Small update on progress and ongoing 'projects'...
The charge pipe got some tabs welded on so that I could make a support bracket to hold it in place
As ali is notorious for stress fracturing from vibration I decided to use isolating bobbins to try and mitigate that...
Added and extra strap to help with support...
I still need to make a second bracket for the other tab but as yet not had the time to work out where that will go as its a little less straight forward... but will update once I have done that..
Obviously I have now had a chance to paint the charge pipe and apply the obligatory OEM charge pipe warning label
Another 'work in progress' is the trim for the DSG gear selector lever... the 8P trim has a plated metal finish and I was struggling to get the transition sanded out so it wouldn't show through the paint so resorted to using a plastic filler..
This appears to have worked out...
The mod is still not finished as I need to secure the leather gaiter to the mounting ring (normally stapled) but even my heavy duty stapler is not really managing to get staples through the plastic mounting ring so I have some Evo Stick on its way...
One thing that reared its head now that the engine is turbo charged relates to the brakes... more specifically how the vacuum in the servo disappears quite quickly when having a spirited drive... this will potentially get worse once I go DSG and VAG actively fit electric vacuum pumps to auto's so a little research ensued and picked up this...
This was from a Mk4 Golf but they are still fitting these to more modern cars like A1's and the like... further searching about for how these are actually fitted netted a Self Study pdf (SSP 257) dedicated to the vacuum pump in question... Seems it runs in one of two modes...
Open loop... this is where the ECU guestimates the 'vacuum' available and kicks the pump in as needed...
...and closed loop... this is where the ECU actually uses a sensor to measure vacuum and will kick in the pump when required...
Both setups use manifold vacuum as well so the systems supplement each other... I plan to use closed loop control as I can use a MAP sensor to measure vacuum and then set Ignitron to switch the pump on and off as required feed from the MAP sensor (separate to the main ECU MAP sensor I should add)
The idea will be to kick the pump in when vacuum drops to around 60kpa (600mbar absolute, ambient pressure at sea level is around 990mbar) and turn it off at around 20kpa... although this change once installed and being tested... of course Ignitron being Ignitron will allow me to log the pressure and I believe also the actuation of the pump so I can fine tune this
I just need to make up a bracket, get some isolating bobbins to stop any potential for vibration through the chassis and hook it all up... that will happen when I make a start on the next 'major' project...
...fitting a CFS alloy radiator... as my coolant temps are getting a little out of control when the car is pushed... VR's do have a reputation of running hotter than most engines but I am seeing over 100deg coolant temps with the fans running and this in turn effects the oil temps so I will be fitting this rad first then looking at an oil cooler later...
Last show and tell for now is the mods to the fuel rail.... now being a big tart this is purely a cosmetic mod and serves no other purpose at all... as you can see from the previous engine bay pic the fuel hoses are looking a little 'untidy' so had planned to get some decent nylon sleeved fuel line to replace it... I just couldn't find a way to terminate the ends that would look 'right' soooo
I bagged some stainless -6AN to 1/8npt adaptors... I could have got some bung type fittings but they are a round profile and not machined for a spanner... I cut off the ends of the OE tails and cut/drilled out the fittings so they would snug over...
They just need welding on now (something Alex has done on fuel rails before so it should all work fine without spontaneously combusting)
I am using PTFE -6AN fuel hose and so need the 'special' PTFE fittings... given this is essentially to replace the fuel feed and fuel return hose in the engine bay there are some 75 quids worth of fittings required
.... although not as bad as Ash and all the stuff he has got for his fuel system lol
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