My 1992 GTI

[DocWalt]

Installed the chip today. Twenty minute job, even in this heat. It feels like it wants to keep going above 6500 now, way more than I was used to. At about 7300 it's really petering out. I haven't felt the need to go beyond that, but my rev limiter is now at 7600. Seems like everywhere in the rev range it's a bit more powerful.

Supposedly it takes 3 cold starts before it learns the car. I'll report back with any changes :)

http://img838.imageshack.us/img838/3648/uec.gif

[DocWalt]

Welp, fuel pump died during my last run at autocross. Had to abandon my car in the parking lot and go home to pick up a spare pump to swap out.

I ended up being 2nd fastest novice and my brother was 3rd fastest novice. Sweet!

I picked up a GoPro so here are some videos. you can pretty much skip the first 1:30 of each, I was too lazy to edit.


http://www.youtube.com/watch?v=uHVvmRJbboY - First run, pretty mediocre


http://www.youtube.com/watch?v=nbujKgBmtY0 - Second run, interrupted by a spinning BMW


http://www.youtube.com/watch?v=YrYiySz39o4 - Third run, my fastest time.


http://www.youtube.com/watch?v=DNBAsbeQjOk - Fourth run & Re-run to make up for the aborted second run. The main fuel pump dies in this video, my car just lost all power.

Supposedly I was hiking up the inside rear wheel in nearly every turn. Waiting for pics as evidence.

[DocWalt]

Replacing the fuel pump:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1072369_10201558121572865_644959098_o.jpg

Resetting the ECU because I stupidly didn't bring a jumper to prime the pump and the ECU over-adjusted too rich:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc1/457366_10201557202389886_719672587_o.jpg

[KeithMac]

Be carefull at high revs if you're on stock rod bolts, aparently they stretch!.

[DocWalt]

Hmm. Not heard of that issue before without some serious power. I'm still on stock rod bolts, and I don't really want to go through the hassle of switching to ARPs, but it might be a good idea especially because of the abuse my engine has already taken.

[DocWalt]

http://imageshack.us/a/img203/8977/l683.jpg

Getting interesting... :) Needs some machine work on the rod journals, but that's not a big deal. Just need to order oversized rod bearings for my "spare" engine build.

My car's been running perfectly. Just not fast enough. New engine will be P&P with some other tricks if everything works out. Will be stock pistons (10.8:1) and rods on the above crank.

[FeaRpb]

So, what do you have up your sleeves?

[DocWalt]

We'll see. I still have to decide if I want to have that crank worked on. It's not a huge performance benefit, but every little bit would be nice.

[HLxDrummer]

So how does this car compare to the VR4 and Evo? I can't imagine it is more fun all around but I'm sure its cheaper!

[DocWalt]

It is a hell of a lot of fun actually. Significantly slower in a straight line, but since I'm not worried about hurting it I'm much more willing to abuse it. It's not really much cheaper than the VR4 at the current rate... At the moment it doesn't need anything except for an oil change and more power :p

[DocWalt]

Did a compression test when I got home from work. 215-212-210-212. Not bad for nearly 170k

[DocWalt]

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1167184_10153121162025615_1218120515_o.jpg

What $100 can buy in VW money, lol. Actually, it came with an alternator and a/c compressor too!

[Turbo Beast]

Get a G60!!!

[DocWalt]

Not yet ;)

I just spent half an hour pulling parts off of the new engine.

It has a snazzy metal breather, woo.
http://imageshack.us/a/img833/8559/t5vq.jpg

Corrosion trail:
http://imageshack.us/a/img825/8910/l24x.jpg

TT Cam gear set at 0* and TPS sensor:
http://imageshack.us/a/img545/8868/4w0l.jpg

Really clean, but it felt like half of the bolts were loose:
http://imageshack.us/a/img692/6567/py1b.jpg

Like I said, really clean!
http://imageshack.us/a/img690/2117/pcs0.jpg

Great crosshatch, ignore the junk in the cylinders. Note the blackened head gasket on the back half of the engine:
http://imageshack.us/a/img690/1925/y1l5.jpg

Blackened back half of the head. Otherwise in pretty good shape:
http://imageshack.us/a/img27/5757/u4qn.jpg

[DocWalt]

Pulled the exhaust manifold from the "new" engine and broke only half of the studs for the downpipe... Guess I'll reuse my current manifold, but port match it to the gaskets. Should be quick-ish work, but I'm kinda ticked that it's still a delay that will hold me up during the engine swap. I also pulled the intermediate shaft and the adjustable cam gear. The intermediate shaft is getting some special work, the cam gear is getting cleaned.

[DocWalt]

I finished stripping the block today. It's ready to go to the machine shop once I figure out what I'm doing about the head.

http://imageshack.us/a/img9/7811/7qmw.jpg

http://imageshack.us/a/img5/3438/opsz.jpg

http://imageshack.us/a/img841/2712/n3v4.jpg

The pistons do have a bit of scuffing on the opposite side, but they fit very tight in the cylinders and there's no scuffing in the cylinders.

I went for a cruise yesterday with a few friends, car ran nearly perfectly. It's running a bit rich and would soot up the plugs a little bit and feel kinda flat. I advanced the ignition timing a couple of degrees today and it really seemed to help. It hasn't been an issue for autocross, so I should probably just leave it alone at this point.


http://www.youtube.com/watch?v=J9UH3oLYL_4

[Snook]

Needs moar vr6.

Sent from my HTC One VX using Tapatalk 2

[DocWalt]

I don't want a boat anchor in front of my front wheels :p FWIW, my car should be as fast as a stock VR6 now, and more so with the new engine. I'm still hoping to get my car dyno'd up at GZP to do a before after of the chip, and also to have a baseline before the new engine.

[Snook]

I gotta show you my friends 83 gti vr6 swap.

Sent from my HTC One VX using Tapatalk 2

[DocWalt]

Post up some pics!

A tiny bit of excitement is on the way... ;)

http://imageshack.us/a/img203/1408/bjch.jpg

http://imageshack.us/a/img849/8971/k17a.jpg

[DocWalt]

Went autocrossing yesterday. I didn't do all that great. I had great lines some places and crappy other places. Comparing my videos to my brother's, I also need to get closer to the cones. :rolleyes3: I ended up coning really stupidly on my second run, which was my fastest by ~7 tenths of a second. The course was getting less and less grippy as the day went on with the quickly rising temperature. My dad ended up beating my brother in PAX, even though he was a bit under 3 seconds behind in raw time. My brother was pretty ticked, haha.


http://www.youtube.com/watch?v=b1yLreQsCQs


http://www.youtube.com/watch?v=PK3MgHnBbPI


http://www.youtube.com/watch?v=smzdUbzcGjE


http://www.youtube.com/watch?v=bmqlNdB2BfY


http://www.youtube.com/watch?v=Q-iayZcxZnI

[Alex3000gt]

Replacing the fuel pump:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1072369_10201558121572865_644959098_o.jpg

Hope you were using a jack stand under there, sir.

At NGs I'm quickly becoming known as the jack stand nazi, quickly throwing jack stands underneath unsupported cars. I'd rather be known as the annoying guy warning about the perils of not using jack stands than see another member get squished.

[Alex3000gt]

Probably nothing, but why is the intake runner on cylinder # 2 significantly cleaner than the others?
http://imageshack.us/a/img692/6567/py1b.jpg

[DocWalt]

Hope you were using a jack stand under there, sir.

At NGs I'm quickly becoming known as the jack stand nazi, quickly throwing jack stands underneath unsupported cars. I'd rather be known as the annoying guy warning about the perils of not using jack stands than see another member get squished.

I wasn't, mostly because my brother forgot the jackstand at home. I wasn't under the car though, it only looks like it. Thanks for looking out though.


Probably nothing, but why is the intake runner on cylinder # 2 significantly cleaner than the others?
http://imageshack.us/a/img692/6567/py1b.jpg

It's some sort of corrosion, I have no idea why. The intake tract on the head looks similar. I'm thinking it leaked coolant and sucked it back into the intake when it was stored. It came from ~10 miles away from the ocean, which is why everything is really nasty looking.

[DocWalt]

A special part showed up yesterday... I should start seeing a LOT of boxes show up shortly.

http://imageshack.us/a/img51/9493/46g3.jpg

The p&p head has been delayed a bit because the shop found an issue with a valve not seating properly, so they're having the machine shop fix the issue. Silly problems, but much better to catch it now rather than later.

These are on the way now too:
http://i89.photobucket.com/albums/k233/loomis00/image_31_zps57d10c54.jpeg

Waiting on a refund on the first set of cams I bought for this build, there was a lot of shipping damage on the lobes, and some of the journals were completely trashed.

