Stacey's Belated Yo Yo Build Thread

Update on the gearbox.....

Had some friends come round and helped remove the box for me whilst i rested my back.

Results are quite shocking, I think I need to be a bit less eager when changing gear lol

The brass sliders had worn through the sides and broken up causing the loss of 3rd and crunching of 4th gear but the reason this had happened was due to the fork being bent. The fork being bent had caused the brass sliders to wear on oposite corners where it was now being twisted at an angle in the syncro ring groove











These next photos are were you can see that the fork is bent, by eye and up to a square







The center locating part has also been bent and suffered wear to the plastic cover



The 5-6th fork is showing a little bit of wear but nothing durastic and all appears straight and in good condition







Following this I've now rebuilt it with another steel fork including the brass sliders, but have swapped out some of the gearbox out with another broken one i had as the syncros were in better condition on this one.

A friend as a solution has strongly suggested a SQS shifter to stop me being able to break the forks on these boxes

Prawn said:

Will an SQS shifter actually be any kinder to the box though?

You'll still smash through the gears with the combined might of every man in Essex

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Haha kind of hoped it would be a bit more out of my control as was under impression that shifting with the sqs shifter is done by solenoids although may be wrong?

Westy said:

You have some nice friends Stacey!

Good luck with the next box config. Smooth out those gear changes mate.

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Cheer mate, there was 3 friends counting on me making the next entry for their crew tickets so was an alteria motive. Was just chatting to a friend the other day about your old car as it's now going in for a BT conversion.

Hope you Helen and family are well.

snowy said:

The E version might work for you - SQS shifters

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Had read there before some time back about the mech and E version, had assumed the E was purely electronic rather than assisted electronic, more research was required me thinks

Update...

Car made it to Ultimate street car at Santa Pod for Friday morning for an early set up and some run what you brung activity to see if can improve on my PB before the FWD Drag series that was entered in for the Saturday and Sunday.

We got there and got setup including some BBQ'd breakfast



Then once unloaded the car and made some adjustments we went down for first runs. I was one of the first on track to which first run went superbly and netted my new PB!! I had beaten my previous best time by nearly 0.5s and run 5mph higher ET



This is the log from the PB run, i was being carefull not flatshifting 1st-2nd which may net me more next time but you can see its doing its stuff between gear changes.



The following run the launch control would only go to 3k for some reason to which resulted in bogging down and netting a high 11. Following this i tested the car at standstill and launch control was all working again.

Went for another run and car did the same again on the line only going to 3k before retarding ignition for boost build, i then let off the throttle and clutch then back on to which then worked and went round to 5k as supposed to, this netted me a mid 11 as suspect car was getting a bit hot from 3 runs in a row whilst track was quiet.

So back to camp to investigate what was occurring? All the inputs that i could think of that could effect it appeared to working fine, I checked the clutch, throttle and speed inputs to which feed back was perfect.
Looking back over the logs you can see if you look very carefully that on the first run pictured above that the revs initially hesitate at 3k momentarily. This is wierd as flatshift and launch control worked absolutly fine two weeks prior at bugjam on the same map.

Looking through settings the flatshift min threshold was set at 3k which now explains where the 3k was coming from. We changed this to 5.5k above the launch control setting and all worked fine, strange as no changes had been made to the map but just started to do it.

None the less I went round for my last run. Upon launch the car just span, same through 2nd and 3rd with also some in 4th which netted a 13s run. I suspected had broken the prop doughnut or something simular, fearing this pulled over as soon as was off the strip to inspect and could see nothing wrong as everything was in place and sitting where it should be.

I drove the car slowly back to the pits to which had started to hear some noise's, then when I went to stop had to pump the brakes to get any bite, at this point i had a good idea what had happened.....my thoughts were soon confirmed

Snapped shaft!! But hadn't anticipated the other one to be twisted as well!!





The drivers side i suspect had deformed or started to break up in the hub as well putting extra load on the bolt as there was no way at all that the bolt was coming out. We tried impact guns, broke breaker bars and tried heating it but would not budge.

The result ended up being the car sat in the air until shafts and hub were picked up from a breaker sat afternoon. The weekend just contained lots of drinking and eating from here on.





