Stacey's Belated Yo Yo Build Thread

A few more pics of the car after painting and with the masking removed











Also some car porn bits that have been sitting over the states for a fair amount of time in my mailing account and there's also more to come at a later date

A fair few of these parts are for the mk1 gold build I'm also involved in with my friend, we're both looking to enter some drag series next year with himself going for the FWD completion clutch series all being well :)

This one mainly contained parts for the mk1 apart from some smaller bits for me like 2 044's, head gasket etc



This one for myself had my turbo, clutch, HPA controller, Devils own direct port and various nozzles etc to play with.



Full race for the mk1 golf (absolutely sexy I may add! Do love this mani)





My HTA3586 with bronze bearing upgrade (although was supposed to have they're own slightly smaller comp cover but will have to make this one work)



I've gone for the 8.5' twin plate clutch masters were as the mk1 will sport the 7.25 as he's really aiming for a really revvy engine





TBC
 
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Good work dude... loving the paint booth ;)

What plate material did you go for on the clutch and what weight is the flywheel? I have been looking at twin plate clutches myself... have had a chat to CG Motorsports about one but TTV are bringing one out too... apparently the TTV one will have an option for organic friction plates which will give a better drive on a road car but with higher clamping force and OE feel pedal... the flywheel will be solid but only a couple of kg's lighter than the DMF which should help with the gearbox chatter inherent with the lighter SMF's

<tuffty/>
 
Cheers mate had to improvise a little, would take it a lot more seriously if was painting the outside but with the inside I wasn't to fussed about and was more of a matter of throwing it on to protect it and get it one colour.

TBH I really can't remember which one I got as bought it in last years Black Friday sales, will see if can find the emails for it
 
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Fullrace friends
 
This may be of some help Paul



What engine is that on mattie? Full race stuff is lovely, just wish they did a v band 1.8t mani
 
3b03585fe0b8a768add964acc646d4a2.jpg


just one or two bits,
Fully forged
flowed, port & polish
over size valves
dual valve springs
high lift cams
full race manifold
gt42 turbo
walbro 450 pump
1600cc injectors
fmic
fully polly bushed

an still loads left todo/buy/make

about 4-5 years in the making
d68128a9585d57d60b95f65f9d0dff8c.jpg
 
Dude... learn to take pictures in focus!! LOL

<tuffty/>
 
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Very nice that turbos huge! Bet that flys once it's up and going :)

You drag race it or something?

He may still have a couple of bits if was interested? One of the craziest bits he had made was a carbon prop shaft. He wasn't aiming insane power wise (400-500) but was going for lightweight and a quick spooling EFR setup on individual throttle body's







You had yours up and running yet?
 
not had mine running, its killing me having it sat, the shell looks awsome!! an that head...ooooosh!! lol

little belit jelouse haha
 
mattiekane said:
not had mine running, its killing me having it sat, the shell looks awsome!! an that head...ooooosh!! lol

little belit jelouse haha
Click to expand...

Know that feeling mate, is horrible just looking at it sitting there :(

He has done some lovely work on that build and is such a shame to see it abandoned like many projects

Be nice to see yours when done :)
 
i cant wait to see mine when its done haha, so he just selling it all off? may i ask why its getting aborted?
 
Yeah selling up and giving up. Has now just got married, moved miles and miles away for a new job at prodrive and is looking at purchasing first house....I know it really hurt him doing so but needs must!
I think he's kept some of the engine, he had custom rods and Pistons made to move the pin further up the piston and use a longer rod to better the rod angles occurring, lots of different touches on this build, was really looking forward to seeing it up and running.
 
oooo alot of work done then!! if i had the cash id be stright in there
 
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Gearbox time

I owe a lot of this work down to Andrew and the 02M build thread on here I had planned shift forks and some kind of strengthening of the casing but the thread pointed me straight towards the epytec gear. Thanks for pointing them out mate ;)

The main reason my car was taken off of the road in the last occasion was due to a shift fork breaking and this is the second box have now done this to :facepalm:



Steel shift fork next to it



A while back one of my saved ebay searches picked up on a R32 used peloquin LSD about 20 miles from my work, so a bit of bartering back and forth and I managed to get a nice price on it :)
Would love to get a rear diff at some point as well but unless a used one pops up that'll b a long way away.

The crownwheel was different on the LSD compared to my mine as must have been for a different ratio, so this meant needed changing it over.



Whilst I was changing the diff crownwheel over I put some new bearings on. It's worth going to local bearing suppliers for these as I paid only a very little more for 2 from them as Audi for 1.



Part # in the pic



Whilst the box was apart I gave it a thorough clean, starting with the jet wash, followed by solvents with a rotary wire wheel to loosen up tough bits and finally another jet wash.
Once was it clean and was happy I slapped some silver hammerite on there to tart it up a little.



I the same Andrew opted for the casing support plate, 4th gear support and billet shaft mod.





4th gear support







Billet shaft mod



Even though it had to be pressed in I did put two blobs in there with the mig to further make sure I doesn't migrate back out.

I then on reassembly of the casings found that the hex bolts for the casing support plate were fowling on the welds and shafts. I used a paint pen to help reassure where it was fowling.



I ended up grinding around 3mm off of the heads of the bolts, chamfered the edges/corners and also removed a bit of the weld had put on the input shaft to get it to a point where I was happy with it.