Only about $400 worth of parts left to order, and whatever I'm charged for the machine shop work on the block. Then I'll only need to spend some money on some grinding wheels and flap wheels to port the intake and exhaust manifolds, then cleaning supplies, and paint to make everything spotless.

I'm going to be in for ~$3k on this engine... :eek:

[DocWalt]

Stock Lifter:
http://imageshack.us/a/img10/6848/6k32.jpg

Lightweight lifter:
http://imageshack.us/a/img4/1756/icco.jpg

[DocWalt]

Decided to gasket match my intake manifold...

http://imageshack.us/a/img31/2694/hkzi.jpg

http://imageshack.us/a/img826/8973/cvyp.jpg

The lower intake manifold casting was really bad, I should have started with one of my other manifolds. I spent a few hours knocking down huge casting ridges just in two ports of the lower. I've only done the upper and half of the lower and I'm tired of it already. I still need to do some sanding, but it's already pretty smooth to the touch. Much smoother looking than the pictures seem to show.

[FeaRpb]

Boobies

Sent from my SAMSUNG-SGH-I337 using Tapatalk 4

[DocWalt]

A bunch of parts showed up yesterday:
http://imageshack.us/a/img844/7366/mb4n.jpg

TT Street Cams:
http://imageshack.us/a/img547/5945/x72x.jpg

EAA SS P/S hose
http://imageshack.us/a/img854/3262/g80a.jpg

I ordered an AEM UEGO, I'm tired of shooting in the dark for tuning the fuel properly. I'm hoping it arrives in time to install it before autox on Sunday.

[DocWalt]

Rode my motorcycle today so my brother could fix this junk from the PO:
https://sphotos-b-lga.xx.fbcdn.net/hphotos-ash3/q87/s720x720/1236569_10201900061641153_1351993467_n.jpg

Now with proper submersible fuel line and better clamps:
https://sphotos-b-lga.xx.fbcdn.net/hphotos-prn1/q88/s720x720/1235959_10201900060721130_1548221117_n.jpg

[DocWalt]

A second OEM Bosch pump died on me. Awesome... Looking for a pump in the 'yard tomorrow, if I can't find one, I hope Amazon can come through for me.

Got this stuff in the mail today :)
http://imageshack.us/a/img836/257/l6xi.jpg

[anyonebutme]

love the quattro shirt

[DocWalt]

Thanks!

Today I replaced the fuel pump & installed the wideband. The wideband needs to be mounted somehow and my interior needs to be reinstalled, but it's functioning at idle and steady RPM.

[anyonebutme]

pics or didn't happen

[DocWalt]

See below, abm :p

Wideband installed :)
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1294545_10153246506725615_330710191_o.jpg

Anti-chafe hole edging to protect the wiring. Using a factory hole in the firewall.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/1277578_10153246506985615_988600463_o.jpg

Neatly installed wiring, thanks to my brother. I ended up using the stock O2 sensor heater wiring to power the wideband, with a third wire running back to feed a narrowband signal to the ECU.
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc3/1273467_10153246507295615_1331488265_o.jpg

Still looks pretty good :)
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/1269894_10153246507155615_2092347810_o.jpg

On my first test drive, I was pegging the wideband rich at WOT, and cruise was ~11:1 AFR. After a bunch of adjustment, I'm now cruising at stoich, and WOT is fantastic. Spikes to ~12.5:1 initially, and rises to ~13.5:1 by redline. Dead on, IMO. So much faster now, and I'll probably see better than 20mpg, haha.

[stealthee]

http://i.imgur.com/nQwc6YM.jpg

[DocWalt]

Classic picture! Too bad it's only an 8 valve.

Got my block back from the machine shop. Don't worry, the hone is perfect, there's just some discoloration left over :p I rust converted it after masking and cleaning everything, then painted it black. No pics of the black, it's too dark now.

http://imageshack.us/a/img580/6066/d7nx.jpg

http://imageshack.us/a/img19/7949/wdc3.jpg

http://imageshack.us/a/img819/2373/xjk8.jpg

http://imageshack.us/a/img14/6154/g4hw.jpg

http://imageshack.us/a/img29/900/0gcp.jpg

[DocWalt]

All painted up:

http://imageshack.us/a/img600/9653/821l.jpg

http://imageshack.us/a/img14/723/5k54.jpg

[DocWalt]

The block is back from the machine shop, they had to reinstall one of the bearings because it wasn't installed properly.

I also picked up a 50mm intake from a couple of half drunk British guys over for H2O:
http://imageshack.us/a/img13/6840/6c8x.jpg

The 50mm runners look huge compared to my 42mm runners, haha.

[DocWalt]

I spent a few hours this morning dropping in the pistons and torquing down the rod caps. I dropped the crank in the other day and it specced out at .04mm clearance, dead on. The rod clearance was .05mm, also dead on. The ring end gaps were a little odd. The first rings were perfect at .35mm, the second rings were all a bit too large (according to the Bentley service manual that I have, maybe there's updates) at .6mm. Weird, but nobody makes rings for a hone, only for oversized pistons. Oh well.

http://imageshack.us/a/img35/9775/1nuz.jpg

http://imageshack.us/a/img31/38/cr37.jpg

A bit of boredom led to this comparison between the 42mm (on top) and 50mm runners:
http://imageshack.us/a/img94/9991/2yol.jpg

I have a feeling this is why the fuel pumps died. The entire surge tank under the car was filled with muddy looking sludge.
http://imageshack.us/a/img31/2554/d515.jpg

http://imageshack.us/a/img40/7378/0u9s.jpg

[DocWalt]

Here's the current status of the engine:
http://imageshack.us/a/img801/7067/crnl.jpg

[DocWalt]

I rolled over 170k miles yesterday on the way to autocross. I did reasonably well, only 6th in class which isn't too horrible all things considered. I need to focus more on the course walk to not make as many early mistakes, as well as remembering that the tires are cold. My runs in order 1-7, #4 was my best clean time of the day. #7 would have been my best, but I clipped a cone somewhere.


http://www.youtube.com/watch?v=W_DcceK4Ifk


http://www.youtube.com/watch?v=K5fe42QRXxs


http://www.youtube.com/watch?v=6TeXuP6aic0


http://www.youtube.com/watch?v=CampWZ6zl_o


http://www.youtube.com/watch?v=igotZhZr9i0

[DocWalt]

Continuing the videos from above...


http://www.youtube.com/watch?v=em2H2CVLqvQ


http://www.youtube.com/watch?v=ks23WQ3hYB4

[R/T93]

man, 7 runs, LUCKY!! You really smashed some cones your first run, lol

[Hans@GZP]

So, what's going to break next?

[vroom4]

man, 7 runs, LUCKY!! You really smashed some cones your first run, lol

We consistently get 10 runs....for $12.50 per event.

[DocWalt]

So, what's going to break next?

Well, the exhaust manifold is currently broken...

[Snook]

ouch.

[R/T93]

We consistently get 10 runs....for $12.50 per event.

Wtf :(

From the phone.

[DocWalt]

Exhaust manifold replaced and high flow cat installed. Need to slide the mid-pipe back a bit, it's bumping a chassis brace now when it's cold and I'm on the brakes.

[DocWalt]

A bit of boredom...

http://imageshack.us/a/img547/1504/nyur.jpg

http://imageshack.us/a/img51/5123/qntj.jpg

http://imageshack.us/a/img818/4584/rez3.jpg

[anyonebutme]

rear bumper looks like ass, fix it

[DocWalt]

It'll get fixed when I paint the car.

[anyonebutme]

unacceptable, use some of that back to black sh*t or something.......now

[DocWalt]

Doesn't work, it needs painted.

[DocWalt]

Autocross this weekend was a ton of fun! My last two runs felt absolutely fantastic, I was really pushing it. I was shaking after those two, haha. I felt very comfortable with my times considering I'm on all season tires and my car is floppy.


http://www.youtube.com/watch?v=W-a5v6AdUuI


http://www.youtube.com/watch?v=wz1prPX5Shk


http://www.youtube.com/watch?v=TPkjzMxQh7s


http://www.youtube.com/watch?v=i5fVTIpmPuU


http://www.youtube.com/watch?v=b4Cu3Rz2w6k

I had state inspection today, which includes an emissions test. I was a bit close on the HC limit, but clean for everything else. Awesome! My driver's side door handle broke though, so I had to replace that this afternoon. My brother cleaned and lubed the lock for me and it feels fantastic now. Good stuff.

