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The DADMOBILE- 91 244+t

Got wasted spark running, although not perfectly but that's due to my choice in VAG cop ignition coils. I will be making a heatshield/hold-down bracket for these soon, but for the moment I'm still trying to get the extra circuit I had to build set up right.

Also got my b21 valve cover fitted, and started deleting a/c stuff because I don't ever use it anyway and this way I can't be coerced into fixing the system for my wife's convenience.

 
Eh after a recharge it worked for a day or two then promptly leaked it all out the compressor. As long as the lady's car has a/c everyone's happy. I wouldn't mind an extra spot in the dash open for another switch anyways... I got an idea brewing about an arduino electronic boost controller
 
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I took a fluted bit to the very back wall of the cover so it would clear the last cam cap, pulled the studs and used washers and bolts. Had to use a little rtv in the back.
 
Managed to get my christmas present fitted this past weekend. 25x12x3 cxracing intercooler



Very minimal cutting, I guess it wasn't absolutely necessary but to get it where I wanted it I only removed a tiny bit of metal. Used the brackets supplied, and cut up some leftover piping and hoses from the old 745t as a temporary solution. Not the best and I have a feeling one of the joints where I had to stack hose to couple a 2.25" to 2.5" tube is leaking a little. When I went to test drive it I could tell a huge difference, quicker spool and picked up a bit of power at speed. Until I found my first problem with the piping and a hose blew off..



Running the dizzy again until I can fab a heatshield/holding bracket. I did make it up to my old tech school (only place I could find a lab scope nearby) and scoped out the coils while making some modifications to the ezk, and the changes are taking so I'm pretty close to having the COP's running perfect. I'll probably just buy the VEMS harness for them at that point.
 
So I was making the finishing touches to my wasted spark setup... I took a piece of metal off of the parts car, cut/ground it until I thought it would fit, used a 1-1/8" hole saw to cut some holes to pass the coil through, fit some grommets in to protect the coil bodies from the metal and popped it on. With the valve cover in the car the angle is perfect, and the width was nice. It perfectly meets the tops of the factory spark plug wire heat shields to create a little shielded space with room in the front for airflow. Here's how it looked on the spare head sans grommets:



I didn't get to put many miles on this setup though.
The #4 coil is touches the firewall in a 240 when using these coils on an 8v, and apparently I should have cut the hole for #4 a little further towards the front to allow some room; I put some stress on the head of this coil when I installed the bracket, and after running for a minute the head of the coil cracked, spewing its guts and a nice cloud of smoke.

The coil in question



So a friend of mine who was over at the time, informed me to quit screwing with these, he's tired of hearing about what I've had to do to make them work, and the smell of a burnt coil is horrible... so he was generous enough to donate four LS truck coils, with the factory mounting bracket and pigtails and some wires. Friends are awesome.

I've pulled the trigger on a t5 swap and am going to talk with a local guy about a unit laying in the floor of his shop. Came from a v8 car but pops out of 3rd, for $200. So I've got that to look forward to now.
 
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Installed a forge knock-off with the intent of tuning LH to run well with it, and I guess I'm lucky but I have no problems like stalling and such. Very slight rich spikes but it works well and doesn't effect driveability.


Installed some of the externally-heatsinked d585 ls coils, dialed dwell in to about 4 ms and they perform flawlessly. I've put some pretty good hours on them already without any hiccups. This is a temporary mounting/wiring solution but it is working. Launch control is halfway functional, just stuck at 2k rpm for some reason.. waiting on a replacement board. Excuse the poor nighttime picture quality.


Made a small board that will allow me to run two different 32k bins on a 64k chip. Stacked the bins in tunerpro and with a little help from ipdown I was able to make it happen. Is currently installed in the EZ116K ecu and works fine for the pump gas map but when I try to switch to my e85 map it acts like there's nothing on the chip at all.. might need a bigger resistor in there.


But, no components got fried so I went ahead and filled up with e85 and tuned it, and oddly enough I'm still able to run 15psi and not go lean at all.. on a 32lb/hr injector??:wtf: the car loves it, and runs very happily. Even before I switched to my super corn-spark timing I could tell it was running happier at the same boost and timing. And I filled up for $20:cool:

So naturally when I switched to my e85 ignition map the car feels like it really hauls ass now. I'd be interested to put it on the dyno and see what this thing is putting down in absence of a real turbo..
 
So I finally got my e85 tune squared away, and wanted to finalize the installation of the switchable system.

So instead of trying to build another switchable board, I wussed out and bought the same thing from moates.net. Only cost me about $20 more than the supplies I bought to build my last one, and in my opinion it was worth not having the headache.


Burned a chip with both programs on it, and here's the chip and the "two timer" as moates calls it, installed. I don't have a pic of my switch board installed in the EZK but suffice it to say it doesn't look as tidy.



