Bobby Singh's Audi S2 avant project

[bobby singh]

Rear crank seal fitted using this borrowed tool

Oil pump machined - this is to allow the fluid filled pulley to have some clearance

All sump bolts cleaned

Getting there

Cheers
Bobby

 

[bobby singh]

Head parts are finally here:

Door card cloth

So the doorcard on the S2 have been degrading over time and the backing has been breaking away:

As you see above I managed to get hold of the origional material from Audi Tradition

Next task was to drill off the plastic welding for the door pockets

(wonder how long that gum has been there)

Ready for action:

Final result:

Used cable tie as welding rod and plastic welded the pockets back on:

Cheers
Bobby

 

[bobby singh]

New exhaust cam - managed to get hold of a brand new ABY exhaust cam

New s2 boot badge

B5 fuel tank shield (apparently with minor modification it can be used on the b4). Mine was totally rusted through so removed it sometime ago.

Boot wiring repair kit

Found this on ebay - have no use for it but old new stock is always nice

Cheers
Bobby

 

[bobby singh]

Home made tool for the fluid filled crank pulley

Cheers
Bobby

 

[bobby singh]

There's been a lot going on with the S2 in the background and its finally back from a full paint job.
Yes it was done last year however I wasn't happy with the colour match so best way to get around that is to have the whole lot done.
It come out very good and I'm impressed by the Bodyshop I used - they get my recommendation.

Nice to see the car is still solid under the body kit.

Here is a video:




Cheers
Bobby

 

[bobby singh]

Boot wiring repair loom

Cheers
Bobby

 

[bobby singh]

Rust from the door mirrors removed and now the rubber sit flat against the aluminium body

 

[bobby singh]

ECU Maxx preps:

Lambda 4.9 wiring

Cheers
Bobby

 

[bobby singh]

Car has been detailed by https://www.instagram.com/reflective.detail/ after the paint. Results are just mind blowing:

Cheers
Bobby

 

[NHN]

Stunning mate

 

[bobby singh]

Maxx ecu mounted in the OEM position

3 x 0-5v inputs
6 x egt's
Wideband

6 bar back pressure sensor wired in

Cylinder head -
I bought another 7a head and had it converted to ABY spec (the other head had a tight cam bearing which will get fixed and kept spare) with new guides, all high points machined down, valves lapped in and skimmed

I will install the new inlet ABY cam (purchased from AT) with a 7a exhaust cam

Cheers

 

[bobby singh]

Maxx datastream

So the Maxx ecu has a nice feature whereby it can datastream over bluetooth.
Bought an 8" tablet and made it removal by installing Neodymium magnets behind switch blanks

View: https://i.imgur.com/NOPnITY.mp4

RS2 spec on Maxx ecu:

To get a base line of the current spec with the maxx I went back to the dyno:

Running 1.75bar (previously 1.85) and now making 370hp / 515nm (wouldn't want anymore than this on stock rods)

 

[bobby singh]

Heat protection by http://www.thermomet.co.uk/

Head mounted:

Random pic with the coil cover on

Cheers
Bobby

 

[bobby singh]

Replacement Cam belt cover (back) - Previous one was cracked and not suitable for turbo coolant return

New EVAP unit

Some AN fittings for the turbo oil & coolant

Cam cover hs been Cerakote (Thin ceramic coating) - Sprayed on with advantages being:
stable against UV
Chemical can not touch it (even acetone)

High grade turbo studs and bolts

Cheers

 

[bobby singh]

Im also planning on using PWM for the fuel pump - This R8 item is a nice simple 5 pin unit

Bought this bracket to mount the actuator in the bottom location

 

[bobby singh]

EFR83 test fit:

RS2 turbo and wagner manifold removed for a test fit

(very tight but should be doable)

 

[bobby singh]

EFR83 test fit:

RS2 turbo and wagner manifold removed for a test fit

 

[bobby singh]

Been having problems with hosting pictures

So I had water coming into the boot area and at first I thought it was the rear lights and the rear number plate panel

Roll of sealant

Lights cleaned

This did not fix the issue so I ended up in the boot to track down two holes which are meant to be covered at factory. I can only assume the OEM tape was removed during the repaint:

Sealed

During hunting the leak I found some rust (drain hole)

Cut out

Plate made and treated the area

While at it I waxed sealed the both sills

Being a summer car its often on trickle charge and I wanted a more easier way of doing this.

Used the OEM grommet under the battery (so no extra holes)

 

[bobby singh]

Rear axle rebuild

This has been on the to do list for a while
Every bush has been changed (some very hard to find), sub frame powder coated, diff seals and oil changed, cv boots replaced, KW v3 suspension etc etc

So far these KW v3's are very nice and comfortable which was my main concern.

