24vVR6T CQ Project: EATSGTR rear firewall fab.

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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Tue May 06, 2014 3:04 am

MORE!!!
I also got started on the hanger braces for the turbo/ex mani and the downpipe as well.
Just a few sneak peeks of the mounts for the braces, those will likely get finished this week as well.
start of dp and turbo hangers.jpg
start of dp and turbo hangers.jpg (1.25 MiB) Viewed 10752 times

turbo hanger brace detail.jpg
turbo hanger brace detail.jpg (1.63 MiB) Viewed 10752 times

dp hanger brace detail.jpg
dp hanger brace detail.jpg (1.55 MiB) Viewed 10752 times


I also made up a heatshield for the front passenger CV boot/joint, its ultra thin alu for now and ease of mockup, I’ll be making it out of 0.125” aluminum sheet for the final version.
front pass cv boot heatshield.jpg
front pass cv boot heatshield.jpg (1.05 MiB) Viewed 10752 times


I also started making a heatshield for the upper radiator hose. I will anodize and then wrap it in gold foil. the upper radiator hose is 20AN earl's with FlameGuard sleeving as well. I'm more concerned with keeping the hose itself from extreme heat vs. coolant heating up just a tad. between the heatshield and the sleeving, I'm sure it'll be fine.
upper rad hose heatshield2.jpg
upper rad hose heatshield2.jpg (1.4 MiB) Viewed 10752 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby speeding-g60 » Tue May 06, 2014 9:30 pm

very much coolness goes on here.
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby DE80q » Wed May 07, 2014 9:35 am

Keep it up Tim, and you might just have this running in time for carlisle next year!
"If you can't find one, make one"

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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Wed May 07, 2014 11:01 am

speeding-g60 wrote:very much coolness goes on here.

thank you sir, you've made some pretty epic stuff too.

this shall be the summer of badass vrt cq, minimal work until mid august, so its gametime!!!!


DE80q wrote:Keep it up Tim, and you might just have this running in time for carlisle next year!

yeah itll be damn close mechanically, but its paint,cage, eng mgt that's my big huddles financially

getting more done every day. if all goes well by the end of this month, intake manifold will be done, downpipe and w/g dumps, all boost/inlet plumbing complete, custom axles and spacers, custom subframes and rear tie rods.

I also have a batch im prepping to go and get clear and black anodized, so a lot of the aluminum work will wrap up this month.

back to the garage, more updates to come!
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby glibobbo21 » Tue May 27, 2014 5:53 am

wheres the pic dump? i know youve been doing stuff!
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Wed May 28, 2014 10:01 am

glibobbo21 wrote:wheres the pic dump? i know youve been doing stuff!



well I had been making epic progress, down pipe done, WG reroute all done except the hole in DP and the v-band flanges welded on, and , I guess, in my progress I totally spaced putting my tube SF back. so I located the lower v-band for the downpipe properly for an OEM SF vs. my custom SF. so I'm back out to cut a chunk of DP off, relocate the v-band connection and finish up the WG re-route.

ill get an update done here shortly, but no more exhaust pics until the WG and DP are DONE!!!
but I've finished up plenty of other stuff to still have a meaty update. check back late tonight


and a single teaser pic!!!
exh teaserr.jpg
exh teaserr.jpg (1.41 MiB) Viewed 10604 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby All_Euro » Fri Jun 06, 2014 2:46 pm

With all the GTR talk lately I can't help wondering where this is at...?
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Sat Jun 07, 2014 12:08 pm

All_Euro wrote:With all the GTR talk lately I can't help wondering where this is at...?



Exhaust is done from head to tailpipes except for some EGT and 02 bungs.
wastegate merge and dump back into DP is done
Turbo hanger brace is nearly done

BIG thanks to Shawn, vt10vt, for coming down and giving me a hand for the day!!!
we got the oil cooler mounting nearly finished, cv boot heatshield final ed. made. also worked on my upper radiator hose heatshield,
epic progress, ill get an update loaded tonight
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Tue Jul 08, 2014 10:49 pm

UPDATE TIME!!!!!
Ok let’s get caught up. I got 3X 10AN male bungs welded on my valve cover for the catch can lines.
valve cover breather bungs.jpg
valve cover breather bungs.jpg (1.35 MiB) Viewed 10288 times


