Screw weight saving....just add more HP (Project Turbo Smurf)

[Stonewall]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Some good pictures thats for sure. Have you tried heating up that hose with some hot water?

[Triple G]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Hose is on, used a heat gun today.

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

the power of thermal expansion is amazing.

graeme we should get drunk later in the week

[nordex]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Can you record and you tube the first time start up

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

if someone wants to bring a video camera sure.
i will likely let it idle for a good 20 minutes when i first fire it up to build the pressure and just make sure absolutely nothing is leaking once it is all pressurized and the fans have had a chance to cycle

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

haha starter is on upside down, gotta fix that tomorrow.

[Mitcheh]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

haha starter is on upside down, gotta fix that tomorrow.

lolol

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

blame graeme...he put it in

[Triple G]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Looked right to me, but what do I know, I only drive slow 4 Cylinder VWs

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

yea...or girlie mazda's.

im gonna work a half day tomorrow...feel like doing some more work, either on yours or mine?

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

oil cooler and intercooler are ordered.

went with the mocal thermostatic VR6 plate, a 19 row oil cooler, russel fittings, stainless lines. Ordered through MMP and they are gonna build it for me. I didn't realize how bad some companies like eurosport etc. cheaped out on their kits til i finally did some research.

ordered a garrett intercooler core. Dimensions are 22"x10"x2.3" Should fit nicely into the front end while giving me lots of surface area for cooling.

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Tried getting some odds and ends done today, wasn't able to make nearly the amount of progress i wanted.

Went through the bolt box and bolted up a few things, and dug up a few things I had forgotten about. Threw in the Cam Position Sensor, and dug out the coilpack and stuff.



Biggest thing I wanted to do today was to get the axles in place. They are sitting too far forward and basically have to be tucked up behind the oilpan and tranny so that they will be in the right location to be bolted up.

So got things in the familiar position....




But 3 hours later, lots of swearing, bruised hand, and pinched finger later....zero progress has been made on that front.

I did flip the starter around. Good thing I went and checked this because the bolts were finger tight, must have been in a rush when we put it on the first time we didn't torgue it down. I will be going over everything, but it was a good reminder.




Also replaced all the parts on the thermostat housing and sealed it up so it wasn't ever gonna leak again.


.
.
.
.
Little bit of permatex gasket maker...

.
.
.
Voila'


That thing wont be leaking anytime soon...and if it does the whole unit is going in the trash and its getting cemented up. I was careful not to get any on the area that touched the o-ring, but the outer edge of that lip and the rest of the way round has a nice seal to it. Need to swing by the dealership and get some new sensors and gaskets tomorrow and I will throw it on and add it to this...


.
.
.
.
.
.
.
.
.
.
The other thing I tried figuring out is this damn throttle cable bracket, Alexi maybe you can shed some light on this:

.
.

.
.

.
.

.
.

.
.

.
.

.
.
.
.
.
How do I pull those coolant lines out of the throttle body? And then i assume I am tapping both of them, and then drilling out the stock cable bracket to fit?
Does any modification have to be done to the frost plug that is in there? What do I do with the two lines that originally had the coolant? I have heard there is a recirc modification some do but I wasn't able to find anything on it.
Any info on that would be appreciated.
.
.
.
.
.
Also when deleting the stock heat exchanger/oil cooler and running a mocal thermostatic plate and external oil cooler can someone give me some pointers here. I know the stock heat exchanger gets removed and the thermostatic plate gets bolted up. It will have two fittings on it, I assume one is oil feed and the other oil return, sending oil to the cooler. What happend with both of the stock rubber hoses here?
One I know gets deleted because it goes from the stock crack pipe to the heat exchanger, so that one can be removed. But what happens with the other? does it get removed? If so what do you use to plug the hole in the block? If it gets kept where on the plate does it hook up to?
.
.

.
.

.
.
.
.
.
Will likely have some better updates tomorrow as the axles go in properly and a few more things can then be bolted up once I know i dont have to worry about getting the jack and hoist back in there.

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

February 25th, 2008 - It's beginning to look like a VR again
.
.
.
.
Biggest job today was to get the axles in place, they have been pissing me off sitting in the wrong place, and the knowledge and fear that I might have to pull the engine up to seat them properly has stopped me from bolting a bunch of other stuff up that needs the engine sitting in place first.
.
So first up was getting that job done. Had to remove the knucles to allow the amount of play needed to get them into place, rather than yanking the whole engine out again.
.
.

.
.
Once they were in the right position it was time to lube up.
.


.
.
Packed the cups full of axle grease and then tightend them into place. Nice and messy job, helps to have a second set of hands to hold things out of the way and then rotate the axle round for you while you tighten things up. Still need to torque them *Mental Note*
.
.

.

.

.
.
.
Because we had to undo the front mount to get enough play to move things into the right place I took the opportunity to undo the front mount and spin it around into the proper position. Apparently the little tabs on the mount have to point backwards. So i sorted that out. (see i am listening when you say something ain't right)
.

.
.
.
Double checked the orientation of the thermostat in the housing, and then put all the gaskets into place and bolted in the lower flange that attaches to the crack pipe
.

.
.
Next bolted up the coilpack into place,
.

.
.
.
Followed by the auxillary waterpump, and all the bits that went along with it, including the connection for the main part of the wiring harness.
.

.
.
With that bolted up there were a few bits that don't have a home anymore, one of them is this grounding wire and sensors. Originally it would have bolted up to the intake manifold, now I'm wonder where it needs to be bolted to??
.