[DocWalt]

New DD. I've got a fun cruise planned this weekend to feel it out. :)

https://scontent-a-lga.xx.fbcdn.net/hphotos-prn2/1425670_10153464759390615_1559961505_n.jpg

[HLxDrummer]

Man I'm jealous! VR4, Evo, BRZ, Triumph, GTI.. Share the wealth!

I have a feeling you won't think the GTI is so fun anymore lol

[DocWalt]

Don't worry, it's still fun. It's easier to drive fast since the controls aren't as sensitive. With the new engine it will pretty much be an even match in the straights, and with the ARBs and LSD, I'll be able to run sticky tires and outrun the BRZ in the corners too.

[HLxDrummer]

Is it sad that when I saw ARB i immediately thought of a class of drugs (angiotensin receptor blockers) lol!

I'm surprised it will be able to keep up in turns or straights! How much does it weigh/how much power? You should take both to the same autocross and see how they compare.

[DocWalt]

Haha!

The GTI will be pushing ~180-190 at the crank (hopefully!) with 400 pounds less weight. It's not much slower now, especially to 60 since the BRZ's 2nd doesn't quite get to 60 with the stock revlimit. It would be very hard to compare both of them on the same course, I'm not very comfortable yet pushing the BRZ like I am the GTI. The GTI is "safe" in that it will just understeer when you floor it, so you can very easily play with the throttle to make the car turn tighter or wider. The BRZ understeers in steady state cornering, but any sort of overstep with the throttle and you can end up sideways which was not a problem on the GTI.

Another thing, the BRZ has EBFD (electronic brake force distribution) which feels very weird. It feels like the car wants to move around while threshold braking just because the ABS system is trying to modulate the grip for you. Very odd sensation, but it's obviously a lot better than my GTI's "dumb" brakes. Not confidence inspiring though.

I'm really looking forward to pushing the BRZ around a bit this weekend, I think it will be spectacular once I'm feeling more comfortable. I haven't driven a RWD car since my first car, which was a big motivator to get the BRZ over a Fiesta ST.

[Disrupter]

Nice purchase!

[HLxDrummer]

The EBD would feel strange.. never thought about that. I HATE pushing a car that doesn't have confidence inspiring brakes (on the street, at least). Speaking of which I need to bleed the brakes on the VR4 lol

I'm sure you will have a blast in the new car, especially once you get used to it.

Isn't the Focus ST a little more comparable to the BRZ? I didn't even know they had a Fiesta ST (although I know you have a fetish for the Fiesta haha)

[DocWalt]

Nice purchase!

Thanks!


The EBD would feel strange.. never thought about that. I HATE pushing a car that doesn't have confidence inspiring brakes (on the street, at least). Speaking of which I need to bleed the brakes on the VR4 lol

I'm sure you will have a blast in the new car, especially once you get used to it.

Isn't the Focus ST a little more comparable to the BRZ? I didn't even know they had a Fiesta ST (although I know you have a fetish for the Fiesta haha)

The Focus is more comparable in some ways. Other ways the Fiesta is. The Fiesta ST is really new, but acceleration wise it's somehow slower (same HP but 50+ ft-lb more tq) than a BRZ. The Focus has hideous taillights, IMO, lol

[IPD]

i think i would have opted for a genesis coupe over a toyabaru. i do love the focus st though. and just in case i haven't screamed it loud enough...i still want a scirocco turbo in the states. F-U, VW.

[DocWalt]

Genesis Coupe kinda handles like poo. The Hyundais don't have as noisy of a DI pump though.... :suspect:

[IPD]

handling? look at how a stock 3/s handles, ffs. :p

[DocWalt]

Which is why I moved away from the platform until I can afford to have one as a weekend car. ;)

Drove the GTI around tonight. All season tires sure are mushy :lo5l:

[DocWalt]

I'm frustrated with CIS. Committing to MegaSquirt II running MSII Extra. I'll be running VW's G60 injectors, so I should be able to do about max 200hp crank on the initial setup. Should be fun, I already ordered everything except for the ECU, its wiring harness, and associated bits and pieces.

[nodoze]

Keep me updated on the cis swap may be in my future

Sent from my XT881 using Tapatalk

[DocWalt]

All of the parts are ordered except for injectors and I need to figure out what I want to do for the intake. I think I'll get it running then worry about doing a fancy intake. I'm still trying to find a set of G60 injectors...

[DocWalt]

http://img849.imageshack.us/img849/8272/slxh.jpg

At this point I'm only waiting for the ABD Intake, and waiting on injectors to ship. Everything else is on the way. Two weeks off of work, and not much else to do so I'm happy to have something useful to do. I hope everything arrives in time to allow me the time to get it done and with a drivable tune by the time I get back to work.

[DocWalt]

I'm about two-thirds of the way through the harness installation. Hall sensor, coolant temp sensor, idle valve, injector power/signal wires to weather pack connectors, all power wiring, and new fuse block installed. I only need to wire up the TPS, wideband power & signal, and intake temp, as well as building the fuel injector harness. The fuel injector harness is the most complicated part, weatherpack connectors are a bit annoying.

ECU firmware flashed, and my circuit mods are tested. The ignition setup works perfectly including tach. I calibrated the idle valve and it works perfectly too. I'm not 100% sure about the coolant temp sensor calibration, but that's not a big deal to tweak down the line. I'm super excited that everything is working out!

[DocWalt]

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/q77/s720x720/1075821_10201586706006485_275562568_n.jpg

Current engine status:
https://scontent-b-iad.xx.fbcdn.net/hphotos-ash3/q71/s720x720/1457561_10153644598470615_2071138864_n.jpg

Megasquirt harness is completed. I need to buy some smaller wire loom to finish tidying it up after I get the car started, but it's looking great so far. All of the sensors are looking good so far, and all of the control hardware checks out. Now it's just software setup which has been well documented, so I'm expecting everything to go relatively smoothly from this point on. :D

Also, my ported & polished head arrived with the stainless header. Looks fantastic, but I need to clean a lot of glass blasting beads out of the ports and coolant passages.


As of today:
https://scontent-b-iad.xx.fbcdn.net/hphotos-ash4/1509254_10153647827100615_1353571684_n.jpg

Megasquirt is fully installed. Just waiting on a throttle body. Don't worry, the CIS stuff was just for mockup ;) It won't fit with the big bore intake and my strut bar anyway.

New head intake port:
https://scontent-a-iad.xx.fbcdn.net/hphotos-frc3/1476417_10153652372355615_95097480_n.jpg

Exhaust port:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/1521789_10153652372195615_1964150643_n.jpg

Assembled with the TT cams and the lightweight lifters. What a pain in the ass.
https://scontent-b-iad.xx.fbcdn.net/hphotos-frc3/996772_10153652372040615_1294938601_n.jpg

[DocWalt]

More progress on the new engine, ARP undercut headstuds installed, head dropped on and torqued down. I set the timing and torqued everything down except for the main crank sprocket bolt. That will have to wait until it's in the car, I think.

https://scontent-b-iad.xx.fbcdn.net/hphotos-frc3/1479082_10153658239375615_220042445_n.jpg

https://scontent-b-iad.xx.fbcdn.net/hphotos-ash3/1012812_10153658239480615_1173968767_n.jpg

https://scontent-b-iad.xx.fbcdn.net/hphotos-frc3/1507201_10153658239555615_1528977620_n.jpg

https://scontent-b-iad.xx.fbcdn.net/hphotos-frc3/1468567_10153658239650615_119874138_n.jpg

[DocWalt]

Megasquirt installed and I'm about 75% of the way done tuning. Runs great at WOT, and runs well pretty much everywhere except idle. I had the idle tuned very well but I decided to try using the stock VW idle valve to bump up the idle when I'd need it using MegaSquirt's closed loop idle control. What a PITA, haha. Sounds kinda silly in the video cause of that, but oh well.


http://www.youtube.com/watch?v=m15k76y1qE0

[Alex3000gt]

Nice Kenny! You sure have put a lot of work into that Volkswagen!

[Jimvr4]

Nice job!

[DocWalt]

Thanks guys! I've spent some more time on the idle and it idles perfectly at ~1000 RPM when warm. I need to tweak the warmup stuff, but I'm getting closer! Pulls like a train at WOT. WOT tuning is cake in comparison to idle. No wonder why the flashable ECUs are selling like hotcakes compared to standalones, tuning all of this cold start and idle stuff sucks.