Managed to get the car all fixed and able to drive home but it is very clear that i will be needing a trailer ASAP as can't compete with the security that will make it home without one.

The lads did manage to get a couple of rolling shots there and back





Next event thats planned is VW Action in september, i'm hoping by then will have sorted an issue with my meth solenoid and can start running direct port meth again, that and maybe more practice may net me that 10s run before the years out.

Front wheel drive.

For me rear end disconnected and lots of wheel spinning on road tyres

Need to get some slicks to be anywhere near competitive

Got a video of my PB run from a friend, its not the best video in the world as suspect he could do with some lessons on how to use a camera properly lol



Didn't get any more decent videos but am constantly trying to draw them out of my firends, i swear one of them must have got something pretty good

After a bit of fiddling i managed to retrieve a corrupt video from my SJCam that was in the car.



This was of my PB run of 11.02, watching the video i can still gain some time back from 1st - 2nd change would may tip me over the magic threshold

g60leigh said:

Get them wiper blades swapped for more aerodynamic ones. Them bricks must cost you a good thousandth lol


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Haha not bad thinking! Got mi4 aero' son there but maybe I should take the wind mirrors off, that'll make the old girl more slick

Right guys..... following recent events i will be picking up a new box tomorrow and fitting m,y upgrades to it.

The place near me that i will be going to collect from has 3 boxes and want to make sure i get the best suited option. Is there any more differences between the boxes as two i had here that had different codes apeared to have the numbers of teeth on the gears that checked.

The codes they have available which they say all came from TT's are FHB, FMT and DXW. I ideally want the longest ratio set out of these but was wondering if there was any other differences or rumoured to be stronger boxes?

My old box.....Rest In Pieces due to stripping 4th gear mid acceleration around 5k













Considering other strengthening mods like Cryo treated gears if not to dear and people see it as a worthy thing to do?

FHB looks like the one then! Just looked and I've been currently using a DQB which had been doing me well enough to now. Would be nice for more in 4th but looks like I'm at the limit.

Quite funny how the only difference between the FHB and my DQB seems to be such a minimal reverse different ratio

Update time.

Picked up the gearbox and rebuilt in the glorious sunshine in my garden with a few beers, I passed over all the upgrades to the new one but a billet input shaft due to lack of time to turn an insert.



The car was all back together and running within a couple of days

I'd noticed that my throttle body had been hitting my bonnet which i suspect was on launch. The powerflex bushes did start to look tired and worn out, this called for an upgrade to powerflex black series.





New one all built



Not noticed to much more noise or harshness in the cabin but it was already pretty loud.

VW Action last weekend. Went up on the saturday morning this time with the mrs and kids for their first event. Due to forecast of rain and wanting to spend time with the kids i opted out of running on the saturday and had a good few beverages

We had a brilliant crowd of friends which made the weekend. My little girl needed some comforting with the noise but soon settled in after a cuddle with the old man





Sunday was a test and tune prepped day with limited numbers, with this i payed the premium price to run hoping for many many runs....this wasn't the case With a short bit of down time i only managed 3 runs, with queuing times varying from 2.5 hours to just under an hour to get on strip, it certainly wasn't what i had expected for the extra money being sold as max of 100 cars signed on.

First run i snapped yet another driveshaft off of the line which threw that one out of the window.



After a quick change with one of my spares i took with me i was up and running again in around an hour. This next run i went easier on the launch and had less boost off of the line all trying to prevent another breakage. It did result in a slower 60ft of 2 seconds but a reasonable run there after producing an 11.31 @ 132mph.

Simon managed to get a video from behind me on the start line which was nice to see it in another perspective.



Following this run and seeing it was going to be the last of the day i turned the boost up 5% duty cycle across the range, was hoping this would give me that little bit more to hopefully net that holy grail of a 10 second run.

When I lined up i was thrown off by the fact that they had changed to the sportsmans tree rather than the Pro tree they had been running all day, due to this as soon as i saw amber i went to start the antilag and build boost on the line but had to come back out as was to soon. In the past i have found the launch control doesn't always set if isn't from low rpm, so i had to let the revs drop before initiating it again.

The added boost resulted in wheelspin which i then missed a gearchange mid track, all in all without a doubt not my best of runs. It seemed once it all went wrong on the line it seemed to follow down hill from there on.



