[death 4kqt]

it runs, drives and it pretty quick. I'll update this at some point after Carlisle. Way too much left to do before then.

 

[ralleyquattro]

So we get to see it at Carlisle? Yeah!!!

 

[death 4kqt]

So we get to see it at Carlisle? Yeah!!!

thats the plan. I put it on the road this morning officially, alignment tomorrow.

Its going to be ugly with primer and rust spots, but I am feeling good about how its running.

 

[death 4kqt]

Got a bunch of miles on it now, maybe 250. Got to play in the snow this morning too. Lots of little tweaks happening, but its a really nice driver.

 

[dubsmith]

Hell yeah man. Way to finish this out. Any guess on how much you have into this swap? I'm trying to justify the time and expense to do a similar swap in my quantum but...

 

[death 4kqt]

Any guess on how much you have into this swap? I'm trying to justify the time and expense to do a similar swap in my quantum but...

Oh man, don't make me do that! :dur:

I have a LOT into this car, probably as much as my big turbo 20vt car, which is pretty depressing.

I'm not sure, but lets make a short and not even close to inclusive list:
-engine $600
-stuff to refurb engine $500ish
-clutch, flywheel starter, $1000. I am changing my clutch and flywheel AGAIN. Learn from my mistake. Use a DMF, and use a proper european 240mm unit with the transmission spacer and the accompanying starter. These are all available from Dutch Auto Parts. I currently have a 1.8t DMF and southbend clutch. The clutch holds, but the diesel is raping the flywheel. It bottoms out the springs in the torque peak in higher gears and make a horrid shuddering. My first flywheel was too light.
-transmission $900
-linkage $150
-used hank trans mounts $125
-turbo, manifold, oil lines etc about $800-1000
-stuff to make exhaust $300
-egt/boost combo gauge $280
-big injectors $350
-injector balancing $225
-custom tune $300
-chip burner $180
-radiator $150ish
-intercooler and stuff to make the piping $200-300
plus so much more that I can't think of. Add all that up and triple it, and thats probably what it costs to effectively convert an old audi to diesel.

Plus the cost to totally retore an audi that was in much worse condition than advertised, but you know what you are starting with.

It is awesome though, I have still not accepted the fact that I need to pull the trans again, and drop another grand into ANOTHER clutch setup. I underestimated the violence this engine would produce.

 

[NiTeC]

man the clutch deal is a bummer...we'll meet up when I`m back on the east coast so you can test my setup - that Valeo kit is surprisingly good

 

[death 4kqt]

man the clutch deal is a bummer...we'll meet up when I`m back on the east coast so you can test my setup - that Valeo kit is surprisingly good

I'm shocked its holding for you, but that is an amazing value. That flywheel must be really heavy.

I'm sort of an idiot for thinking the 1.8t DMF would work. I found some posts on TDI club where people were using them with no issue. Scott said he had used them several times. These people must have been running stock or stockish tunes/turbos. Any real throttle below 3000 rpms in 4th 5th or 6th totally overpowers the flywheel. Expensive experiment for sure.

I think I'm just going to pull the trigger on the DMF setup, my car is loud and clattery enough, and I really like how it sounds and drives with the dmf. I want this to be the last clutch setup for a long time.

 

[pkw]

it runs, drives and it pretty quick. I'll update this at some point after Carlisle. Way too much left to do before then.

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That looks like a sweetie Dana.
and you deserve a bump for having one of the only two post that are not spam this morning.

 

[death 4kqt]

That looks like a sweetie Dana.
and you deserve a bump for having one of the only two post that are not spam this morning.

thanks man! it really is turning out to be an awesome car. Lots of little issues, but overall it feels like it was meant to be this way.

I haven't really been taking many pictures. Been pushing hard to get this thing to Carlisle. Its a bit ugly,rusty and primery but mechanically she is going well. Been daily driving it all week, and tweaking things/fixing all the little issues that come up with a build like this.

Random pics from the last month of busting ass.

Wiring hell!

hybriding a diesel euro cluster with my original. Correct working tach, glow plug light integrated, auto check and mph speedometer. I also swapped over the diesel fuel gauge. No more "unleaded fuel only"

clutch setup #2, a failure. DMF for gasser cannot handle torque at 2500 rpm.

1552 wheel fitment test.

clutch/fw #1 coming out

added a resonator last night. That made the car 100% better. This thing was way too drony and booming. The bigger turbo really lets a lot more 4 banger noise through, and it wasn't good.

This resonator is amazing. I cannot believe how much it quieted it down inside and out the car. The exhaust is a straight pipe otherwise. It totally makes the car, and it is extremely compact. Highly recommended. Not that a 4 banger ever really sounds good, but it improved this car 10 fold.