[DocWalt]

I've got MegaSquirt working very well! A little bit richer than I'd like at idle, but I need to do that to stave off the heat soak of the IAT sensor. I don't really want to mess with the IAT correction to make it less sensitive t heatsoak over 100* but I think it will be worth trying so I can save a bit on gas and have less worries about emissions testing. I definitely need to spend more time fine tuning, it's correcting the mixture quite a bit sometimes at cruise, but still great at WOT, and transitions smoothly between on/off throttle almost everywhere. Below 2k is still a little bit jerky because of the dashpot tuning, but my BRZ does the same stuff.

Random picture of how I connected to the stock CIS lines since I had the intake out to epoxy the bung to the tube temporarily.

http://imageshack.us/a/img593/1034/poc8.jpg

I definitely need to find a good solution to the intake, maybe run the stock plastic pipe to a Digi2 airbox with a cone filter adapter and a silicone coupler. I doubt that the ABD intake will line up and fit under the strut bar using the Digi2 airbox.

[DocWalt]

Update on the trans situation... More money than I expected, but full rebuild and brand new diff.

Swaybars will be here tomorrow. :)

I replaced the MAT/IAT sensor with the open element style sensor and it's a LOT better to tune with. The closed element style sensor heatsoaked like crazy and generally sucked. I'm unsure why I wasted so much time with it.

I've spent a lot of time making the idle work well, and here's the results.
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc3/1506100_10153709043300615_2113715619_o.jpg

Here's the AFR map that I'm aiming for. This map is what tells the MS to trim fuel while driving around. It's also what the VE Auto Tuning app aims for, so you can use the autotune to get your tune really close, which is what I did. Note that I've set the idle area on this map richer than reality so if I decide to use the autotune in the future it won't lean out the idle since lean idle is really unstable.
https://scontent-a-iad.xx.fbcdn.net/hphotos-frc3/1511270_10153709043295615_1247737889_n.jpg

Ignition timing map. MS will use this map to set the ignition timing based on load, RPM, and some other factors. Notice that it's targeting the stock 6 degrees of advance in the little "pool" at idle. MS will advance the timing if the idle drops too low which pushed the idle RPM back up. Works well!
https://scontent-a-iad.xx.fbcdn.net/hphotos-frc3/t1/1560582_10153709043305615_2052145731_n.jpg

Volumetric Efficiency map. This tells MS how much fuel to inject at certain loads and RPMs. I need to smooth it out a bit at some points, but it idles very well, and drives smoothly. Plus it makes tons of power at a safe 12.5-12.7 AFR at full throttle. I'll probably lean it out a little bit to make a little bit more power.
https://scontent-a-iad.xx.fbcdn.net/hphotos-prn1/t1/1013697_10153709043390615_1304232962_n.jpg

I need a new battery and I forgot to change to lightweight oil for winter, so it's not very nice to start up when it's cold out, but oh well. I'm really liking MegaSquirt.

[Alex3000gt]

Change to that light weight oil! Save yourself startup wear and tear!

Alex

[DocWalt]

Eh, new engine is going in soon enough.

I think I need to add a bit more fuel at cranking, it spins over a few time then slowly catches itself. Takes off really well and runs superbly after that though. Awesome :D Also, catches itself about 99% of the time when dropping to idle. Hot starts make it idle surge until you drive around a bit and cool it off, I'm hoping that having an airbox sucking cold air will help that a lot. I'm not sure it will help the IAT sensor heatsoak issue though. Unsure how else to tune around it without messing with the way it will run when it's actually sucking hot air.

Also, sent the money for my trans. Everything is rebuilt and waiting for the LSD to arrive. LSD: Peloquin Transaxles (http://peloquins.com/products_020.html)

[DocWalt]

Picked up a brand new OEM coolant expansion tank today. I'm tired of mine flashing the low coolant light at me, more Meyle junk...

Also, did some video work...

http://www.youtube.com/watch?v=aQJ4ht23UEs

[Alex3000gt]

https://scontent-b.xx.fbcdn.net/hphotos-ash3/t1/1897945_10201783843621735_739542191_n.jpg
Had to tow Kenny back from the track today.

[stealthee]

Dat wheel gap..... Looks like my car did when I bought it.

[DocWalt]

lulz. broke my throttle body today.

https://scontent-a-iad.xx.fbcdn.net/hphotos-prn2/t1/1779747_10153814769160615_1174230317_n.jpg

[DocWalt]

My brother fabbed up my Digifant to 3" air box today. Needs some longer bolts to mount the cone filter adapter, and needs some sanding and painted up so it looks factory, but it's going to be extremely effective. It will quiet down the insane intake roar I have, but it will make tuning a bit easier since it will be sucking cooler air. I might need to pop out the intake venturi to let enough flow in, we'll see if I'm pulling any vacuum at WOT now.

http://imageshack.com/a/img585/7130/p9fd.jpg

This is what the airbox looks like without the MAF mounted:
http://i.ebayimg.com/t/VW-GOLF-GTI-MK2-8V-PB-DIGIFANT-AIRBOX-AIR-BOX-JETTA-VOLKSWAGEN-UNDRILLED-/00/s/MTIwMFgxNjAw/z/jegAAOxyyF5RRNn0/$T2eC16N,!%290E9s37E2%28DBRRNnyPS2g~~60_35.JPG

[DocWalt]

Finished up my airbox. Still need to loom half of my megasquirt harness...

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc1/t1/1896933_10153859293000615_32711944_n.jpg

[DocWalt]

Finally bought some wire loom and finished my MgeaSquirt harness.

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/t1/1901401_10153883974980615_1215867622_n.jpg

[DocWalt]

Engine is pulled and on the garage floor. Got some cleanup and other work to do, mostly swapping parts between engines and installing the new parts.

https://scontent-b-iad.xx.fbcdn.net/hphotos-prn1/t1/1974989_10153902301450615_2097054970_n.jpg

My front engine mount is a lot worse than I thought...


http://www.youtube.com/watch?v=fBXzQIJ_xLg

[DocWalt]

EAA Engineering power steering line. Very high quality stuff! I put some wire loom on to protect everything else from being rubbed by the stainless braid.
https://scontent-a-iad.xx.fbcdn.net/hphotos-ash3/t1/1527790_10153911933650615_2046063874_n.jpg

https://scontent-a-iad.xx.fbcdn.net/hphotos-frc3/t31/1956728_10153911933450615_2076072978_o.jpg

New clutch installed and ready to bolt the rebuilt trans on.
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/t31/1502613_10153911933630615_1966154399_o.jpg

Supersprint header installed. Shifter also rebuilt. No, the axle bolts aren't installed yet :)
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/t31/1941352_10153911933455615_882729329_o.jpg

Stopping point for tonight. New coolant bottle ($$ :facepalm:), nice fresh ATF in the power steering, new front mount, euro non-A/C alternator setup (picked it up from Orchid Euro, great guys!), and lots of other odds and ends.
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc1/t31/10012663_10153911933465615_613610473_o.jpg

Try to ignore the el-cheapo filter that's just there for break in ;)

[HLxDrummer]

Need to clean that bay homie!

[DocWalt]

When I get it painted, sure. Not happening before then :)

[DocWalt]

Fantastic news! My engine is trash.... :( Not sure what's damaged, but I can't turn it over when it gets warm and it makes horrendous noises.

[FeaRpb]

Fantastic news! My engine is trash.... :( Not sure what's damaged, but I can't turn it over when it gets warm and it makes horrendous noises.

http://24.media.tumblr.com/8a67bb8cd245e1f10ae2e04e7f00eb32/tumblr_mque5mGa881s2amn4o1_500.gif

[DocWalt]

lulz.

[R/T93]

Nooo Kenny :(

Thats terrible, man.
What now?

From the phone.

[DocWalt]

Swap the old one back in and tear down the new one. Assuming the head is good (unsure, if the piston was smacking it I'm not sure what to do) I'll put it on the old bottom end with the intermediate shaft swapped as well.

[j2k4]

Ah...crap.

[Jimvr4]

Damn :(

[DocWalt]

Thanks for the support guys. My brother got the engine out and the old one ready to go back in. Salvaged some of the pretty bits at least. Hopefully I can get it buttoned up this weekend when I get home, and start tearing apart the dead engine. I guess I'll drain the oil and pull the head first. When I pulled the dipstick it came out black with a very familiar golden color...

[Turbo Beast]

Ulgh dat sucks

[DocWalt]

I got a metallic fro going on:
http://i.imgur.com/GnOXimq.jpg

In the drain pan:
http://i.imgur.com/D1hoWOI.jpg

The old engine is back in and running. I'm having some trouble getting all of the air out of the cooling system, but that's easy enough. I need to swap a tie rod, get it aligned and get new tires on it this week. Back to Oregon next week and then autocross a day after I get back. Tight schedule!