Slip for my 3 runs, it quite clearly shows the breakage on the first run and my f**k up on the 3rd.



Heres a couple of shots from a Facebook page that a friend kindly pointed me towards





Overall i had a fantastic weekend and loved having the family there to join me. Its become very apparent that I really need a trailer and better accommodation if the mrs and kids are to keep joining me. The sunday "test and Tune" was in my eyes no where what i expected and how it was sold to me, I certainly won't be paying the extra for it on a weekend or when there's an event again, i will do one on a weekday where i'd expect it to be quieter though.

Thats all for now and expect everything will slow down update and development wise for a considerable time now as have eventually completed the purchase of the remaining 75% of our home this week producing more debt besides the obvious mortgage than ever foreseen! But at least it is ours

Madmax199 said:

Hi Stacey, sorry to hear about your issues with axles. I have not seen many wih this platform with axle issues besides myself (although my problem is I break the outer wheel front CV cage while powering out of corners).

A long shot, but are you pre-loading your clutch? I used to use more transfer cases than oil changes in the EVO until I learned that pre-loading the clutch removes a great deal of the shock load. After I started to clutch-preload my launches, I did not break a single transfer case. So if you are not doing it yet, it's something that will definitely help remove more than 50% of the stress from launching (it's like pushing a something to get it moving VS hitting it with a hammer to get the motion).

You also should look into a set of raxles axles. They are a bit more expansive but lifetime warranty, they also can take twice the TQ before snapping. A good investment IMO in your situation.

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TBH Max I think you are right on the money. I had started to preload the clutch at this meet on the 2nd run following discussions with some friends. I did find on the second run although my launch was slower the car launched better/smoother doing this. I will certainly be doing it in future and if the 2nd run is anything to go by I will be able to hold the launch control for longer putting more boost into it via this method.

To be truthally honest i'm gagging to get back to the strip doing more runs in this way and perfect it.

I will be trying the stud type of shaft and outer CV first then if i still have more issues will be looking for other solutions. Raxles will certainly be a good investment one day but it is currently in a long que on my wishlist of future upgrades lol

g60leigh said:

Can I slightly hijack for a moment and ask what you're meaning by pre losing the clutch.


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You basically bring the clutch up to biting point putting load against it whilst on the line.

This stops as much of a shock load going through the drivetrain on initial bite when launching, especially with my 8.5' twin plate clutch.

Not updated in a while.

As most have probably got the jist by now, i can't leave things alone for to long and have to tinker with everything as my family would say.

Winter was setting in which meant the car tent made an appearance again for winter developments.

AIM OF THE GAME this winter is increased power to weight ratio



Car back in its winter home.





Got a new toy as well for my B day from the Mrs and family which will help with the plans over winter.



Been trial fitting some control arms and improved geo subframe.







It is very well made but does require some modding and shaving of other bits to get it in. Bonus being though is the rack is mounted higher and so are the arm mounting points to keep them flat with the average lowered car.
I did also weigh all components and with my previous cast arms/OEM subframe to the new tubular setup the car has lost 7.6KG which is always welcomed.

I really can't wait to get it out and see how much sharper it will be with the subframe and once again less weight up front.

I spent the afternoon making some bits to aid the next part of the project





Target to be back running is Feb, this will allow some running/shake down time ready for mapping and then some racing me hopes....we will see.

That's all for now

Update!

Progress has been no where as quick as i would have hoped as aimed to be hitting the road for mid feb but have still none the less made some decent progress.

Theme of this winter works was mainly weight reduction hopefully with a side of some more ponies lol

I go the car on the spit ready for a helping hand to turn it over.

'

Couple of friends that were round on a friday eve helped me flip it on its side and didn't realize at the time that one had been writing graffiti on the screen :facepalm:



I then sat away for many long long periods removing all the under seal from the car in preparation for some fresh thinner stuff. The underseal had been burnt in a few places whilst doing the cage etc so this was another reason behind doing it.



Its really surprising how thick it really is in some areas.



Quick coat of Carplan underseal



Rear end is still under construction but that will follow shortly.

In the mean while i got some new injectors after maxxing the 1000's and even when turned the pressure up i was still seeing 90% IDC at 4.75bar fuel pressure. I was going to go for 1600's but with future plans i wanted to leave some head room which saw me jumping to Fuel injector development 2000's supplied by Pro-Race Engineering.





