More wiring pics:















This is very tedious work and is taking so long...

 

More wiring pics:















This is very tedious work and is taking so long...

 

Wiring complete and ready to go in the car:




Installed in the car:


Wiring covered in split loom:




Upper intake manifold installed:




Left to do to start engine:
1. Finish the crank trigger wheel (I have to remove the 2 teeth and set the air gap)
2. Install the radiator and electric fan
3. Run heavy gauge power wire from the battery to the fuse box near the TEC
4. Mount coils and connect leads
5. Fabricate and install spark plug wires
6. Make minor connections inside the car (Tach, CEL, 2-step rev-limiter circuit)
7. Put oil in the engine and coolant in the rad

To do on the chassis:
1. Install Tokico/KYB shocks, Koni springs, and Koni sway-bars

 

Wow I just realized how many pictures of just wiring I have and how boring this thread is so far...

 

More progress:

(Note: still need to scrub and paint some parts)


I'm going to change this sensor right now... I think it is causing issues (i.e. no-start :P)




The car is ready to go, but I'm having an issue with the crank sensor that I have to work out. The only thing left before she can go back on the road is to reinstall the headlight motors (only after repairing the linkages though).

I can't wait to get it going again. My A4 breaks too easy, I need something to beat on!

 

All done!












The car is so much more fun with the additional power now. I'm taking it out lapping on Wednesday. Hopefully all goes well!

 

I'm very impressed. I'm guessing with the CNC and Solidworks access you're either a professional engineer or engineering student?

 

^ In between actually, working on my P.Eng right now (tests, etc.).

 

Right, I didn't mean a P.E., per se, but just of the engineering persuasion.

I'm on the downhill side of a bachelor's in engineering.

 

Very Impressive, I cant wait to see what your turbo build is going to look like . All the pictures where great even the boring stuff, it just show how much work you put into the car. Good luck with the build.

 

How did you activate the 5th & 6th ports, and VDI with the S5 Intake?

 

Sleeves are removed on the 5th and 6th ports, and I have the VDI actuator hooked up to a vacuum line from the pressure source on the pre-silencer.

 

Went to the track yesterday. The car isn't completely tuned yet, but I went anyway. The AFRs are still in the 10's in the high RPM range, so the car gets through 1st and 2nd relatively quickly, but falls on its face in 3rd and 4th.

Never having taken this car to the track, I didn't know how to launch it well. First run, I launched too low and bogged out of the hole. Ended up with a 15.2 @ 94mph and a 2.4 second 60'.

On the second run, I did a longer burn-out and launched from about 5000rpm. The car spun hard off the line and then hooked at about the 60' mark (more on that later). I ended up with a 14.9@94mph and a 2.25 second 60'. I also blew the diff on the launch.

Turns out my limited slip wasn't work all that well, allowing one wheel to spin during burnouts and launches. When I launched on the second run, it spun the passenger side tire hard. The spider gears in the diff didn't like this too much and locked up, which is why the car hooked hard at the 60' mark.


Regardless, I'm happy with the time I ran. Once I have the car completely tuned, I'm confident it will run 14.5s, all other factors being the same. If I pull the super restrictive Racing Beat exhaust and run slicks with a working limited slip, I think I should be able to shave off another 0.5 from that time, which would put me into the high 13s. Further to that, I can start pulling weight out of the car, as I had a full tank of fuel, some junk in the storage bins, and the spare tire all in the car when I ran.

Ironically enough, there was a guy at the track running mid 11's with a stroked 383 Chevy making 450hp in his first gen, with a stock GSL rear end. Kinda funny how I'm the one with the blown diff...

 

nice car,love the white.

 

I've replaced the differential with a GSL unit, which definitely locks better than my old -SE diff. The swap was a piece of cake.

I went back to the track yesterday and did a few more passes... I ran a best of 14.6@94mph with a 2.2 second 60'. I couldn't get the car to hook up (I don't know any of the tricks with these cars yet).

I left a new RX-8 and S2000 in the dust, which was satisfying.

 

sweet project! i wish i had the know how and the skills to do what you do. keep up the great work.