I got a TON of AN plumbing supplies for the oil system, trans and dif coolers and pumps, catch can lines, vacuum and boost reference lines, blah blah.
got soem plumbing to do now.jpg
got soem plumbing to do now.jpg (1.59 MiB) Viewed 10288 times


Last fall Jim and myself stopped by a scrap yard a few towns over and I found a few of these!!! They are from electric pole turnbuckles. They shoduld make for some good, strong, removable tow hooks. The longer one goes in the front, so it can stick out through the bumper and the rear is a bit shorter and even thicker ahahah.
extra rugged tow hook.jpg
extra rugged tow hook.jpg (1.9 MiB) Viewed 10288 times



I welded a plate on either side of the reciever threaded part. The plates are slide up through a hole in the bottom of the frame rail, up into slots cut for the upper edges of the plates and seam welded on either side.
front tow hook reciever plated into framerail.jpg
front tow hook reciever plated into framerail.jpg (1.13 MiB) Viewed 10288 times


They are a tad recessed and only need a little bit of flapper disc to make them smooth. I then welded a 2x3” plate around the entire area. It had qty. 8, 3/8” holes in it along the weld seams of the reciever’s plates. And again plated and seamed below the framerail. I just need to drill a hold in the front aluminum cross member for the tow hook. I knew I was going to do this when I built the front cross member and there is a ¼” wall thickness 1.75” tube going through the mounting plates for just this purpose.
tow hook welded upper plate.jpg
tow hook welded upper plate.jpg (1.26 MiB) Viewed 10288 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Tue Jul 08, 2014 11:01 pm

UPDATE!!!
The catch can will be mounted under the strut tower bar just like the coolant tank. I will make it out of some round stock and a cap, as well as a box for the upper.

Here it is as a template
catch can lower template.jpg
catch can lower template.jpg (1.71 MiB) Viewed 10286 times



I am using dual K&N 1” breather filters on the catch can outlet. I went a tad over the top and beadrolled the ends of tubing where the filters attach. If there is any real pressure buildup to the point of needing the beadroll, I’d be screwed. So its more of a fit and finish thing.
catch can breather tubes.jpg
catch can breather tubes.jpg (1.71 MiB) Viewed 10286 times


And taped together.
catch can body mocked up.jpg
catch can body mocked up.jpg (1.62 MiB) Viewed 10286 times

catch can body mocked up2.jpg
catch can body mocked up2.jpg (1.44 MiB) Viewed 10286 times

catch can body mocked up3.jpg
catch can body mocked up3.jpg (1.39 MiB) Viewed 10286 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Tue Jul 08, 2014 11:06 pm

MORE!!!
Catch can ready to weld.
catch can body ready for welding.jpg
catch can body ready for welding.jpg (1.47 MiB) Viewed 10303 times



I drilled a ton of holes in a thin plate and will be using that as a separator layer for the media.
catch can media sep layer in can.jpg
catch can media sep layer in can.jpg (1.45 MiB) Viewed 10303 times



And here is the catch can all finish welded and mounted up. I still need to clean it up a bit near some welds,( thin thin material) caused a few blisters. Give it a good sandblast and some clear powdercoat.
catch can finished and mounted.jpg
catch can finished and mounted.jpg (1.1 MiB) Viewed 10303 times



I then made up the valve cover to catch can lines in Earl’s black Pro-Lite 350 Hose, 3X 10AN 90’s to straight’s, into the can.
they are just threaded on and not correctly aligned.
catch can lines.jpg
catch can lines.jpg (1.24 MiB) Viewed 10303 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Tue Jul 08, 2014 11:16 pm

UPDATE!!!
I finally got back into exhaust work after taking a short break from stainless. Here is the downpipe, nearly ready except for adding a small wedge.
DP jsut needs a wedge.jpg
DP jsut needs a wedge.jpg (1.13 MiB) Viewed 10300 times


Lower portion of the downpipe tacked together.
downpipe from under, tacked.jpg
downpipe from under, tacked.jpg (1.61 MiB) Viewed 10300 times


Here is the front Wastegate outlet that needs to be finished. It’s a bit tight up front with the Wastegate outlet, airbox intlet, headlight, radiator and shroud, but it fits!
need to finish Front WG.jpg
need to finish Front WG.jpg (930.89 KiB) Viewed 10300 times

front WG dump connection.jpg
front WG dump connection.jpg (1.43 MiB) Viewed 10300 times



