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eS2 evolution

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 Post subject: eS2 evolution
PostPosted: Thu Mar 29, 2018 7:05 pm 
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I sprinkle rubber on my Cherios

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It's time to start a thread on my project... This is one of two Coupes that I currently have, I purchased Afterthoughts Coupe with the intent of combining parts from both cars and ending up with black rather than white. Ultimately I decided that the slightly stiffer chassis of the 91 was my preference over the colour. I was able to sort Afterthoughts cooling issue and I will likely be putting it up for sale in the spring as I need the space…

My white car is one of the original eS2 builds, and certainly well documented. Started with this...

http://www.20v.org/s2/home.html" onclick="window.open(this.href);return false;

I did a little digging and found the original builder of the car... long story short he still had a full box of photos and documentation from the build. Very interesting looking at the effort that went into collecting the right info and then executing the build. Keep in mind that the internet was still developing and there was nowhere near the information that is readily available now. There were a few more things that went were done to the car beyond what is shown on the site. 01E 6 spd, brakes, rims…
So now on to the scope creep. Started out that I was just going to install a GT 3071, intake, header and exhaust, then a leaky head gasket and transmission 1/2 shift issues. To say the least the plan has changed. I still have a few minor things (hopefully minor) to sort out / make decisions on.
As anyone that has ever been under the dash knows there is the potential for many sleepless nights lurking under the dash. Not unlike any other Audi of this era there were a few intermittent electrical issues. Seats would stop working, battery would be dead after sitting for a night, windows, occasionally the blower motor would come on, or not and then the biggest pain was the fuel pump stopping. The wiring job that was done during the conversion was very good, the only way to tell that it is not a factory loom is because a red friction tape was used on everything related to the ECU. I think the gremlins are related to the electrical connectors age but can't say for certain. After some digging I decided that I neither have the time or patience to try to resolve the electrical issues. Installing an aftermarket ECU and separate fuel pump circuit would make it less likely that I didn’t find myself sitting at the side of the road waiting for the demons to leave, but… I decided that I would install an Infinity Box Can Bus wiring system… there are a few things that I need to integrate from the factory wiring but I am confident that won’t be as challenging. Obviously, the system isn’t cheap but I felt that my time is precious and that in the long term it was money well spent.
I won’t dive into the details on my parts list but will throw up pictures as I go along…
- FRP built engine (Big thanks to Jeff for all of his guidance / assistance with this)
- Upgraded fuel system
- Dual disc clutch
- Some Iroz and 034 parts
- Rear brake upgrade
- Rewire as mentioned
- Advanced Automotion tranny – RS4 FDP gearbox. I liked this gear boxes RPM drop… other than of course 1-2…
o After 1st Shift: 4,320 RPM. 46.00 % RPM Drop
o After 2nd Shift: 5,206 RPM. 34.92 % RPM Drop
o After 3rd Shift: 6,289 RPM. 21.38 % RPM Drop
o After 4th Shift: 6,668 RPM. 16.65 % RPM Drop
o After 5th Shift: 6,789 RPM. 15.14 % RPM Drop

o 1st Gear is 41.38 MPH at 8000 RPM
o 2nd Gear is 76.63 MPH at 8000 RPM
o 3rd Gear is 117.75 MPH at 8000 RPM
o 4th Gear is 149.77 MPH at 8000 RPM
o 5th Gear is 179.69 MPH at 8000 RPM
o 6th Gear is 211.74 MPH at 8000 RPM1

Seems like I have way more boxes stashed than this but these are the core components…
I’m going to need to decide what I am doing with some of the stock parts, RS2 Airbox, exhaust manifold etc, need to double check but I think it is an K26 7200 (RS2 turbo)…

Did the Lizard Skin noise and heat treatment... cleaning up the engine bay before I start putting stuff back together (wiring first).

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Last edited by Fbatwork on Fri Mar 30, 2018 11:43 am, edited 1 time in total.

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 Post subject: Re: eS2 scope creep
PostPosted: Thu Mar 29, 2018 7:09 pm 
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 Post subject: Re: eS2 scope creep
PostPosted: Thu Mar 29, 2018 7:14 pm 
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 Post subject: Re: eS2 scope creep
PostPosted: Thu Mar 29, 2018 7:16 pm 
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 Post subject: Re: eS2 scope creep
PostPosted: Fri Mar 30, 2018 6:13 am 
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Man it looks so good in there . What is that tool that you used to clean the crap off the inside floor with? I’m getting ready to clean the undercoating from one of mine and trying to find the best tool.

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 Post subject: Re: eS2 scope creep
PostPosted: Fri Mar 30, 2018 6:27 am 
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I sprinkle rubber on my Cherios

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It's an oscillating tool - primarily for wood work, I have the corded Bosch unit and a cordless Milwaukee. I've had mine for years - mostly for working on cabinets, hardwood floors etc. they work fantastic. There are lots of different manufactures but I would recommend spending a little more and buying a better quality due to the pressure you put on the head when removing the noise barrier crap. There are lots of attachments, I used about 3 different ones, the most effective one is made by Bosch - you can see it on the picture below on the Milwaukee. I haven't decided but I will likely do the tunnel with the ceramic coating and get rid of the factory heatshield...