Cheers
Bobby

 

[bobby singh]

Rear abs sensors

Since doing all this work to the rear axle I had notice the abs would kick in at low speeds so decided to change the rear sensors:

They put up a good fight:

Unpinned the plug to get the rubbers into the correct location

Done the trick and now abs was behaving as it should

Next task bigger front brakes

Decided on:

Porsche GT3 996 caliper (larger than the C4s)
Ultra performance brackets
Merc ML350 discs - 330mm x 32
Brembo HP2000 pads

Also got my hands on cast front suspension arms

Replaced all the seals

Freshly powder coated:

Old Vs New

Brackets

Discs

Pads

All fits under the 17" wheels

Cheers
Bobby

 

[bobby singh]

In preparation for servo assisted braking rather than hydro I'm currently preparing a single stage power steering pump. The dual stage pump currently supplies pressure to the brakes and steering rack. The safe pressure for the steering rack is around 110bar so using a 100bar unit is totally.

For those that are interested Back side of the pump is from a 050145155A (100bar) & Front from a 048145155F
Servo, MC etc - 4f0612105F

Bought this seal kit:

https://www.autodoc.co.uk/meat-doria/12886193?fbclid=IwY2xjawGOD2ZleHRuA2FlbQIxMQABHYPTXv1Lxc534Swx_VxtXIWU-HJkGQwEeuLBamJR53PsF6DxEQiiAJuDqw_aem_x_Cfg7_lO6qitn2dinBw2Q#gasket-set-hydraulic-pump

Next install the kit and paint the unit.

Cheers
Bobby

 

[bobby singh]

PWM & Walbro 525

Finally got around to setting up the R8 PWM unit

Pin out:

Used 6mm2 cable for all load terminals

Perfect location next to the ABS unit

Stock pump wiring was end of life

Stock wiring Vs 6mm2

Stock connector re pinned

Level sensor wires renewed

After testing it I found the controller would power the pump even with the key out for around 15s
Looking at the wiring diagram on a R8 it turns out the controller is powered via relay.
So looking through some old diesel wiring looms I found a 40amp OEM relay with a holder which I repined with 6mm2 wire (used the oem fuel pump wire as the trigger)
Another great location for the relay under the PWM controller

Walbro 525 pump install

The fuel pump basket was a pain to remove

Pump installed using a 034 adapter

Basket installed and mapped in

The unit uses a 20hz works from 11% to 93% duty cycle
Works great and now the car can idle with just 3.4v with 35% duty cycle

Cheers
Bobby

 

[bobby singh]

Here is a full parts lists for the PWM set up:

PWM - 4F1906093B
Plug - 6N0973755
Terminals:
963709-1 AUTOMOTIVE CONTACT, SOCKET, CRIMP, 11AWG
927833-2 CONTACT, SOCKET, CRIMP, 40A

Fuel level repair wires
000-979-135 E

Repining walbro fuel pump to oem connector 000979212E (2.5mm2)

The OEM 4 pin relay I used also used the 927833-2 terminals so buying these in bulk paid off.

One thing I would say is buy from a good source and not cheap ebay terminals.

I used https://uk.farnell.com/ & TPS

 

[NHN]

Nice crimping btw, which tool?

More great work.

Surprised the OEM wires melted like that tbh.

 

[flybynite]

Surprised the OEM wires melted like that tbh.

I've seen it a few times, including when I put a Walbro in one of my older machines. R8 had it in one of REperformance recent vids.

What surprises me is more cars don't go bang but I guess lack of air saves most of them

@bobby singh Epic work mate

 

[bobby singh]

Nice crimping btw, which tool?

More great work.

Surprised the OEM wires melted like that tbh.

Thanks mate - I use Toolaid 18650 kit, its not the best but does correct crimping

The OEM pump wire is now over 30 years old and the car has been running a Bosch 044 pump for the last 10 years or so.
I was reading some of the posts on the S2 forum and you would not believe some run the stock wiring with a walbro 450 at 600hp.

I've gone over the top with 6mm2 wire but its not something I need to worry about again.

 

[bobby singh]

I've seen it a few times, including when I put a Walbro in one of my older machines. R8 had it in one of REperformance recent vids.

What surprises me is more cars don't go bang but I guess lack of air saves most of them

@bobby singh Epic work mate

Thanks mate - its slow progress but working on it between jobs

 

[bobby singh]

While running the cable for the PWM unit I noticed the front insulation was damp.
I started digging and found the water was coming via the pollen filter housing:

Cleaned up the whole area

The seal itself had been overlapped on one side and off course its no longer available
So used 3M sealant

Whole area was then sealed with Dynax-UC clear wax

Cheers
Bobby

 

[bobby singh]

Fuel Rail pressure sensor

Next task was to install a fuel rail sensor to enable fuel tracking:

Fuel pressure sensor X

Fuel pressure sensor Fuel pressure reference Atmospheric pressure Manifold pressure (MAP) - Must be used to be able to use the fuel pressure deviation tracking features below.

maxxecu.com

Had mount machined out of stainless steel and I used a Mercedes M10 x 1 fuel pressure sensor from their diesel application - rated to 11.5bar

Powder coated

Perfect fit:

Got exhaust manifold pressure sensor mounted from a PSA rated to 6 bar - used the psa bracket into brace

Managed to get my hands on new oil cooler - might not be man enough for the new engine but for short weekend blasts hopefully its ok.

Cheers
Bobby