Start of the tight radius outlet for the front Wastegate.
tight radius WG outlet.jpg
tight radius WG outlet.jpg (678.33 KiB) Viewed 10300 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Tue Jul 08, 2014 11:25 pm

MORE!!!
Completed front Wastegate outlet
front WG tube.jpg
front WG tube.jpg (1.23 MiB) Viewed 10298 times

front WG tube2.jpg
front WG tube2.jpg (1.35 MiB) Viewed 10298 times

front WG tube3.jpg
front WG tube3.jpg (1.21 MiB) Viewed 10298 times

front WG tube4.jpg
front WG tube4.jpg (1.28 MiB) Viewed 10298 times

front WG tube5.jpg
front WG tube5.jpg (1.83 MiB) Viewed 10298 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Tue Jul 08, 2014 11:34 pm

MORE!!!
In order to make the Wastegate outlet “Y” removable without taking everything apart, I will be adding an additional Tial v-band connection for the front gate, just before the “Y” junction.

I purchased two additional MVR 44mm Wastegate inlet flanges that would normally belong on an exhaust manifold. I put these on the lathe at Ryan’s and cut them down to fit and recess perfectly with my 2.0”, 304SS 16ga. Tubing that is used on the Wastegate outlets.
tial flange lathed for tubing.jpg
tial flange lathed for tubing.jpg (1.84 MiB) Viewed 10297 times


And another shot of the rear WG outlet.
rear wg dump.jpg
rear wg dump.jpg (1.37 MiB) Viewed 10297 times


And a few pics of the Wastegate outlets merging
finished WG merger.jpg
finished WG merger.jpg (1.48 MiB) Viewed 10297 times

both WG tubes finished.jpg
both WG tubes finished.jpg (1.6 MiB) Viewed 10297 times


And the Wastegate merge back into the downpipe, its dual 2.0” to 2.5” v-band and flex-joint and then back into the downpipe.
wg dump into downpipe.jpg
wg dump into downpipe.jpg (1.48 MiB) Viewed 10297 times


NOTE: the sizeable hole between the downpipe and the Wastegate outlet Y , flex, v-band etc. the steering rod has to fit through there!!! With the HTMS steering arms on my strut tubes and upper ground control plates, the steering rod has been run through full droop and compression at full steering range of motion, and it clears!!!
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Tue Jul 08, 2014 11:44 pm

UPDATE!!!
I got started building a turbo hanger brace. The main vertical is ½” stainless rod and the side supports are 3/8”. It attaches up front to two spare m8 bosses in the head, just forward of the exhaust manifold flange.

The rear mount is on an upper boss on the cylinder head and a studded boss located very high up on the exhaust manifold.

The lower center mount is a stainless, extra large diameter shoulder bolt, so the machined should part of the bolt goes though the mount arm and in shear. It is very strong
turbo brace bracket.jpg
turbo brace bracket.jpg (1.56 MiB) Viewed 10378 times


Im just waiting on a 1” punch and flare, sheetmetal tool and I’ll be adding one small, punched sheet brace to the turbo hanger brace to finish it off.

I’m awaiting some machined SS adjusters with LH and RH threads, those are just welded bolts for mockup
turbo hanger brace heim.jpg
turbo hanger brace heim.jpg (1.51 MiB) Viewed 10378 times


turbo hanger brace.jpg
turbo hanger brace.jpg (1.49 MiB) Viewed 10378 times




And a few pics of the oil cooler mount that Shawn, (vt10vt) helped me make up when he was down here a few weeks ago.

I just need to add another leg to a silicone isolater mount tab under the frame rail, to triangulate it, and it’s done, and time for plumbing.
oil cooler bracket from side.jpg
oil cooler bracket from side.jpg (1.58 MiB) Viewed 10378 times

oil cooler bracket from above.jpg
oil cooler bracket from above.jpg (1.28 MiB) Viewed 10378 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby PRY4SNO » Wed Jul 09, 2014 12:14 am

Fvcking love updates to this thread.
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|| Spare parts for sale
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Wed Jul 09, 2014 12:15 am