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 Post subject: Re: eS2 scope creep
PostPosted: Fri Mar 30, 2018 6:28 am 
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 Post subject: Re: eS2 scope creep
PostPosted: Fri Mar 30, 2018 6:30 am 
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I didn't track my time but it likely took about 8-10 hours including using lacquer thinner to get all the little bits off... then a sand, prime the bare metal, mask and then sprayed over 4 days (a day per coat)

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 Post subject: Re: eS2 scope creep
PostPosted: Fri Mar 30, 2018 6:53 am 
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Jesus you would think I could capture my thoughts in one post... another good tip is to use tin foil on oddly shaped things - buy the heavy foil and use care when wrapping stuff...

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 Post subject: Re: eS2 evolution
PostPosted: Sat Mar 31, 2018 1:00 pm 
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So many things to like in your posts!

Those CF door sills are awesome... aronmatic2/CarbonDesign off S2F?

The Lizard Skin looks awesome! I'll likely go that route when I do that job. How does it compare to DynaMat, sound wise?

Would be nice to see a post about the Infinity Box, looks like a powerful unit.

That link to the 20v.org build is epic. Dates back to '98, when they were not only innovators in the eS2 realm, but across the entire web. lol Nice spin down memory lane.

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 Post subject: Re: eS2 evolution
PostPosted: Sat Mar 31, 2018 5:32 pm 
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I sprinkle rubber on my Cherios

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The CF door sills were part of the “parts” pile that I got when I picked it up, there are also b pillar carbon fiber covers on the car as well.

The Lizardskin is very good - especially when combined with the ceramic heat control, 2 coats of noise and 2 coats of ceramic, it works very well.

I will keep posting as I wire on the Infinity box but have a look through there website as well - by far the most versatile wiring system that I have found - I went with pretty much every option except for the environment control - taking my heater core in to see if there is anything that can be done with the plastic top... sooo much work to pull it out

https://infinitybox.com

The box of stuff that I received was even better - every photo, the original owners manual, stereo etc... the car was very well sorted other than the few wiring gremlins.

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 Post subject: Re: eS2 evolution
PostPosted: Sun Apr 01, 2018 3:14 pm 
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Half the forest in the heater box... switching it over to manual controls...
ImageImage

And all the initials on the assembly line.
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 Post subject: Re: eS2 evolution
PostPosted: Tue Apr 03, 2018 2:18 pm 
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Fun project! I look forward to watching what you all do with the old gal! I picked up a pearl S2 clone this winter myself. Can't wait for spring to get here in MN so I can start my build. :)

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 Post subject: Re: eS2 evolution
PostPosted: Tue Apr 03, 2018 6:12 pm 
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s4.branden wrote:
Fun project! I look forward to watching what you all do with the old gal! I picked up a pearl S2 clone this winter myself. Can't wait for spring to get here in MN so I can start my build. :)


Thanks - can’t wait to get it on the road...

I know most have dropped the bomb and moved to vac assisted brakes but I am seriously considering going with a electric power steering pump and possibly a modern accumulator... the Mini Cooper (up until 2008) has a unit that runs pentosin and a remote reservoir. Downside is 100 amp fuse and failures due to heat.. Volvo has a pump as well but reservoir is attached. Does anyone have any experience / feedback?


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 Post subject: Re: eS2 evolution
PostPosted: Sat Apr 07, 2018 10:04 am 
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Has anyone found a good solution to replacing the foam inside the heaterbox for directing air? I am converting from the electronic to manual controls but both boxes foam are done....

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Also looking for the plastic clip that holds cable onto box.
Broke clip
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Good clip
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 Post subject: Re: eS2 evolution
PostPosted: Mon Apr 09, 2018 3:10 pm 
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looks good keep it up!


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 Post subject: Re: eS2 evolution
PostPosted: Thu Apr 19, 2018 8:21 pm 
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I sprinkle rubber on my Cherios

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Okay so I ended up using some high temp silicone foam from McMaster Carr part # 1059N269

Replacing the vacuum controls with cable from RS2.

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 Post subject: Re: eS2 evolution
PostPosted: Fri Apr 20, 2018 4:05 pm 
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Spent some time today Labelling wire to eliminate mistakes once I am inside the car working.

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 Post subject: Re: eS2 evolution
PostPosted: Sun Apr 22, 2018 5:36 pm 
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So the weather has finally gotten decent enough to roll the car outside and get rid of 27 years of grime.

Looks better in person but much better.

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 Post subject: Re: eS2 evolution
PostPosted: Mon Apr 23, 2018 7:30 am 
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Very Nice!

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 Post subject: Re: eS2 evolution
PostPosted: Tue Apr 24, 2018 5:26 am 
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hey man, nice work!

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 Post subject: Re: eS2 evolution
PostPosted: Wed Apr 25, 2018 8:30 pm 
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Thanks! I am hoping to get started this weekend with fuel system and wiring...


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 Post subject: Re: eS2 evolution
PostPosted: Sun Apr 29, 2018 2:01 pm 
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So before I get to carried away on pumps I needed to hang exhaust... didn’t want to do the back bit until I had done the subframe bolts... should have searched too see best technique but didn’t.

Here is what worked best for me.

Loosen all 4 bolts.

Remove the 2 bolts so that you can lower as needed for access. Support with jack.

Image

I used an air chisel to chop off the top rubber to make removing easier.

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Then I used a socket between frame and car and let the weight of the car act as a press. 10 minutes once I got the system figured out.

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 Post subject: Re: eS2 evolution
PostPosted: Sun May 13, 2018 4:37 pm 
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Engine bay cleanup, ready to start running wire (although I still have front subframe bushings to do...

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 Post subject: Re: eS2 evolution
PostPosted: Tue May 15, 2018 6:56 am 
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Getting modules mounted for running wiring.

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