Installed another switch and verified that the two timer is operating as designed, and my dual-fuel setup is now fully functional!



On another note, I've installed a 4.10 gearset as well, and I'm thoroughly enjoying it.
 
I've been so busy with my wife's car the last few months, just getting it up to her standards and prepping for +t that mine has been slightly neglected. So I pulled the fogs off my 87 745t parts car and mounted them up! Ran through the factory rear fog switch, with a cheapo ottozaune relay.

Had my little one helping me buy some electrical parts and the store. Gotta start em early



All set up on a freshly washed car



They work great, got to use them while I was out the next day and actually ran into some fog! Providence I guess.
The aim on the left was slightly off but I got it corrected and I'm very happy with them.



And found my next turbo upgrade. Had to replace the turbo on a 11 chevrolet 1 ton truck with the duramax diesel engine.. Good grief what a pain. I am extremely grateful for how simple it is to do anything on a redblock.. don't have to pull the cab off for anything at least.



I know, I know.. it'll never spool
 
Got my turbine housing back from g-pop shop, they machined it for the stage III wheel on the chinabay turdblower I just picked up from a local vw aircooled guy.





Assembled!

 
Installed a set of ls9 injectors with a later style fuel rail that has the pressure port and no csi. Snagged a plate off another intake I have to block off the csi port.

I had to swap the orings on the ls9 injectors out for the o rings off my old t5 injectors, put some ev6-ev1 connector adapters on, and the injectors already had adapters to make them a bit longer when I bought them.

None of the clips I had would work, and when I tried to fire it up without clips it promptly spat one injector out of the rail and sprayed fuel everywhere. So I decided to modify the clips I had from an older rail to work.

The clip on the left is unmodified, clip on the right is the finished product.





With injector and clip installed:



They're working great so far. Will tune for e85 this evening, and finally be able to run more than 12psi on the corn.
 
Well the wife's turbo took a ****, so her car is getting the 12b from mine, and I'm bolting up the t3/t4. Got the actuator from a 12b mounted up to it, tested with shop air and the wastegate is working just fine.

So to prep, since I don't have a downpipe flange for the cossie turbine housing, I went to a local exhaust shop to see if they could find me a 3 bolt flange and flare a pipe, to which he responded, "No way I can get a flange for that, you'll have to order it from a parts house. And my machine's not big enough to flare that." Went down the street to see Jim, an 85 year old guy that still runs a low-key muffler shop, and asked to dig through his scraps. Within 30 seconds I found a flange that would bolt up, and he flared a pipe for me for $5. So I'll just cut it to fit and weld it on there after the turbo is on. Still need to mill the manifold flat and find some studs/nuts but otherwise I've got pretty much everything I need. Will be starting the swap this evening.



 
Got my good 12b swapped to the '85 yesterday, and it is once again boosting flawlessly. Today I'm planning on milling the manifold for the t3 inlet, and most of tomorrow will be spent on the swap.

I have run into a small problem though, as the oil feed line that midnightsaint ran on this before I bought it uses a JIC 45 to 12mm banjo adapter for the inlet to the td05; I had planned on just taking this off and attaching the female fitting to my -4 AN oil inlet but now I'm not sure if it will seal.
 
Well the 46 trim is in and running. Just previous to installing it, installed new Kjet main pump and new 740 turbo in tank pump.





The only issue I ran into with getting it going was a hole in the fuel line in the gas tank that was allowing the pump to suck air in. Replaced that hose and got her running.

After I had babied it around to make sure nothing was leaking, I decided to see what it could do. I was immediately disappointed by almost zero boost up to about 4k rpm, then I could get it to build about 7 psi from there to redline. Looked today and found that the 12b actuator I had installed (which, by the bench test, was working flawlessly) was not pulling the wastegate shut entirely. I confess it's a bit rigged, and side loading the wastegate arm which is what seems to be holding it up.

I forced the w/g flapper closed and pulled the w/g hose off and took it for a spin and it boosts to the sky and back so that's the issue.

So I created a very UGLY but working adjustable length w/g actuator. Split the actuator rod and welded a carburetor stud from autozone onto it, then welded the nut for the that stud onto the other end. Still getting it dialed in just perfect but it seems like it ought to work.

 
Made some more progress. Been busy with a new job, so I haven't had much time to update.

Got the car on the dyno, couldn't build any boost past 17 psi and it would creep back down to 12. At this point, the car made 250 whp, and 320 ft/lbs.





Took the car home, set as much pre-load on the actuator as I could, and made 20+ psi immediately. And this point, the first time I even got on the gas intercooler pipes blew off. So I got the guy that did exhaust on my old 745t to make a few pipes for this one.





Now the car is boosting great and holding together, but the trans started to act a bit unhappy. So this evening, I went ahead and did the accumulator mod and took care of that situation.

So, tomorrow is a dyno day and then next weekend I'll be off to the drags!
 
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