouldn't normally see.

With regards to the 'it's not that much bigger' statement, working out the maths it actually is.

The WellyCooler core is 600 x 300 x 76mm. Cubic volume is 13,680,000 mm.

The proposed WellyCooler 2 core is 21,000,000 mm. It's over a third as big again.

I shall fit in the name of testing. If it doesn't work I shall use it as a washboard or something....

 

[Prawn]

if you've removed the aircon condenser welly, you can trim the slam panel back to set the IC back another inch or so if you so desire to keep it all inside the bumper.

Obviously, if you'd rather not then go nuts!

I've been considering an offset stick on plate and more holes in mine recently....