Much to my surprise the flow was nearly bang on 2200cc per injector but very closely matched flow rates. Should certainly provide more than enough fuel unless I switch to something more exotic.



Relocating the fuel system, WMI, power steering pumps etc.

I had previously made an enclosure in the rear of the car to house all these items, but have now decided that it was unnecessary weight, alongside the eagerness to remove the spare wheel well i thought i'd combine the two

I started by cutting out the rear wheel well, I wasn't entirely happy with the amount of strength that would be removed, to compensate and strengthen the back I added some bracing that would also aid mounting a plate over the top and a central parachute mount shall I hit the magic figure and need one.





I then have set about mounting my pumps etc in the rear and making more braces to the haldex mounts.





The old manifold exhaust system etc has now been passed on and will soon be on the residents bumble. Was good to meet Ian today after he drove the length of the country and back to pick it up. I'm sure he'll make good use of it all and look forward to seeing the results.



Been collecting some more bits ready for the next round of under bonnet changes




TBC

Andrew@A.L.D said:

Nice. Twin scroll turbo setup.

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Yeah seemed the logical step if making my own manifold and aiming for more flow. Can't wait to get it together and see how it behaves.

I expect a fair amount more lag after discovering the old GT35 housing i had appear to be an opened up GT30 0.82ar housing, god knows what AR it worked out to in the end? Explains why was as lively as it was for an 86mm comp wheel and the wall of flow it hit.

May need a supercharger conversion to fatten up the lower end, then can wack an even bigger turbo on

Well over due update although very brief with some big gaps to fill at a later date but she's running

First start thursday afternoon then towed straight to santa pod for running in and some running down the strip for testing and adjustments.

Couple of quick pics

Crank to flywheel strengthening



More bottom end strengthening



Engine built



4" Downpipe with exhaust to be finished at a later date



First start











Will do a more detailed update when have the time

Little update,

Car made it to pod after 20 miles of road use and started to map and make some adjustments there. After 3 runs at actuator pressure of 0.5 bar i kept increasing the duty cycle bit by bit to bring some boost in and wasn't getting any results which was strange, i got up to some quite high duty values and couldn't work it out why had no boost.

After some thinking had worked out that Freddie (2 years old) whilst had been playing in my car had flicked an old switch to disconnect the boost solenoid. Doh so few runs wasted trying to sort that but never mind.

Did get one final run in at 2.2bar before the weekend was out. Launch was terrible and bogged right down, gear changes were also pretty abysmal with 3rd-4th gear change taking 1.6s according to the logs lol (gear linkage mech still hadn't been alligned) all in all though the car felt very lively when was on boost and really looking forward to see how well it performs with flatshift working to keep the big turbo moving and a reasonable launch to nip the 60ft time.

Couple of pictures of me on the strip and the few cars in our group in the pits. The "no worries" text on the window was some banter back and forth with the commentators after they accidentally said "SHE" has done.... over the tanoy lol





The 2nd team car, the mk1 golf with a pretty similar engine setup to mine, bit of a handful.





After santa pod i managed to get the rest of the downpipe and system finished all in 4" 102mm pipe from turbo to tip.

I'm really starting to enjoy the TIG now have had some time on it, i'm not fantastic by any means but it has without a doubt improved the more i have done. I will now just generally hit you with loads of pics of boring tube stuck together.









Getting this blunt carbide burr a bit to hot before she hits the bin



A few shots of under the car with 2 x boxes/silencers to quieten it down.



Still got to fully weld exhaust tip exit on









Quick video of its first start up on the new exhaust



More to come at a later date...

Hopefully have some times and dyno plots by the time i get round to updating again

badger5 said:

decent progress there dude. nice one

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Thanks Bill just can't wait to get some seat time now and enjoy it again

So what a few weeks of hell ive had with the car!! 90% of it fueling, some spark related and also a starter motor to throw into the mix.