[DocWalt]

https://www.youtube.com/watch?v=IVsCd5NqZM0

In all its 3.5 cylinder glory.

[DocWalt]

Welp. Tore into the engine. The head looks ok. Needs a VERY thorough cleaning, but otherwise looks ok.

1/2" thick of metallic sludge in the pan.
https://scontent-b-ord.xx.fbcdn.net/hphotos-prn1/t31.0-8/1553528_10153965153025615_1880490922_o.jpg

Windage tray is also full of metallic sludge. The Oil pump is packed with metallic crap too.
https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/t31.0-8/1782382_10153965152935615_1906459947_o.jpg

#1 rod cap is on the left. It got VERY hot... Probably because there was literally no bearing material left. #4 is on the right with whats left of its bearings.
https://scontent-b-ord.xx.fbcdn.net/hphotos-frc1/t31.0-8/1911966_10153965152975615_874963177_o.jpg

#1 rod journal is trashed.
https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/t31.0-8/10014802_10153965153270615_1217588942_o.jpg

#4 rod journal... trashed.
https://scontent-b-ord.xx.fbcdn.net/hphotos-ash3/t31.0-8/1888824_10153965153245615_1850418677_o.jpg

[CoopKill]

Ouch!

[mb3000]

Damn....

[DocWalt]

It lives on all four cylinders! Mostly... I was out on a five minute tune to make the tweaks for the header and the car just straight up shut off, tach dropped to 0, etc. Looked over at my laptop hooked up to the ECU and it was reading 0 RPM even though the ECU still had power and the engine was still spinning at 3 or 4k RPM. Weird... Parked it and started messing around with the distributor and didn't notice anything wrong. Called someone for help and it magically started right back up after hanging up. Called them back and drove home... Strange.

I played around with the idle tuning a bit and drove to Advance to pick up some unrelated stuff. I actually got to jumpstart somebody with the GTI! It's normally the other way around, haha. It pulls pretty darn hard, lights em up rolling into it in first, and spins into second still, even with the LSD. The real test will be after I get it aligned on throw on my new tires.

Also... all of my subframe bolts were finger tight. Oops.

[DocWalt]

Freedo aligned :)
https://scontent-b-iad.xx.fbcdn.net/hphotos-frc3/t1.0-9/10168002_805454082815383_769738352_n.jpg

My new tires next to a set of wheels my brother just picked up. The Rivals are a bit wider than Falken RT615K's.
https://scontent-a-iad.xx.fbcdn.net/hphotos-frc3/t1.0-9/1499576_10153974263945615_401587007_n.jpg

[HLxDrummer]

Any idea what happened to cause the engine failure?

[DocWalt]

Probably didn't fully prime. Maybe the assembly lube dried out (idk why it would, the lube that's on the outside of the bottle is still quite wet and sticky). Don't really know though...

[DocWalt]

Did a bit of autocrossing today. Had some issues, but a LOT of fun. I was very competitive in my class, which has me really excited. I ended up 4th out of my class.

Run 1, a bit slow and the wrong way through the slalom.

http://www.youtube.com/watch?v=jFPXTv4VCyw

Run 2, with a bit of two wheeling action...

http://www.youtube.com/watch?v=kSpo5r58DFc

Run 3, a bit faster now...

http://www.youtube.com/watch?v=ZePs-2cUlxY

Run 4, my fastest run of the day. Placed me 4th in our local Street Tire Prepared/Modified class.

http://www.youtube.com/watch?v=PK9SrKaLokg

[CoopKill]

Looks like FUNNNN!

[DocWalt]

Got a nice snap of my car :) https://www.flickr.com/photos/steezykittyphotos/13683034215/in/set-72157643557205644

got this too :)
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/t1.0-9/10156014_10154006144210615_761160712148622201_n.jp g

[j2k4]

Nice!! :)

[DocWalt]

Flushed my lifters, and I'm glad I did. Lots of bearing material.

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/t1.0-9/10250186_10154023973500615_7324040483311783511_n.j pg

Also, snapped a pic of my car while I took a break from popping apart lifters.

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/t1.0-9/1559565_10154023971870615_8714480554765642302_n.jp g

[HLxDrummer]

So how come your not autocrossing the BRZ?

[DocWalt]

I'd like to keep my warranty intact.

[CoopKill]

Boooooooooooooooooooooo!

[HLxDrummer]

Will they seriously void it if you race? How would they know?

[anyonebutme]

He's still in denial that he spends more on crap vw than he would enjoying the brz..... let him be.

[CoopKill]

:lmao:

[DocWalt]

Subaru's known for checking SCCA entries when you have warranty issues with drivetrain.

[anyonebutme]

Subaru's known for checking SCCA entries when you have warranty issues with drivetrain.

Weird.....because they use to give out free memberships to the scca with a car purchase.

Easy fix......run with a different club.

[DocWalt]

or just keep using the GTI...

[anyonebutme]

Wrong answer.

[HLxDrummer]

I wonder how that works legally. I just SCCA entries are public domain but I would what the fine print in the warranty says. I remember reading something where as long as it isn't a head to head timed competitive thing that insurance companies will pay up.. Who knows!

[stealthee]

I remember going to PRP and seeing a bunch of Subies with their tags removed and a piece of paper over their dash VIN. LOL

[HLxDrummer]

Thanks awesome haha I just came up with a great idea.. Take off the plate/block the VIN, and use a random name for your SCCA registration ;)

[DocWalt]

or just keep using the GTI, lol.

[stealthee]

Still the wrong answer.

[HLxDrummer]

Be a real man and take both cars to the same event. Tell them you can't work the course cause your other car is in the next heat:victorious:

[anyonebutme]

Local FASE team sometimes have a "rent a corner worker", where for a donation to the FASE team will get you a guy to work your shift, lol.


Best, idea, ever.

[DocWalt]

That's pretty awesome. Our local corvette club supposedly hires corner workers with the profits from their hot dog stand, lol.

[Chris@Rvengeperformance]

Local FASE team sometimes have a "rent a corner worker", where for a donation to the FASE team will get you a guy to work your shift, lol.


Best, idea, ever.

we need to do this at NG. I would've paid $20 for a guy to stand out there for me, my back doesn't like standing still for long periods :(

[stealthee]

we need to do this at NG. I would've paid $20 for a guy to stand out there for me, my back doesn't like standing still for long periods :(

My back, my knees, and my legs in general don't do well having to stand in one place. I need to move.

[DocWalt]

Stroker pistons arrived. Notice the offset wrist pin hole :)

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/t1.0-9/1483217_10154056647440615_7329855372552863767_n.jp g

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/10171707_10154056647590615_219222491366606579_n.jp g

[vroom4]

Or just beat the crap out of the brz, since you know, you are paying 400 a month for it, might as well enjoy it.

[DocWalt]

I'm not paying that much a month for it :p

[DocWalt]

For the heck of it... a video from the other night. Had my brother go for a quick spin so I could hear my car from outside with the header. Sounds insane, heh.


http://www.youtube.com/watch?v=Twp9MjNCxgs

[CoopKill]

Sounds like a honda???

[DocWalt]

:( meany

[R/T93]

Lol. It kinda does. Oh well. Im sure you will beat up some turbos at ng autocross with it.

From the phone.

[DocWalt]

I know, the header made it sounds more like a Honda :( If I go catless it will be full on fart cannon. At least it's not buzzy, and in the car it sounds mean as hell.

[CoopKill]

I was just playing. Hondas do not have German accents... :suspect:

Sent from the Man Cave!

*\( ^o^ )/*

[HLxDrummer]

You going to NG? Don't see your name in the list:Spank:

[DocWalt]

Yeah yeah. Signing up shortly.

[R/T93]

Excellent *Mr. Burns*

[Hans@GZP]

Lol. It kinda does. Oh well. Im sure you will beat up some turbos at ng autocross with it.

From the phone.

My money is on it being broken and him taking the BRZ

[HLxDrummer]

I bet he'll have the GTI. Looks like he is getting pretty fast at swapping motors and has more than one so I think he'll pull it off :)

[DocWalt]

My new motor is blown up, and I have no spares. I also sold my spare transmission to my brother to fund the stroker. There's no way the stroker will be done in time, but unless I blow this engine up in the 500-600 miles or so I'll put on before and on the way to NG, I'll be in the GTI :p

So Hans, dyno time? :p

[Hans@GZP]

Bring it on in. I'll buy extra straps to hold the beast down.

[stealthee]

I got some bungie cords you can use to hold it down. Probably all you will need. :D

[vroom4]

Open the garage door and let the wind hold it back.