.
.
.
At this point we broke out the laptop with all the photos so we could see where certain things were pre-turbo build.
.


It's amazing how helpful having detailed pictures of everything can be. Really makes life a hell of a lot easier.
.
.
.
Next I installed the sensors into the thermostat housing, lubed all the o-rings up with some oil on the finger, and installed the rest of the coolant system up to the block. This was an area that used to leak a lot before, so I had taken the time before to clean it all up properly to hopefully stop any further leaks. Such a bad design in the system, it's no wonder half the VR6 owners I know deal with leaking coolant on a regular basis.
.
Thermostat housing bolts up here.

.
.
.
And everything in place.
.

.
.
Next up was pulling off the stock oil cooler/heat exchanger and the coolant lines that went along with it. The new stuff should arrive tomorrow from Shawn @ MMP.
.

.

.
.
.
I know I need to still install the oil feed line and that means removing the blue sensor and putting the T-fitting inline of it, but aside from that we noticed the white sensor in the back left seems to be busted?
.

.
.
The prong or sensor top seems a little f@cked. So I was gonna replace it. Anyone know what it does?
.
.
.
Next up hooked up the power steering fluid rail across the front end.
.

.

.
.
And bolted it into place
.

.

.
.
.
.
Also began hooking up the rest of the coolant lines.
.

.
.
So now it almost looks like a real VR6 again...
.

.
.
.
.
Now what are some of you doing to combat the heat back here on the coolant lines that go from the top of the head to the firewall? It runs awefully close to the DP/Turbo/Manifold.
.

.

.
.
Does some type of heat wrap need to be installed on the coolant lines to stop blistering?
.
.
.
.
.
.
Gonna take these two coolant lines that run to the throttle body and recirculate them. Lucky for me the hose had previously torn and there is a connector already in place. So i'm just gonna undo the one end and get rid of it and loop the other back round and in. Voila'.
.

.
.
.
Now the master and slave cylinder tray it sitting at a weird angle in its place. I believe its supposed to be horizontal but I can't seem to get it to go back to horizontal. I dont know if when we pulled/installed the engine if it may have brought that up slightly. But does anyone have any idea how to get it back to level again?
.

.
.
.
.
Also trying to play lets identify where this bolts up? I'm thinking passenger side, somewhere around the old MAF/TB location but I'm not sure where it bolted up to, or what runs through it?
.


.
.
.
.
.
.

More to come tomorrow if/when the oil cooler arrives. It will get installed, and other odds and ends will continue to be bolted up and hooked back up again.
Still waiting on the intercooler core, but I think I'm making decent progress. No use going any quicker, there is still a good 2 months before the roads will be cleaned up from all the gravel from the winter before the car can come out without risking getting sandblasted.

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

What can brown do for you?.......make me very happy thats what.

Came home to a nice package on my doorstep

.
.
.
.
Lots of pretty metal things inside
.

.
.
.
.
Mocal Thermostatic Plate

.

.
.
.
.
Mocal Oil Cooler (16 row)
.


Also stainless lines and russel fittings.

i am happy. time to start installing....

If you are interested in the kit let me know. This was a custom kit I put together but I can put you in touch with the guys that can get you the parts. There is only 1 place in North America you can get Mocal stuff from, and these guys can do it for a hell of a lot cheaper than anyone else could.

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Spent some time doing some more polishing tonite. It's no where near finished, but you can get the gist of where its headed. Still have a few more nights I figure before it will be ready to go. Then i will have to have it clear coated, or live with polishing it anytime it rains or gets moisture on it.
.

.
.
.
Also to appease rhys i spent a little time scrubbing some stuff like the front mount area down which were still dirty. used some diluted simple green as I think the super clean was too strong and taking the finish off of the stuff i was cleaning. Didn't do a ton of stuff....but it'll get there.
.

.
.
.
.
.
Also spent some time playing around with the different positions i can mount this thermostatic plate. There is a small black plastic clip that attaches to the oil filter housing, i didn't take the housing off to see how vital the piece was, but it limits where I can and can't position the plate.
.

.
.
.
Without removing the tab I am really only limited to a few options, some of which wont work anyway once the 45* fittings are put in place.
.

.

.

.
.
I will have to do some more research and figure out how most are mounting their plate and where they are placing the cooler itself. It's tough to tell where there will be room just yet as I don't have an intercooler and piping to check and see fitment in areas.
.
.
.
.
Also got around to playing around with the coolant lines a little bit. On the advice of some of the guys on the vortex I am going to eliminate a few of the T fittings in the piping as I no longer need to send lines to the throttle body. So I took off the one T pipe that runs from the top of the coolant reservoir, and then splits and heads to the top of the rad, and the throttle body
.

.
.
.
Disconnected the long end off of it
.

.
.
.
And then hooked the long end up directly to the fitting that goes to the rad. I know its a little long....I will prolly take 2" off of it before it's all finally hooked up. But doing this saved me going out and buying new coolant hose.
.

.
.
.
.
Next up I threw on the manifold and throttle body just to see what kind of room I would be working with for a few other things.
.

.
.
.
.
Decided to dig out my AC lines just to see what kind of room I had when I reinstall them
.

.

.

.

.
.
.
.
As you can see it's gonna be quite tight. I may have to get some custom AC lines made up, or portions of lines. I pulled the AC rad out with the other part of the line and it is really tight. Those lines come right through the space that I want to run the piping from the intercooler to the Intake manifold. So there is going to be some definite custom work needed to make this all fit. But it doesn't seem as bad as I originally thought it might be.
.
.
.
.

Everything as it stands at the moment
.



More to come in the next few days