I started getting the occasional miss fire under boost and had a coil pack on number 4 fail which i suspect was due to heat. Following this I set about a coilpack conversion to move the coilpacks away from the heat and to make #4 easier to access following a slight design flaw on the manifold wastegate placement lol (will be getting some longer leads as well as don't like how tight they are, i didn't mount the coils in the original position i had planned)









Whilst it was off the road i had also planned on a couple of fueling system changes, i changed the rail feed to -8an from -6 to cope with the extra flow required and hopefully reduce pressure drop making it easier on the pumps, at the same time I relocated the fuel filter to Just before the rail. I even had Freddie get all keen and try and help out. Got to start them young



Cheeky little look on his face. Strict instructions from the Mrs though the children are not allowed in the "racecar"



Addition of once again another cooler on the car.



Upon running the car after it had sat for some time i found that I'd only get a few miles down the road and the car would start to misfire and die on me, it done this to me a few times and had to get the mrs to come and recover me and the car much to her disgust.
It was really hard to pin point what it was causing this, spent many hours thinking monitoring and trying things, i relocated the fuel pressure gauge into the car to help with diagnosing the issues.

It turns out my surge tank was running empty and pockets of air were being picked up causing me occasional misfires on longer pulls, this got worse and worse over time until it got to the point the car wouldn't run and the gauge pressure drop was evident. Upon much more digging, it would turn out to be that the DW65V intank pump doesn't pick up from the other saddle without load against the main outlet. Usually main outlet is minimum 3 bar but on mine with the surge tank etc it is absolutely minimal which causes the suction jet/venturi system for other side pick up to not function correctly. I found that by putting a clamp on the feed line to make it build pressure solved this but was inconsistant.

Next up was dyno day which had crept up far fa to quickly and wasn't prepared as would have liked to have been.

Car strapped in at street racers



We quite quickly was greated with occasional misfires after multiple pulls etc, which shockingly again was the intank pump not picking up from the other side of the saddle, brimming the tank sorted this.
Not long down the road we hit the same sort of issues again but the tank was pretty full. Upon pulling the intank craddle out and dismatling, it was very apparent what had been causing the next round of issues. Swollen o-rings becoming unseated.





A quick bit of pikey modifying sorted this issue though and the pump functioned with no o-rings in the basket lol



After a morning of irratic fueling we was hopeful that the afternoon would bring us more Joy

Gordon started by trying to get a nice steady base boost profile around 1 bar across the board, had occasional reocurring misfire on boost, after changing the plugs we brought the gaps down from 0.7 - 0.6mm, this certainly sorted it. For now!

We then started to put some a little more boost into it up to 1.2 bar but was greated with more occasional misfires again. We started hunting high and low trying to work out what was going on until it progressed and started running on 3 cylinders

This turned out to be a dead coil pack which i may add was brand new 2 weeks prior!! Luckily i purchased 5 so would be covered.....I left the sodding thing at home! B******KS

We ended up proceeding by linking a Honda coil in that was knocking around to get us out of Jail so could progress on,there was nowhere that we could find a new coil to purchase, to drive to pick mine up is a 5 hour round trip.





Thinking we was getting somewhere now and all this was behind us he started mapping again.

Once again after some time we discovered that the fueling system just wasn't keeping up, and this time it was the 044's. It took a few runs and a little while before we realized that fuel pressure was dropping off during the pull but not the same characteristics as before with air being drawn in.

By this point we flew the white flag and called it a day as knew that there was no point progressing. Below is a couple of graphs and relative logs.







On this run it did have a bit of a boost spike but fueling was rich at the same time robbing power at that point as went below 10:1 afr, but does most certainly look promising making 400hp @ 1.1 bar boost at as low as 6700rpm.

Next one was more of a test run to accentuate the fuel pressure dropping with a boost pressure to raise fuel pressure. We saw it dropping by nearly 1 bar nearer the end of the run.





Once again running rich made the power start to tail on the graph but very happy with how the potential of how this setup is looking certainly wasn't expecting it to spool and make this much power this low down for the size of turbo. 420hp at 5300

All in all what a ****** pain in the **** it has been but the potential is looking massive once put some real revs in there as hope power will still keep climbing without finding the point of leveling off like the HTA3586.
Wondering if will see the main bulk of the range of the new 5 bar MAP sensor as well as expect it will still keep gaining power around 3 bar region....who knows?

Cant wait to get it mapped full with timing and boost suitably optimized to find out though