[DocWalt]

Hahahaha. You guys suck :(

[IPD]

don't feel bad. my kia makes 80hp. so probably closer to 50 at the front wheels after you factor in the slushbox. ;)

[CoopKill]

This needs to be placed in another thread with many others.
http://www.3sgto.org/customavatars/avatar82_85.gif
It has haunted me for far too long...

[IPD]

doc could just start a thread for unedited pics of his avatar--new pic each time he changes it.

[DocWalt]

I had done that at one point, it's in the member's section... Let's keep this thread on topic ;)

[DocWalt]

So... we got rid of my brother's old Golf finally. It didn't fit on the trailer right side up...

https://scontent-a-iad.xx.fbcdn.net/hphotos-prn2/t1.0-9/10269577_10154099358480615_7610480069725957642_n.j pg

https://scontent-b-iad.xx.fbcdn.net/hphotos-frc3/t1.0-9/10264315_10203639892535838_8997890927186973929_n.j pg

[CoopKill]

Lmao

Sent from the Man Cave!

*\( ^o^ )/*

[DocWalt]

Had an autocross today, and had a blast. Unsure if I got 2nd or 3rd in class, but I beat the times all of my friends were setting. :D


http://www.youtube.com/watch?v=dJ1_lwD6KIg


http://www.youtube.com/watch?v=c9ENFifXq3M


http://www.youtube.com/watch?v=im9ixywdfDs


http://www.youtube.com/watch?v=A5szYg0Lygs

[HLxDrummer]

Looks like some good wheeling there home boy!

[DocWalt]

Prepping for NG! Checked for fluid leaks and swapped on new rotors and some Carbotech AX6 pads. Thanks Terry @ Maximal Performance!

https://scontent-a-ord.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10346188_10154282752305615_5460416080092037877_n.j pg?oh=221579fb9a0c1cbdfb3db6fcdbf47c38&oe=54205804

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10393896_10154282752190615_6978946620595373973_n.j pg

https://scontent-a-ord.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10486132_10154282752370615_8736558588781581443_n.j pg

[Jimvr4]

^^best pads I've run so far although they do leave a lot of dust.

[DocWalt]

^^best pads I've run so far although they do leave a lot of dust.

They left a pile of dust on my driveway where I turned in after bedding them in, haha.

[IPD]

looks like it's time for doc to post up the photo-shoot source for his new avatar in the members' area. ;)

[DocWalt]

NG hype! All washed and prepped. Just need to pack my personal crap and head out on Tuesday.

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10402678_10154289299705615_2669377930274175015_n.j pg

[DocWalt]

I had an absolute blast at Pitt Race/Beaverun with the 3/S National Gathering! I now want to take my car on more track days... :laugh:

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10255430_10100989553823295_7173704899882477014_n.j pg
(awesome picture courtesy of lethal_vr4's wife!)

We also ran an autocross on their skidpad, which was an epic course. Easily my favorite course ever, and it showed in my times. I ended up having the fastest time of the day by 4 tenths against R/T93. So much fun! I'll have my videos of that up shortly.

I also ran at the dragstrip. My best of the night was a 15.6 @ 90mph in the 1/4. Struggled with tons of wheelhop so the times were pretty meh, but the mph is about what I expected to do. About what a stock N/A DOHC will do. :)

[stealthee]

Thats just a hair slower than what I ran my last time out in the Stealth.

[DocWalt]

Autocross videos, in run order. My third run got me the fastest time of the day. My last two runs were filmed by checkeredvr4, and I'm linking his video last. Conveniently pre-edited by his wife :)


http://youtu.be/tnG8FVBNfu0


http://youtu.be/7VWSBVEJ2ZI


http://youtu.be/Q3Pqe0tPKDg


http://youtu.be/0hm2iyyZJvI


http://youtu.be/sBZygK5hhvQ

[DocWalt]

http://www.youtube.com/watch?v=0AP5d0x9czM

[R/T93]

Yessss.

From the phone.

[CoreyB]

Wicked awesome!!!

[CoopKill]

Awesome vids, nice "kill"! :lmao:

[DocWalt]

Had another day of autocross today. We were at the Wells Fargo Center with Philly SCCA. The surface had a LOT less grip than last year, so LOTS of understeer. Pretty frustrating coming from the grippy surfaces I've been on recently. I ended up 4th in class by 0.007 seconds to a WRX. I had a faster raw time but lost in PAX. Oh well. The more interesting videos are the second and fifth. My second run was embarrassingly bad, I managed to induce cowl shake, haha. My fifth run was my fastest.


http://www.youtube.com/watch?v=CeR5GyD7ldM


http://www.youtube.com/watch?v=2E5tJkVvy7U


http://www.youtube.com/watch?v=JkQuSQfyTys


http://www.youtube.com/watch?v=1od5OtOGOGk


http://www.youtube.com/watch?v=oL-9YfynNiY

[DocWalt]

Well, my new cams are VERY close to hitting the head, but they spin smoothly without contact.

Intake:
http://i.imgur.com/kd5C4yk.jpg

http://i.imgur.com/1GezjvL.jpg

Exhaust:
http://i.imgur.com/LuJ0QYo.jpg

[Chris@Rvengeperformance]

Well, my new cams are VERY close to hitting the head, but they spin smoothly without contact.

Intake:
http://i.imgur.com/kd5C4yk.jpg

http://i.imgur.com/1GezjvL.jpg

Exhaust:
http://i.imgur.com/LuJ0QYo.jpg

holy cow, I think I'd grind some of that away. When that head gets hot...

[DocWalt]

It's not quite as close as the pics make it seem, but it's a LOT closer than factory cams. I can fit a few sheets of paper in there, I'm not too worried about it. :)

[DocWalt]

I was a touch bored, so played with a gearing calculator. Fifth sucks terribly on track now, but it makes highway driving so much nicer.

http://i.imgur.com/cS4YBpV.png

[anyonebutme]

Has that car ever reached 120 on the track?

[DocWalt]

It was pretty close on the back stretch at Pitt Race. It doesn't make much power over 7k RPM so I was shifting right around there.

[anyonebutme]

new cams should fix that hopefully.

[DocWalt]

Yup. Cams should make power to 8k, hopefully the bottom end can do it.

[DocWalt]

Blew it up yesterday. Coasting along at ~35mph, rolled back into the throttle to maintain speed and it ran on three cylinders with a horrendous metallic clanking. I'm dropping my new engine bits off at the machine shop this week. I'll pull the pan on the old engine sometime this week. I'm perplexed why I completely lost the cylinder when the engine failed, every other time I've spun a bearing it kept running on all four.

[DocWalt]

Compression test results...

210-200-48-45psi.

Sounds like a Subaru and makes terrible metallic noises. Ugh.

[DocWalt]

http://www.youtube.com/watch?v=L2NRIDGTPYw

[anyonebutme]

private video is private

[DocWalt]

dafuq? I uploaded it as public a few days ago lol

[stealthee]

Sounds like a Subbie

[HLxDrummer]

What is wrong with your car sounding like a Subaru? I love it :)

[DocWalt]

It sounds more like a Subaru than my Subaru :p My new engine is at the shop, so things should be happening. Might have word tonight if everything looks OK to use.

[DocWalt]

Don't really have a better place to put these... I won C Street today first try with my bone stock BRZ. My fourth run was my fastest, for a win by 0.7 seconds.


http://www.youtube.com/watch?v=HlDOSbQtS6w


http://www.youtube.com/watch?v=9h2YucHwScU


http://www.youtube.com/watch?v=n1B-bcPcJ9A


http://www.youtube.com/watch?v=-ZAggYNVTbY

[vroom4]

You couldve destroyed the class without that little extra curricular activity before the final element.

[DocWalt]

I got 6 runs in today. My fastest was the 6th run. I essentially didn't have much competition today, I was about 3 seconds ahead of second place, which was running a Porsche 968 Spyder


http://www.youtube.com/watch?v=l9K3GnFtC1I


http://www.youtube.com/watch?v=ld2fvgpYEtI


http://www.youtube.com/watch?v=iWF8-Igy5uQ


http://www.youtube.com/watch?v=-inV51vf-mU


http://www.youtube.com/watch?v=IhiIolYOCDU

[DocWalt]

and my fastest...


http://www.youtube.com/watch?v=Tf9sMjN1uI8

[j2k4]

You're a bad man, Kenny. :)

[DocWalt]

Someone started a smack-talk post on my local SCCA's Facebook page... The first post was this:

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/10614103_10153355049067564_7672223052768916863_n.j pg?oh=4fdbc58a2ccea61201b50e4bf1bdb2d7&oe=551B6F2B&__gda__=1427676831_4920aad127724da55c79a4665fab27c f

:(

[futurevr4man]

It doesn't suck they're making fun of you...
















