Working in the heat!

[dswalterwi at gmail.com (Don Walter)]

Here is my Custom Linkages:
http://scirocco.dyn.dhs.org/vw/list/Don_Walter/Shift%20Linkages/


On 8/7/06, C Boyko <roccit_53@scirocco.cs.uoguelph.ca> wrote:
>
> On 8:54 am 08/07/06 "Dan Bubb" <jdbubb@verizon.net> wrote:
> > Spent Saturday replacing the tie rod ends and aligning my Audi A4.
> > The original tie rod ends, amazingly, have a rubber sleeve in the
> > middle that lets them stretch and contract a small amount, I guess to
> > absorb road shocks, but now with the new solid parts, the car seems a
> > lot less wandery. That was definitely a worthwhile project.
> >
> > Sunday my nephew came over and for some reason all else stops when he
> > shows up. Might have something to do with him owning the only turbo
> > Scirocco in the family! :^( When last dynoed the car had made
> > 208lb-ft @ 3900 where the boost was spiking to 13 psi and 177 whp @
> > 5400 with boost at 10psi. Basically the torque just drops off in a
> > straight line and we've been wondering where the restriction is that's
> > causing the loss of top end. Mike's been slowly improving his
> > Megasquirt maps based on datalogs and by leaning out the top end to
> > match the lower VE up there to get a consistent AFR and playing with
> > the advance he's been picking up a couple HP here and there (or so our
> > butt dynos suspect!)
> >
> > Anyway his car sounded really bad with an exhaust leak that
> > coincidentally seemed to have improved the top end performance of his
> > car? A quick inspection revealed the downpipe was cracked. Turns out it
> > was nearly broken off at the turbo flange and also had a series of
> > little separate cracks in the same area! Well, I don't feel too bad
> > since this was the first downpipe I'd ever made, probably the one I
> > learned to weld stainless steel on, it is totally unbraced and had
> > lasted over 4 years! A little clean up and some bead blasting to remove
> > any carbon in the area so it didn't contaminate the weld and I welded
> > it all up as good as new although it did look a little like a
> > Frankenstein downpipe with all the little weld beads running this way
> > and that. While I was welding that up Mike was playing around with
> > throttle bodies and found out that the bigger A2 TB would mate up
> > sufficiently well to the IC pipe that was shaped to match the small TB.
> > So, we changed that out while we were at it. Recall that he's using MAP
> > based accel enrichment so we're just using regular TB's without TPS, so
> > that was an easy swap. Mike took the car for a test drive and his butt
> > dyno indicated the top had picked up yet more power despite us welding
> > up the power inducing exhaust leak. ;^)
> >
> > The last change was an effort to kill two birds with one stone. I had
> > welded a tail pipe and hanger to a 2.5" Borla muffler I had laying
> > around for my 16V to replace the Flowmaster that sounded like ass.
> > Well, turns out the Borla didn't sound too good either and was too loud
> > for my tastes. I figured we'd swap the Dynomax on my nephew's car for
> > the cobbled up Borla on my 16V. Pulling the Borla off the 16V wasn't
> > too bad since I'd been careful to not tighten the clamp too much.
> > Pulling the Dynomax off my nephew's car was even easier since it was an
> > old old muffler and I just torched it off! ;^) Well, that's when I
> > discovered that those bastards at VW changed the location of the
> > exhaust exit from the body and the placement of the rear most hanger
> > between the 8V and the 16V! Balls! So another hour later I'd managed to
> > reshape the tailpipe and move the hanger. The 16V will have to wait for
> > its muffler!
> >
> > So, his car is a touch louder with a nice rich tone to it and it
> > seems we managed to pick up yet a little more power. Might have even
> > made enough of a difference that a little retuning of the Megasquirt is
> > in order! Another pretty successful project and Mike did all the
> > wrenching! ;^) Did I mention this car is just a kick in the ass to
> > drive??
> >
> > I also managed to drain the tank and replace the crimped tank to pump
> > hose on the 81 I've been working on. That 2 year old gas smelled so bad
> > it almost made me puke!
> >
> > So, what have you all been up to?
> > Dan
>
> Well Holy cow, you guys are all doing great things, first Winchell and
> Jules with that gas tank, now that! I, as usual, was queen of the
> piddly-ass procedures this weekend.  (some of which I've already posted
> about)
> Headache (16V): The red lens in the hatch light had slid, it's back in
> place, slid again, must need adhesive, removed the steering wheel to
> properly attach the lever that activates the high/low switch, relocated
> the
> brown ignition grounds back to the battery terminal from their previous
> relocation to a common ground connection, checked and reinstalled the coil
> wires (small ones), new cap and rotor, test resistance of plug wires, and
> the biggest job was the installation of a new shifter shaft bushing
> (4crawler) and the ever popular Scott Rose solid shift linkage (with
> virtual tech support from Mark and Drew, I managed to bust a bolt)  :)
> Yeah, I was worried about adjustment, but I have all the gears, and it'll
> take a while to get used to, (I think I need to go for another drive :)) I
> keep thinking it can't be in gear, because throw is so short and so firm.
> But nope, it's there. It's VERY un-A1 like in it's firmness, delightful! I
> imagine the Scott Williams version is similar, as Scott Rose doesn't do
> them anymore. Do those joints need any sort of lube? Test drove that this
> morning, right before more practice driving the mighty ARGO in the
> bush(our
> little yellow amphibian)
>
> Klaus: Yet another crack at proper washers for the tops of the Koni
> Yellows, not sure why this has taken me so long to hash out, you can't
> just
> reuse what came out, and my latest replacements have just not suited me
> well enough. He should have a 4crawler solid shifter by nightfall. And as
> usual, there are a bunch of piddly ass wiring concerns to clean up (wiring
> for city lights/get blower fan working AGAIN, etc...)
>
> Bug: Front pads and rotors, oil change. I'd been procrastinating something
> awful on that job, it went fine.
>
> Cabby: It'll be getting a new shifter shaft bushing too (this is the one
> in
> the bracket on the frame), and then the whole lot need baths.
>
> Ed Effinger's "S": I offered technical support (okay, beer) as he and his
> son installed a new bumper.
>
> Other: Trying to find some twisty roads for Track Day cruising (not so
> successful), and a trip to the in-law's cottage.
>
> Hey, you asked!
> Cathy
>
>
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-- 
Don Walter - Waukesha, WI
1986 8V Black Scirocco (Daily Driver)
1984 8V Audi 4000s (RIP 2/14/2006)
1986 2.0L 16V TEC 2 Black Scirocco (see progress at
http://www.cardomain.com/memberpage/708939)
1986 2L 16V Toronado Red Scirocco (Ben's Car)
1988 1.8 16V Toronado Red Scirocco (sold on 3/29/04)
1984 1.8 8V Pewter Scirocco (sold years ago)
1971 Karman Ghia (sold)
1969 Karman Ghia (sold)
1969 Beetle (sold)