This is what it is
http://vibrantperformance.com/catalog/p ... ca90612157

 

[pkw]

Awesome! Keep an ear out for that getting louder though. Not that I have Experience with those but I think that the perforations and packing can get mudded up with gunk and then it is pretty much straight through with no quieting. I have a 900cc L twin bike that went from sounding wonderfully mellow to wonderfully loud over time.

 

[ralleyquattro]

Had the privilege to be in the car and I am very impressed.
Pulls way better than my 2.5tdi... I'll have to sort that out BTW..
Super nice work Dana, very nice conversion and something you can be very proud of!

 

[death 4kqt]

Had the privilege to be in the car and I am very impressed.
Pulls way better than my 2.5tdi... I'll have to sort that out BTW..
Super nice work Dana, very nice conversion and something you can be very proud of!

thank you Martin! It was good to hang out and talk with you. My offer still stands for the trade for the s2 avant :lol:

 

[death 4kqt]

Also, the first MPG report is in....This is from the trip back from carlisle which included many WOT runs, cruising between 75-100 the whole time, and trying to keep up with Matt's RS4 and Shawn's big turbo 1.8t. I was expecting 40 at best...but we have 47.3. I dare say its got 50mpg in it with a light foot, the belly pan re-insatalled and some more legal highway speeds. :lol:

 

[ralleyquattro]

That is pretty damn good!

 

[Mbsjr92]

Fk the car give me that can of Sip and call it a day.

Jk, but really

Sweet build, thing looks like a blast :cheers: :thumbsup:

 

[death 4kqt]

little project update, I have about 2000 miles on the car now, still running like a champ. I took my wheels to get straightened after hitting a massive hole in the road on a main road. Thanks VT road crews. One of the wheels straightened out, another cracked and is currently getting welded. Bummer.

I noticed I have some pretty bad cupping wear on the inner edges of my front tires. Like major wear considering the low miles. Its really only on the first inch or so, so I think that my toe got messed up when I hit the hole. I know camber can wear unevenly, but this is extreme, and I think usually that means the toe is off. My steering wheel was off center after I hit the hole. The only problem is, I cannot find what got bent. Everything is still tight, and looks fine. I want to make sure I get things fixed before aligning it AGAIN.

On other news, I ordered heavy duty valve springs, new lifters and a stage 3 cam (more lift and duration). My engine seems to have trouble injesting air at higher rpms. The EGT's also climb quite high when really beating on it on the highway. I think the cam will help some, but really I have a few things going on:
-crappy factory cam
-10mm injection pump causing a long injection window=inefficient and hot burning
-too much fuel for the amount of air I can get through the engine
-horrible stock TDI ports
-turbo running at the top of its efficiency range
-crappy ebay verticle flow intercooler

I will try cam and springs first, then probably look for an 11mm injection pump to swap in and see how it runs then. I also have a bad itch to do compound turbos using the current he211w as the high pressure turbo and an hy35 as the low pressure. This is most likely unnecessary, but it would be super fun and hilariously cool.....plus, imaging the sounds it would make. Glorious sounds. Compound turbos would certainly help things run cooler too. The only question is....can the stock TDI long block take the abuse of 40 psi? I think maybe....although I might not be nearly Finnish enough to pull that off.

My engine bay lays out so nicely as it is, trying to cram another large turbo in there would be a challenge. But who doesnt like a challenge?

Also, I had to swap back to the borbet wheels that have hilariously bald tires, so I decided to play a bit. Listen to the glorious little holset turbo noises. This test confirms that this winter will be awesome.

 

[Andy10v]

Has the ball joint slid on the wishbone? Toe will eat the tyres, I learned that the expensive way!

Nice build, I like reading your builds, and get her done attitude.

 

[NiTeC]

Loo watch out for that rock hmm that's a lot of smoke for your 30psi wg setting...hopefully the cams help a bit. ..

And I'll see your Hy and raise you an He351...let the biggest Holset compound win also running stock bottom end but going with a PD and R783 nozzles

Sent from my SM-G920W8 using Tapatalk

 

[death 4kqt]

Thanks Andy! Its possible that the ball joint slid, but I cannot really tell from looking at it.

Emil, the majority of the smoke is from getting on the throttle before the turbo is spooled. The current tune allows for 100% fuel at 100% throttle. No scaling from boost at all, so if you wack the throttle before its spooled up its rolls horrid coal. Once its spooled up its just kind of hazy until your really get higher up in the RPMS when the smoke comes back. I think the cam will help, I think a lift pump will help and I think an 11mm pump will help.