It sucks that it's true ;)

[DocWalt]

Got my JDL Auto Design UEL header for the BRZ

http://i.imgur.com/wlcQLLJ.jpg

http://i.imgur.com/lRFoaaW.jpg

http://i.imgur.com/LrwPNw2.jpg

http://i.imgur.com/4txdAYs.jpg

A quick video. I still have the stock catback and it sounds freaking fantastic


http://www.youtube.com/watch?v=a2snjGFrjiw

[DocWalt]

Installed a SRP throttle pedal on my BRZ today...

https://s3.amazonaws.com/achgen360/p/eues0JF1.png

http://i.imgur.com/skKEsvI.jpg

http://i.imgur.com/w3BsX2b.jpg

Also, I fixed my leaky header gasket. The new header flange is so much bigger than OEM that it didn't properly crush the OEM gasket. I installed the gasket that came with the header instead.

http://i.imgur.com/TLXN66H.jpg

http://i.imgur.com/iOEPuq7.jpg

Then I washed my car... It's going to rain tonight and potentially snowing on Wednesday.

http://i.imgur.com/vyRhM3Q.jpg

http://i.imgur.com/5xpMo2o.jpg

http://i.imgur.com/W3RRy5o.jpg

[DocWalt]

I like how it sounds :)


http://www.youtube.com/watch?v=j8vDL8wUwR8

[anyonebutme]

No turbo noises, no care.

[HLxDrummer]

What happened to I'm not racing or modding it to save the warranty? ;)

[DocWalt]

What happened to I'm not racing or modding it to save the warranty? ;)

I think we all knew this was coming :lo5l:

[HLxDrummer]

I think we all knew this was coming :lo5l:

You won't hear me complaining! Haha

[DocWalt]

I installed a Nameless downpipe (overpipe/frontpipe combo)... The Nameless pipe sounded like complete garbage with my setup. It was predented to clear the engine (previous owner's work, not mine lol) and fit really well so I was quite disappointed. The Nameless pipe had a really tinny raspy noise, so I bought a cheapo ISIS overpipe and reinstalled the stock frontpipe. Sounds a lot better and killed a lot of the wooshy noise. I plan on picking up a JDL overpipe and catted/resonated frontpipe eventually.


http://www.youtube.com/watch?v=hnucYYbcF1A

[DocWalt]

Oh and this happened... I ordered a right angle OBD2 plug extension from Amazon and got a rather odd surprise with the cable...

http://i.imgur.com/MJ4j1nx.jpg

http://i.imgur.com/fSJdMyN.jpg

http://i.imgur.com/YXO1ZX0.jpg

http://i.imgur.com/LQ4HvbI.jpg

[green-lantern]

Shouldn't you just start another thread? This one seems to have gone.....off topic. lol

[DocWalt]

new engine is being worked on. GTI still starts and runs on its glorious two cylinders of fury.

[DocWalt]

I bought a borescope and futzed around with it today to inspect the two cylinders with low compression. No detonation damage or holes in pistons, I guess I have to wait until I tear it down to figure out what went pop.


http://www.youtube.com/watch?v=oPxyYzHLxjU

[DocWalt]

http://www.youtube.com/watch?v=tUlLAONnHOc

I installed the JDL overpipe and ultra-quiet frontpipe. A little bit buzzy for my tastes, but no horrible tingy noise like I had with the nameless pipe. The ISIS overpipe (read: ebay) was pretty low grade stainless, it was really nasty when I took it out. Had a couple of pinhole leaks on a weld too.

[DocWalt]

I replaced a crappy Vibrant gasket and made a video of my new exhaust setup.

http://i.imgur.com/DhJ9Ij8.jpg


http://www.youtube.com/watch?v=7fk5EFiID_M

[DocWalt]

Engine is nearly done... just waiting on piston pin clips for final assembly. Apparently the clips that came with my pistons were junk.

[DocWalt]

Like I said, crappy piston pin clips... Besides being 1/4" too big...
http://i.imgur.com/SxEh0EK.jpg

[DocWalt]

My 4th run was my fastest. I got bumped up class-wise due to my header. Still loads of fun!


http://www.youtube.com/watch?v=rcUZNS2Cjmo


http://www.youtube.com/watch?v=xoALMi-DC5Y


http://www.youtube.com/watch?v=LZPfy5Vw32k


http://www.youtube.com/watch?v=FrNy4ceK6r0

[DocWalt]

http://i.imgur.com/yeeaoxg.jpg

[green-lantern]

How much did those set you back?

[DocWalt]

Less than the equivalent set of ST suspension.... ;) ($850 delivered) They need one new spring perch and the correct spanner wrench so they don't get wrecked again...

Not too bad for about 5 hours of work. Swapped the new power steering pump and spent some time messing with oil cooler placement. I also cut some new coolant hoses to eliminate the factory heat exchanger.

I can't find any evidence of what happened to this engine. No metal in the oil and coolant looked fine. I pulled the valve cover and everything feels fine...

http://i.imgur.com/mMIctd8.jpg

http://i.imgur.com/9zamgIo.jpg

[DocWalt]

Got my Maximal Performance oil cooler a while back, I put together some mounting stuff today, and made some mods to the radiator support for clearance. Clears everything and the lines that Maximal provided will be plenty long enough. This is essentially the same kit as what Maximal does for the BRZ/FR-S, so it'll be plenty for my GTI :)

http://i.imgur.com/Mz9l0JE.jpg

http://i.imgur.com/jAkuIXT.jpg

http://i.imgur.com/rTRMuTF.jpg

[DocWalt]

I got the K-Sport/Meister camber plates mounted on my KWs. What a pain, the camber plates weren't designed for a 22mm shaft so I had to do a lot of careful filing to open up the shock shaft hole in the camber plate so it would fully seat into the plate. All good now and you'd never notice when they're installed. Not enough material removed to cause any issues with strength either. :) I'm not 100% sure why the camber plate is designed the way it is, you can see that the shock shaft is pretty deep inside the retaining nut, but it's got 4+ spins of engagement which is plenty. A touch weird, but it works.

http://i.imgur.com/SfbkZJh.jpg

[DocWalt]

Still get dicked around with the engine... but I went autocrossing today in the BRZ. I was really off the pace, no idea why. I even went off course, which I'm not too sure I've done before.


http://www.youtube.com/watch?v=pJTwhafsBtM


http://www.youtube.com/watch?v=XuFjcqTkpmw


http://www.youtube.com/watch?v=UiLicZWCUNg


http://www.youtube.com/watch?v=kn98nJoBDqU

[DocWalt]

So... It's arrived! 288* TT Cams degreed into 0* at TDC, 10:1 CR stroker pistons from Eurospec Sport (that's what they claim, I did the math and they're stock compression), ARP rod bolts, diesel crankshaft, P&P head, TT HD valvesprings, Lightweight lifters, ARP undercut head studs, and a LOT of clearancing work in the block. I'll grab a pic of that once I get it in the car and drop the pan to install the windage tray.

I got the pressure plate on (need to buy some brake cleaner to clean it up), all of the sensors, and pretty much everything else that I want to install on the engine itself outside of the car. I want to keep the engine/trans package small so it's easy to maneuver on the way in.

http://i.imgur.com/pmgQ5Dz.jpg

http://i.imgur.com/RfvnGlP.jpg

http://i.imgur.com/aH50wQq.jpg

http://i.imgur.com/iYURoWj.jpg

http://i.imgur.com/RYJfzqd.jpg

http://i.imgur.com/cM5tpBc.jpg

[DocWalt]

The engine is in and all torqued up. Got the intake and exhaust on, and all of the wiring stuff. I need to check the transmission fluid level, install the windage tray and fill the engine up with coolant/oil so I can tighten up the AN lines on the cooler. Then I can throw the front end on. My plan is to fire it up on Saturday afternoon :)

http://i.imgur.com/zYlwQQ7.jpg

http://i.imgur.com/88c71h6.jpg

[DocWalt]

So, yesterday was not a good day. Spent some time this morning before doing mother's day stuff taking apart the new engine...