Am hoping this should give me a nice solid box to last some time until/if I ever look at changing gear sets :)

TBC
 
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Yeah whenever is good for you, itching to see it. Did you go to that meet? My partner was working that evening so I was in with the little'n.
 
badger5 said:
even heavier now :p
Click to expand...

Yeah did say to my friend about how much work it took to remove brackets etc weighing the same as this lump of steel, plus this is rotational mass :(

It'll be worth it though if don't blow the box on a regular basis...especially launching
 
tom2001s3 said:
Yeah whenever is good for you, itching to see it. Did you go to that meet? My partner was working that evening so I was in with the little'n.
Click to expand...

Didn't make it myself either as was on nights all weekend so spent some much needed time with the family. Will be looking to attend one soon thoughts they're fortnightly...if all else fails can meet at another point
 
Westy said:
Wow, someone's been a busy boy! I wish I still had the time to spend on a car. Oh and nice A3 derv, it's younger than my one and you use it as your run around :(
Click to expand...

Well there's a fair few months worth there and more to come :)
Yeah hate to say it but the derv is a lovely motor to be in and drive especially compared to the golf! It just needs a different turbo and a couple of tweeks

badger5 said:
crazy b'stad

thought I was being happy with badgerwagens 4bar map sensor - lol

you crazy man
Click to expand...

Haha won't be planning on running that level of boost! They include the 1 bar atmospheric pressure so is really 2 and 4 bar sensors....

I expect max boost may end up around 2.5-3 on balls out map if the gains are worth pushing it that hard?

Andrew@A.L.D said:
Should of used cap head bolts then you wouldn't get the fouling shafts. Sounds rude that.
Click to expand...

Did consider that or button heads but they're the ones supplied by epytec, also was to impatient to wait till had been back to work to borrow some so improvised
 
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Yeah do think will need some bigger injectors, will see what can get out of these at 4-4.5 bar then will change as its not much work changing injectors with infinity.

Was going to get some bigger ones but Dannie highman insisted he got over 700hp out of his on the hta35 but now on his gt40 has maxed them at 640 :(
 
With only push boost that high if gains are still worth while, if the returns aren't that great for a few extra psi I won't do it. That map setting will only also be for a balls out drag setting
 
StaceyS3 said:
Haha won't be planning on running that level of boost! They include the 1 bar atmospheric pressure so is really 2 and 4 bar sensors....

I expect max boost may end up around 2.5-3 on balls out map if the gains are worth pushing it that hard?
Click to expand...

What turbo?
I chose 4bar map sensor for badgerwagen so I could run >2bar boost, and have run 2.5bar max so far on it..
Check with the turbo supplier that the unit will support big boost, as some limit the pressure on them.. HTA35 for example I was told by owens as max 1.8bar (which sounded low to me, but what they told me when I asked them)
 
Yeah that does seem quite low in comparison, have seen a few running over 2.5 bar on HTA units.

Did read an interesting thread by Dave Buschur of Buscher racing he done a fair amount of testing for FP and on a high flowing 2.3 Evo engine saw significant gains turning a HTA3076 from 30ish psi to 40 at the instruction of FP iirc....

Was an interesting read, will see if can find the thread as done back to back testing of 3 or 4 of HTA's offerings on the same motor and different boost levels.

Certainly won't push it that hard if gains aren't substantial enough in comparison to the extra strain will be applying. Will want to see the full potential of the build even though won't be run there often :)
 
Knew I'd have some time spare in the workshop at work so brought my manifold in to have a play with the direct port kit.

I thought quite a bit about nozzle positions, 1. Was as close as possible to the head inlet on the opposite side to the injectors but was concerned about it effecting the fuel spray angle and mist.
2. Was a bit further up the runner to avoid interference with fuel injector.
3. Was in the plenum either opposite the trumpets or on the underside in line with them but worries was wouldn't get even flow distribution to all cylinders.

I ended up going in the underside of the runners at a very slight angle pointing towards the head. I went for the underside as thought it looked tidier and positioned them as close to the plenum as possible as leaves room for another set of nozzles for Nitrous if I decide to do so at a later date (what I really mean is if the Mrs will ever let me as she's been very stern with this for a few years and don't seem to be moving lol)





I tapped the tapered thread just about deep enough so the nozzle will ever so slightly protrude on one side and sit flush on the other as it is at a slight angle





I mounted the methanol manifold as tight as possible to the pneumatic manifold to try and reduce the angles on the pipework

This is currently how it looks, not to in your face and quite stealth I'm pleased to say :)





TBC
 
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Compression will be slightly lower as now will be using the correct thickness head gasket which is 0.5mm thicker hopefully taking me nearer the correct 9.0-1 that pistons are specced.

Cams will be main other change as have ditched the cat 3660's for IECVA1's :)

Methanol injection will also help any form of det/knock and am possibly looking at playing with fuel mixtures with AEM's flex fuel sensor and function on the ECU.
More research is needed to confirm can use this for methanol mix but have found info suggesting you can and the sensor and ecu will adjust timing or maps to suit the fuel content :)
 
There is a solution to your nitrous issue.
Get one of those NOS bottles that's actually a sub box, once the the boss is convinced its just a speaker box, quickly run to the NOS shop and get a gas bottle :smile new:
 
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