[Es2] new project scope (long) -need feedback

[Rick Houck]

Ben,

Thanks for your insight. I know there will be lots of little things that
will be overlooked that will cause headaches. As you said, small mounting
brackets to hold components are important, but easy to overlook when looking
at the big picture.

Couple of questions:
Did you bring the harness through the firewall just above the evaporator
connections, and below the battery tray?
Did you leave the extra length behind the firewall or in the engine
compartment?

The clutch issue still confuses me, so I will send a separate post on this.
Thanks.

Rick
----- Original Message ----- 
From: "Ben Klumper" <bklumper at mdbworld.com>
To: "Rick Houck" <rhouck at neo.rr.com>; <es2 at audifans.com>
Sent: Wednesday, March 10, 2004 12:05 AM
Subject: Re: [Es2] new project scope (long) -need feedback


> Rick,
>
> A couple of things:
>
> I found it easiest to run the harness through a new hole just under where
> the battery used to reside. I also mounted the 3B ecu behind the
evaporator,
> exactly where the 7A unit was. The harness is looooong so you'll still
have
> some snaking around to do behind the engine.
> I opted to stick with the CQ's clutch, flywheel and pressure plate. We'll
> see how it holds up. I have a feeling that the clutch will outlast the
> gearbox.
> I know money is always a factor, but if you can find the things like an S2
> downpipe, intake piping and upper rad hose (to list a few) it will make
your
> swap a whole lot easier. There are far more uniquely S2 parts required
than
> you might think to make everything work out. I'm still finding this out
and
> I'm near the end of my conversion! For example, the S2 locates the
wastegate
> frequency valve in a different position than on the 200 just to clear the
> headlight/hood lock. There are many situations you'll come accross where
> either an S2 part or some custom fabbing is required.
>
> Good Luck!
>
> Ben
>
> ----- Original Message ----- 
> From: "Rick Houck" <rhouck at neo.rr.com>
> To: <es2 at audifans.com>
> Sent: Tuesday, March 09, 2004 8:31 PM
> Subject: [Es2] new project scope (long) -need feedback
>
>
> > Hey guys,
> >
> > Now that I have read the complete archives (end to beginning-head still
> > spinning) I see that there are several combinations of chassis,
> > transmissions , engines, and performance goals on your projects. Since I
> > want to install my own stock '91 200tq 3B engine into my low mileage
coupe
> Q
> > chassis, it would appear that my new spare time project is the
easiest(?),
> > cheapest, and least potent of them all.
> >
> > As background, I have already done a 10vt conversion for my track coupe,
> so
> > I have some background, and I know the power boost is what these cars
> need.
> > My 3B came from the car I rolled, and we drove the car from 62k to 119k
> > before the mishap. The engine ran fine and I plan to use it as is. The
TB
> > and water pump are about 15k old. I have taken off all the intake and
> > exhaust components for blasting and cleaning, and new gaskets. I even
had
> > the cam cover powder coated red for fun. I went ahead and installed new
> rear
> > seal, pan gasket, cam cover gasket, and any of the hoses and sensors
that
> > are not easy to get at after installation. I also just installed the
metal
> > cam gear, so I hope it is ready for the next 50 to 60k miles without
many
> > problems.
> >
> > Since this is to be a nice street car, I believe I will be satisfied
with
> > the performance of the stock engine in the lighter car. A chip is the
only
> > enhancement I can anticipate at this time. Keeping my costs down is a
> prime
> > objective, and I don't mind making or adapting some of the items needed,
> > such as front cross member and intercooler plumbing. I pulled the 3B
> engine
> > myself along with all the harnesses I thought I might need. The coupe
dash
> > and drive train are out, and just waiting for the battery box removal.
All
> > cv joints are repacked and re-booted. I have new seals at each drive
hub,
> > and new input shaft seal.
> >
> > Here is my plan so far, making the best use of money as the project
> > progresses:
> >
> > 1: Decide on flywheel/clutch and assemble tranny to engine.
> > 2: Install proper AC line in engine compartment for future use.
> > 3: Stick with stock CQ alternator/AC locations.
> > 4: Find the correct oil filter bracket and hoses for turbo. (may start
> with
> > stock parts until running & ready to invest in the AC)
> > 5: Install harness through new firewall hole (where?).
> > 6: Relocate battery to rear compartment.
> > 7: Install new heater core & possibly complete heater assembly from
manual
> > AC car to avoid climate control issues.
> > 8: Install engine/drivetrain and connect harness.
> > 9: Keep working and working on harness connections until correct.
> > 10: Decide what IC will fit & fabricate cross member & plumbing to suit
> S2,
> > RS2, or stock bumper, depending on $ and what I find.
> > 11: Decide on air box or cone filter and install.
> > 12: Decide to modify 200TQ down pipe or find one for 3B S2.
> > 13: Decide on exhaust. Buy or have one fabricated.
> > 14: Upgrade to 5 bolt hubs. Probably will use the same as my track car.
> > Porsche Boxster w/ A8 rotors up front, redrill rears.
> > 15: New hood and paint.
> > 16: Et cetera, et cetera....
> >
> > Have I missed some important steps? Feedback is welcome as I bounce
ideas
> > off you guys. Tell me where I'm missing the boat. Thanks again, and
sorry
> > for the bandwidth.
> >
> > Rick
> >
> >
> >
> >
> >
> > _______________________________________________
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> >
>
>