UPDATE!!!
I got a 16AN bung and elbow, welded up to the oil pan for the turbo oil drain return. The hose is made up with Earl’s pro-lite and wrapped in FlameGuard insulation, as it runs close to the Wastegate outlet tube.
turbo drain on pan.jpg
turbo drain on pan.jpg (1.92 MiB) Viewed 10370 times

turbo oil drain line.jpg
turbo oil drain line.jpg (1.16 MiB) Viewed 10370 times


I also got a spare rear diff modded up for the pump/cooler return line. It sprays right on the rear differential ring gear.
rear diff pump return.jpg
rear diff pump return.jpg (1.17 MiB) Viewed 10370 times


I just need to make the pump and cooler brackets, more on that later.
I also had Ryan replace the plate on my valve cover with something a bit thicker so some engravings, more on that later
new VC plate for engraving.jpg
new VC plate for engraving.jpg (44.78 KiB) Viewed 10370 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Wed Jul 09, 2014 12:17 am

MORE!!!
I sent some drawings to a machinist buddy of mine and got the these beautiful pieces back!!!

The first is a receiver for a 3/8” rod end. I am also having a threaded RH/LH adjuster made to tension/adjust the serpentine belt. The rod end fits in snugly with washers and Seals-It rod end seals.
upper alt tensioner mount.jpg
upper alt tensioner mount.jpg (353.17 KiB) Viewed 10370 times

upper alt tensioner mount2.jpg
upper alt tensioner mount2.jpg (284.29 KiB) Viewed 10370 times


The second piece is the water/methanol manifold. It has an 1/8” NPT outlet for a 4AN adapter for each cylinder and an add’l outlet for a nozzle at intercooler outlet. It will be mounted on threaded bosses on the intake manifold for nice short lines to each cylinder’s nozzle.
It will also get anodized black when all the parts go out.
water meth manifold.jpg
water meth manifold.jpg (327.26 KiB) Viewed 10370 times

water meth manifold2.jpg
water meth manifold2.jpg (314.58 KiB) Viewed 10370 times

water meth manifold3.jpg
water meth manifold3.jpg (327.41 KiB) Viewed 10370 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Wed Jul 09, 2014 12:21 am

UPDATE!!!
So the engine and trans has been pulled so I can get some work done in the engine bay. Here it is on the engine stand.
steering arm hole.jpg
steering arm hole.jpg (1.32 MiB) Viewed 10370 times

current engine stuff shot SIDE.jpg
current engine stuff shot SIDE.jpg (1.35 MiB) Viewed 10370 times

current engine stuff shot.jpg
current engine stuff shot.jpg (1.53 MiB) Viewed 10370 times
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby my2000apb » Wed Jul 09, 2014 12:27 am

UPDATE!!!
I picked up these ‘70-78 Z car flares online somewhere and will be doing a bit of work to get them to flow well with the CQ, like it or not, I’m doing it, I need/want all the tire I can get under there. 265/40/17 yup no prob, will go 275/35 at some point once its dialed in.
front flare.jpg
front flare.jpg (1.12 MiB) Viewed 10370 times

front flare2.jpg
front flare2.jpg (973.39 KiB) Viewed 10370 times



And just screwing around with a 245 on a 17x8” fat five
rear flare w fat five.jpg
rear flare w fat five.jpg (1.33 MiB) Viewed 10370 times

rear flare with fat five2.jpg
rear flare with fat five2.jpg (1006.22 KiB) Viewed 10370 times



I also picked up a SEAT Cupra R lip spoiler to put on the bottom of my S2 front bumper.

Now back to it!!
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby DE80q » Wed Jul 09, 2014 7:31 am

HOLY SHIT! Now that's an update. This thing is going to scream!
"If you can't find one, make one"

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2007 Mitsubishi Raider(Dakota in disguise)
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby EDIGREG » Wed Jul 09, 2014 8:17 am

NICE update tim!!
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby Zerb » Wed Jul 09, 2014 10:00 am

how much do those flares stick out? the ones im using are universal ebay fiberglass ones, $180 shipped. 3" height on em.
This one time i built an...|-|Audi 90Q|-|2L20v|-|6765|-|Lugtronic|-|Street Tires|-|E85|-|10.7@136|-|...but then i parted it all out
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby scubagli » Wed Jul 09, 2014 10:14 am

I'm about to put a set if those flares on a buddies b5 passat. Your fab work and attention to detail is completely over the top!


Old Audi's rule all.
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Postby themagellan » Wed Jul 09, 2014 10:47 am

Wow, blown away by the fab. Do you own a shop? Amazing stuff.
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