Both cams look like this. The grooves catch a fingernail. I compared to my old engine that also had bearing material go through cams... These are worse, but look to still be usable since the grooves are in the direction of travel.
http://i.imgur.com/1jqdDyE.jpg

#4 rod bearing:
http://i.imgur.com/m7IAPgN.jpg

#1, #2, and #3 looked about like this. This is #3, the worst of the not trashed bearings.
http://i.imgur.com/pOKPz1Y.jpg

#3's bearing surface:
http://i.imgur.com/9NEYA7K.jpg

I thought I took a pic of #4's bearing surface. It looked reasonably OK and will easily polish up with some oiled 2000 grit sandpaper wrapped all the way around as I've done in the past with good success.

The oil cooler core is pre-filter so it's going to be full of garbage. I'll pull that whole assembly and get it flushed sometime before NG and run cooler-less for now (if it was post filter I'd be tossing it). I ordered some new OEM rod bearings and main bearings. I'll try running it and breaking it in a bit to flush the garbage out of the system (I'm not going to hurt it anymore, so whatever) then replace the oil a few times, then do new bearings again before

[FeaRpb]

So what was at fault that caused this?

[DocWalt]

need to check clearance on #4 (with a bearing set from #1). if that's fine (and I expect it is) I have no clue.

[j2k4]

Damn, Kenny, sorry to hear this...:sad:

[stealthee]

OMG, Kenny killed it.

[MDoe8]

:dejection:

What a bummer!

[DocWalt]

While I'm waiting on news about the engine... I got these to throw my all season tires on so I'm not going to abuse my sticky tires too much.

http://i.imgur.com/etDy9G6.jpg

[Uniuno]

Did they not use assembly lube or something? I don't get how it could destroy itself that fast.

[DocWalt]

It's a long story that I'll type up when I have the 100% confirmation... butttt..... Pistons were meeting valves hard enough to smash the rod bearings, and worse on #4 than any of the other cylinders.

[DocWalt]

These arrived today... http://i.imgur.com/lRyXGew.jpg

[stealthee]

Your car needs to be running in order to use them. :suspect:

[DocWalt]

Things are happening again, got the KW V1s installed in the rear (I'll do the fronts after I get the car running and can get the weight of engine and trans to set the heights properly) along with some Carbotech 1521's (Bobcats for the old school name). I'm hoping the new pads don't glaze and actually clean up the rotors, you can see how terrible the rotors look from the Pagid pads not doing their job. The brake pedal was immediately stiffer with the Carbotech pads, I'm a big fan of their products if you couldn't tell :)

http://i.imgur.com/FqRIPN4.jpg

This is a pic from Pitt Intl. last year. You can see how low the rear of my car sat in comparison to the front. I think the H&R springs were designed to handle the extra weight of the VR6...
http://i.imgur.com/lhHz4I6.jpg

I set the KWs at their maximum recommended height, which resulted in this:
http://i.imgur.com/1eb7fwM.jpg

I'm thinking I may lower the car a tiny bit, depends how the front control arms look after I get the whole thing setup. Looks pretty good though!
http://i.imgur.com/qZ5XUrz.jpg

Even though this is essentially a weekend warrior, I figure I may as well finally install the rear speakers I've had sitting around for a long time. I already ran the wires, so it was an easy install while I had the C-pillar/parcel tray things removed for the shock install. The speakers are just some 4x6 Polks. Nothing special, but I'm hoping it drowns out a bit of the highway drone for the drive to KY.
http://i.imgur.com/EDeBkDB.jpg

[DocWalt]

and engine news... Cam bores may not be perfectly parallel to the head surface, which would explain why the rod bearings were progressively worse from #1 to #4. Now the reason the valves hit the pistons in the first place... The piston's valve relief fly cuts weren't machined square to the wrist pin bore, so the right hand intake valve was a lot closer to the piston (and touching at higher revs) which led to the rod bearings being smashed. Valves are fine, don't know how, but Supertech apparently makes indestructible valves, haha. The machine shop should have caught the pistons touching the valves, since they checked piston to valve clearance at a pretty huge 120 thousandths... On the left hand valves only :(

All of that doesn't explain the strange issue of the cams being scored... The shop is not at all concerned about the scoring, and they're going to polish up the cam journals anyway. They are concerned about why the scoring happened, and why the head is so "sticky" feeling. There was evidence of some metallic crap in the cam journals, but nothing copper based. Must have been crap wiping off of the cams or the head wasn't clean enough. Considering the shop spent a LOT of time cleaning everything even drilling and tapping the oil galleys in the head for some fancy hex plugs, I'm pretty sure it was clean enough.

I'm hearing good things from the shop, so the engine may be back sooner than I was expecting. That should take a lot of stress off trying to get it broken in and in a good state of tune for an inspection and fancy alignment.

[DocWalt]

I decided to open up the old engine today... It looks pretty much like I expected.

Blew the headgasket completely between 3 & 4
http://i.imgur.com/eslqJp3.jpg

Evidence that it was ready to leak between the other cylinders too...
http://i.imgur.com/Qyyyrxd.jpg

Block looks good, checked out fine with straight edge. May need rod bearings replaced, but I'm not sure I want to open that up yet.
http://i.imgur.com/4lqF6GT.jpg

Metal just melted or disintegrated.
http://i.imgur.com/NmjnUkf.jpg

#4 also had this odd damage like the head gasket was overcrushed or something. No idea...
http://i.imgur.com/s25dvPA.jpg

Gump, you were right, the head is a POS :p

[KeithMac]

I found my mk2 handled best with the front suspension set up for level/ horizontal wishbones on Koni coilovers.

Mulling over removing my 16v G60 kit and going over to bike throttle bodies.. Megasquirt is already in so that's half the battle.

[DocWalt]

That's pretty much what I'm aiming for, Keith. I was pretty much at level with the H&R/Bilstein combo, but it was so soft it dove right past that point.

I know somebody that may be VERY interested in the 16v G60 kit if you decide to go ITBs. Shipping may be an issue, but let me know :)

[MDoe8]

Good to see progress.

Those wheels look fantastic!

[KeithMac]

That's pretty much what I'm aiming for, Keith. I was pretty much at level with the H&R/Bilstein combo, but it was so soft it dove right past that point.

I know somebody that may be VERY interested in the 16v G60 kit if you decide to go ITBs. Shipping may be an issue, but let me know :)

Will do, it's the Bahn Brenner front mount alternator version, scirocco inlet manifold, Jabba Stage 4 G60. Need to do something with it rather than letting it languish on the drive.

Will see what summer brings..

Nice to see yours coming back together again!.

Did you get the rod linkage box (02Y) on the Mk2 or did they roll out the cable change (02a) boxes in the US?.

[DocWalt]

We have the rod linkage here. Mine has a few mods done to help the feel, but it still feels like gooey crap. It's good enough to get gears, so oh well.

[KeithMac]

I fitted an upgraded linkage bush kit and it made a big difference, also worth replacing the ball and cup on the bottom of the gear stick assy (have to pull that out through the bottom of the car though..).

[DocWalt]

Already done all of that. I'm back to barely above OEM crappiness, haha. I want to pick up the USRT shift kit, but I don't want to fiddle with getting all of the adjustments right...

[DocWalt]

I went autocrossing with my dad today. He very nearly pipped me when he nailed a great run... but he also nailed a cone :( I had a ton of fun, the Fiesta feels like a slower GTI, but also more stable.

I'll link my dad's runs first, then mine. His fastest would have been the third but he got the cone.


http://www.youtube.com/watch?v=TdXDa0JjAeU


http://www.youtube.com/watch?v=XMc2e2x5wvo


http://www.youtube.com/watch?v=AxmnqDCC1Ho


http://www.youtube.com/watch?v=TcFPB1TrLrA

[DocWalt]

Here's my runs, my fourth run was my fastest, but that's the 5th link as I had a run aborted due to a cone on course.


http://www.youtube.com/watch?v=ygY_Tl8DdF0


http://www.youtube.com/watch?v=-TO_OGmL5hY


http://www.youtube.com/watch?v=cQA9hrh_CbU


http://www.youtube.com/watch?v=sKucGO8T_Ts


http://www.youtube.com/watch?v=VcEjbkFI1C8

[DocWalt]

http://www.youtube.com/watch?v=E3CHf57zwmI

I apologize for the quality of the video... but that's not really the point of the video. :) Also, for those that are interested, 8k RPM ends up at the full line on the gas gauge when using a 7k tach.

[j2k4]

http://www.youtube.com/watch?v=E3CHf57zwmI

I apologize for the quality of the video... but that's not really the point of the video. :) Also, for those that are interested, 8k RPM ends up at the full line on the gas gauge when using a 7k tach.

Yeehaw!

Yer old man's pretty quick, Kenny - think he did you a favor with that cone.

Good rubber on your upshift, too, sounds like you guys dueled to a stand-still. :)