Updates? How's it running I'm under the impression that it will eventually end up at my house one sunny afternoon haha

 

i was busy breaking in the engine. i put 1200km on the car in 7 days

It's been so long since i drove the car I cant say if its faster than it was before, but i can say that its damn quick. in stock form the car would peak in power around 5000rpm when the vdi and 6 ports are optimized for the higher rpm. I havent noticed any less power down low from the porting, but the power seems to keep growing it gets closer to redline.

one issue which has risen/gotten worse is the old tired stock exhaust. It has cracked around the welds of the muffler sometime near the end of the season last year, and is now getting progressively worse. As much as I would love to get a brand new shiny racing beat catback, im a little tight on cash at the moment. I may be able to get my hands on a replacement stock exhaust but it's condition is still being confirmed. It sounds ok at WOT but cruising around in traffic it sounds like my neighbors shitbox honda

Diff, intake, and exhaust are things i would love to sort out before the new year or before next season. Right now I just want to drive this thing the way I've been patiently waiting to do for the past few months

going to the drifts at the track this coming thursday so i'll have some photos to post next week

 

Are you not doing the 3-4k rpm limit to brake it in? Redline it acouple times to clear carbon is ok, last thing you want is the apex seals to not seal 100% during break in.

 

because i dont have new bearings 1000km is all i needed for break in. I talked to a builder about it and this is what he told me

 

[QUOTE="ibeljin;11782937"]because i dont have new bearings 1000km is all i needed for break in. I talked to a builder about it and this is what he told me[/QUOTE
Ok sounds good just checking !!

 

This looks great! Real motivation to tackle the few things I have wrong with mine.

 

so my exhaust disintegrated on me on my way to a buddies cottage this weekend. It was splitting around the welds where the exhaust meets the driver side muffler and it decided it had enough of its life and broke right off when i hit a sizable bump. Looks like that exhaust work i was talking about has to happen alot sooner than i planned haha

im going to use a stock cat back if i can find one and upgrade to a racing beat piece when my wallet has time to recover

 

If you can get some pipe we have two rb mufflers that just need to be welded on.

 

Ive been a bit lazy lately to post an update so here it is! Better late then never I suppose. The exhaust began falling off the car and my wheel bearing began failing the other day as well so ive been a bit busy trying to keep this thing on the road. The muffler broke off right at the pipe and none of the local shops wanted to weld it due to the rust. This left me to make my own temporary repair while i sort out the exhaust.

Ive been planning to redo the exhaust on this car and it falling off kinda kicked me into high gear. So i bought myself a set of Racing beat mufflers and off i went. These are older style mufflers that were made of mild steel as opposed to stainless. The pipes/flanges are cut so i need to fabricate new ones to mate to the stock Y pipe

The mufflers themselves are 2.25". Im looking to build a custom exhaust from the engine back including header, and presilencer/test pipe. I need to get around to measuring the stock Y pipe because i dont know if its 2" or 2.25".

Exhaust setup A would consist of stock exhaust manifold, 2.25" test pipe to stock Y pipe and RB mufflers.

Exhaust setup B would include a stainless Header exiting to 2.25" straight through.

Exhaust setup C would include the stainles header exiting to 2.5" and splitting into 2.25" at the Y pipe to the mufflers.

I dont know how unbearable the noise would be with a header and no Cat going to two mufflers so I might be more inclined to keep it 2.25 straight throught which may let me use the stock Y pipe (is it even 2.25"??)

 

NICE CANS!!!!

Show us yer TIPS!...hahahahahhaha!

 

Finally......




Im hoping to drop out the open diff and swap in the S4 LSD sometime after the car comes off the road. The car also needs an alignment again....time to learn something new i suppose

 

Lookin good

 

Awesome job congrats. Working on my s4 build now..

 

So these came in to pull some camber out the rear. Last time I had it on the alignment rack the rear camber was around -2.3deg and it started wearing the inside of the tire more noticeably than the outside.



My parts collection is growing.. Recent additions are coilpacks spare ECU and a throttlebody/TPS. Somebody save me before it gets out of hand

 

You dont know what spare parts are yet our garage/ basement shows all lol and youve seen it

 

Between Logan,Dillon and myself we can build you a Robot hooker that will steal your wallet and fart premix!..but oh the ride.....!..(she already has nice cans..lol!)

Dad,Mom..I'd like you to meet Roxy..Roxy the FC'n Robot...can I keep her?

Let me know when you wanna drop the diff.

 

legend has it she can rev you right up to 8000 rpm without staving ya of lubrication

 

removed rear subframe and diff. Nothing too special or out of the ordinary. Going to clean everything up and give it a shot of fresh paint before it goes back together

 

The new S4 Diff sitting in the sub frame with everything cleaned up and painted. Havent got around to driving the car much to use the locking diff but i can already feel a difference. although i put fresh oil in the diff, I'm a bit surprised that it doesnt whine, grind, or otherwise not work, for a 20 year old use car part.

 

Groan...I ate too many Toblerone!
They are kind of like ME..smooth on the outside..but kind of nutty on the inside..lol!

Diff looks good!

 

Great build so far. Can't wait to see what you do to it down the road.

 

Working on building a hitch and a new intake box that takes ambient air instead of hot air from the engine bay. heres what the progress on the hitch looks like. Still needs some refinement but it fits pretty good!

 

What's the hitch for?

 

bike rack, track day trailer, stuff like that. I mean the darn thing is my daily in the summer and i spend alot of time riding mountain bikes and such. It's also a pretty simply project to start sharpening my fabrication skills

 

looong overdue update. The hitch has been finished, painted and installed on the car. I made an aluminium gauge pannel for some aftermarket gauges which will be going in soon. After driving a friends honda s2000 I also got to work building a homebrew shortshifter. I used an s5 shifter which i had laying around and tapped it to take a fastener which would allow me to change the leverage ratio. Theres a good writup on how to do this mod somewhere on the forums.

For the spacer however, i used a coke can and a PVC pipe to create a mold into which i poured a two part resin to create the spacer needed to run the shifter. I'm fairly pleased with the results. The throw was reduced from around 11cm down to 7cm. With a longer bolt i could shorten that down even more.

Because the s4 shifter has a different thread for the shift *** compared to the s5, I'm also considering casting a shifter out of the same resin to create a temporary ***.

Alot of the bosses in the gauge cluster surround have completely disintegrated so I also got to work fixing those by using copper hardline and casting new bosses. I attempted the acetone ABS method but the pipe i had was an ABS/foam blend. as a result the final product didnt come out to my liking. instead I opted to fill the copper bosses with bondo and that seemed to do the trick.

On another side note, i've been having some issues with my left rear brake caliper. The original one has a sticky handbrake and doesnt actuate properly but the used one i picked up as a replacement makes the brakes feel all spongy and gross. I swapped back the old caliper for the time being for better brake feel but a possible franken caliper is in the pipeline for the future.