[Wizard-of-OD]

Why are you using a 2-PIN VR sensor?

 

[hilly]

Why are you using a 2-PIN VR sensor?

Erm.....

1) coz I already had one
2) The VEMS is set up for it (though not difficult to change)
3) I have used them before with no problems at all. They are pretty reliable if you control the gap, use screened wires and the ECU had a conditioning amp like the VEMS.

If it ends up being a pain then I'll swap it for a Hall sensor instead.

Hilly

 

[newt]

Why are you using a 2-PIN VR sensor?

Lots of OE VR sensors are 2-pin at the sensor. The shield just runs down to the connector, but doesn't pass through the connector.

 

[quattro v1.0]

Boy Howdy do I want a ride in this bugger :woowoo:

 

[AudiSport4000]

How have I not seen this thread??? This is totaly tubular!!! Very nice work :-D :-D

 

[hilly]

More efforts.......................

To finish where I left off last week when my angle grinder died, I bought a new one and now the cutout in the rear cross brace to clear the gearbox is finished.
I now need to add more metal to put a bit of strength back into the brace. A section of 3mm steel was cut and bent to fit into the gap.

Out with the MiG welder and then fit it back onto the car.

That should do the trick.
Just need to send it of with the next batch of parts for powder coating before bolting it to the car.

Now to the major part of this update, brakes………..

The Esprit has the rear brake calipers bolted to the Citroen gearbox, as this has been replaced by an Audi 01X there is no longer anywhere to fit the calipers. So I had 2 options: -

1) Make up some brackets on the new gearbox mounts to fit the old calipers back in the old position.
2) Fit the rear brakes onto the wheel hubs and use new Hispec billet 4 alloy handbrake calipers.

I chose to go with option 2 as it posed fewer obstacles.
So the hunt was on for some suitable discs that would fit. As it turns out BMW use the same wheel bolt PCD, so these will fit between the wheels and the hubs.
I found some 285mm dia vented and cross-drilled discs for use on the rear.
On the front I already had the 256mm PNM upgrade kit, which worked very well.
However, to try and keep the brake balance correct I have upgraded to 300mm discs with Hispec Billet 4 calipers on the front.

First job is to modify the hubs by reducing the outside diameter to fit inside the new discs.

Although the new BMW discs have the same bolt PCB as the Lotus wheels, the hub diameter is a lot larger and so will not fit centrally onto the hub, so I machined a new hub spigot onto the rear wheel spacers to centralise the discs on the hub.

For the front I had to make a small spacer ring to fit behind the disc to locate it correctly.

Now that the discs fit onto the hubs, I need to check the run-out to ensure that I haven't cocked up the machining and there isn't going to be any problems later on with judder, so out with the dial Guage.

1 thou of run-out, that will do

Onto designing brackets to hold the calipers in the correct positions. These will be made out of 7075 high tensile alloy to keep the weight down to a minimum. With the design finalized, time to set about making them.

I started with a couple of large lumps of alloy material 400mm x 200mm x 38mm for the rear and 400mm x 150mm x 30mm for the front.

The required design was printed out on paper and stuck onto the alloy.

Then onto the mill for machining

I got about 95% of the way through the machining process and then hit a snag.

The lathe and mill I have access to are not big enough to allow the brackets to fit during machining of the hub cut-outs. I scratched my head about how to do this final machining step for nearly 2 months until a friend came to my rescue.

At this point I want to thank Kurt and the guys in the machine shop for taking my chunks of alloy and doing a fantastic job of machining out the final holes. Also while I am at it I should also thank my father as well for helping out with the whole car so far (they are his feet you occasionally see in the photos) as without him I would have got nowhere with this project.

Anyhow, here are the finished brackets

I need to do a couple more things to get the brackets to fit, so I'll save that for the next update.

Hilly

 

[AudiSport4000]

Wow, those are some gorgeous parts!! :woowoo:

 

[a4kquattro]

So I'm just going to throw out a wild guess that you're a machinist by trade?

 

[hilly]

Nope, I am an electronics engineer..............

 

[Danforths]

What you see is machining by removal of electrons.....A new variation in EDM :lol:

Either way, great work. :woowoo:

 

[ricola]

Great work and I'm keeping a very close eye on this project as I plan to do the same to my Phantom GTR in a year or so after my other project is finished...
Rich

 

[derracuda]

very sweet!! man, your custom parts is what makes me jealous keep up the great work

 

[hilly]

Great work and I'm keeping a very close eye on this project as I plan to do the same to my Phantom GTR in a year or so after my other project is finished...
Rich

Rich
I quite like the Phantom GTR, always fancied one of those for years.

Isn't the engine transverse though ??????

Hilly

 

[djpdex]

Lookin' good so far! Were the original rear brakes inboard above the halfshafts like a humvee?

Ricola,
I took a look at your GTR project so far- and WOW, nice work too!

 

[ricola]

Yeah, it's transverse with dedion rear suspension. I'll have to figure out what to do there to allow space for the trans, if it pokes back to far for a new dedion tube to go behind it (probable) then I'll probably switch to double wishbone, will give me an excuse to give more clearance for bigger wheels too! Unless you have any other ideas? Not sure if I can put a hoop in the tube to go over the trans, how would I locate it sideways without screwing up the roll centre?

Rich

 

[hilly]

Lookin' good so far! Were the original rear brakes inboard above the halfshafts like a humvee?

Yeap, inboard discs bolted to the gearbox output flange with the calipers integrated into cast gearbox mounts, hence the hassle to modify them.

Hilly

 

[hilly]

Yeah, it's transverse with dedion rear suspension. I'll have to figure out what to do there to allow space for the trans, if it pokes back to far for a new dedion tube to go behind it (probable) then I'll probably switch to double wishbone, will give me an excuse to give more clearance for bigger wheels too! Unless you have any other ideas? Not sure if I can put a hoop in the tube to go over the trans, how would I locate it sideways without screwing up the roll centre?

Rich

Blimey, you have put some work into that thing.
Interestingly I have got an exact same Corsa electric steering column sitting under my bench at work, I plan to fit it once the engine is up and running.

There is no way an Audi V8 and transaxle is going to fit in there, it is just too long !!!!

I think you will defo have to ditch the dedion set-up.

I can give you some measurements of the combined engine/gearbox if it would help.

Hilly

 

[ricola]

Hi Hilly,
I think I'll be picking your brains for much more than a couple of dimensions! I already have some dimensions and bulkhead to axle line is about OK, only need a small angle on the driveshafts (about an inch). I will be doing some major mods to the chassis but it should all fit fine..
The corsa EPAS works well, my mate is still sorting a speed pulse multiplier to get the variable assist bit running properly but even without it's not too light at speed. I added on a load of caster and fitted a much quicker rack and it all works nicely together..
Rich

 

[flyingfens]

Hilly, I'm really digging your......ethos
I have always planned to do a heart transplant to my S1 but I had'nt considered a trans-transplant.
Tell me, on what US model Audi, would an 01X transmmission be found?
living vicariously through your project.
cheers
don

 

[hilly]

Hilly, I'm really digging your......ethos
I have always planned to do a heart transplant to my S1 but I had'nt considered a trans-transplant.
Tell me, on what US model Audi, would an 01X transmmission be found?
living vicariously through your project.
cheers
don

Thanks

Unfortunately I think you will have a hard time finding a 2wd 6 speed trans in the US (01X or 01E) as Audi didn't fit them, all the imported cars with 6 speeds were Quattro (I think???).

However they are becoming more plentiful in Europe (one turns up on UK eBay more or less every month) so you could always import one.

Hilly