[s-cars] Re: [urq] Audisport aluminum blocks

[Fluhr]

>With regard to your low HP levels, you really need to find a shop that can 
>help you.  You once shared with me, this problem has plagued this project since 
>before Bruno, so I'm betting you need to find someone that can figure this 
>out.  Drive it, ship it, deliver it somewhere.  Using *any* of these lists will 
>get you free opinions, and a plethora of them.  But bottom line is, I'm reading 
>of modifying an aluminum block, which sounds an alarm in my head, something's 
>not right, and I'm betting it still won't be when you are done.  Or worse.

I am pretty confident that the primary problem with James' engine is just ignition
timing.  I suspect he is running Lehman code designed for a true 3B 9.3:1
engine, with an actual compression ratio much lower.  With a bit of dyno time
and someone adapting the ignition timing map back to the correct range for
the compression ratio, I'll bet he recovers the power and gets that engine up
over the 300HP mark pretty easily.  It may even be as simple as running the
timing tables from a Sport Quattro. 

>One thing I would ck before I did much else is the code vs the pin 
>location/pickup on the flywheel.  I've seen several times over the years, that 
>audisport/Lehmann have moved the locations of the timing pins fore and aft, which could 
>dramatically affect driveability and actual power output.  

Checking flywheel pin timing is an excellent one.  However, as you point out,
we don't really know where it should be relative to what the code wants.  I
would start by using the 3B timing points as a good reference to compare against.

>You also need to make some hard choices here in terms of what approach you 
>are taking to this project.  Since this won't be and never was an audisport car, 
>I'd sure consider putting in the improvements that made the 20vt one of the 
>best audi production motors to date.  ....
>I'd certainly take a stock AAN motor and harness swap, before I'd touch my wallet
>trying to 'fix' the aluminum block/3B setup in any way. 

You offer a very practical, guaranteed approach to fixing the car.  I have seen just
about everyone recommend the same thing:  crate that aluminum motor and put in
an iron block 3B/AAN; it surely is a sensible thing to do.

I'll offer a different view. I personally think that James should tune up the KW motor 
to a reasonable level of performance, and then drive it until it breaks.  The car has
already been through a significant rally with no ill effects, and I am sure that James
would take extremely good care of it over the years.  With reasonable power levels
(I'm talking low 300's here), I think it can be a solid performer, and help the car
maintain its uniqueness.  It doesn't do anyone any good to crate that engine, unless
it is going into a museum somewhere or someone will pay big bucks for it, and I highly
doubt either of those propositions will happen.  I'd rather see the engine used and
worn out than waste away in a box, hidden in storage.  If for some reason the engine
does give out down the line, swap in an iron block and pack the aluminum one away.
At least then you got the use out of the KW that it was intended for.

Regards,
Eric
'82 urq