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Thread: Alex's CGT - 7A Swap Prep

  1. #51
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    twardnw is just really nice twardnw is just really nice twardnw is just really nice twardnw is just really nice twardnw's Avatar
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    Yeah, that's a really handy link!
    -Tyler-

  2. #52
    Regular Member Helios is on a distinguished road Helios's Avatar
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    Bookmarked. Thanks for sharing!
    -Chris S.

    "If they ain't a little too wide, they ain't wide enough!"
    '76 Mk1 / '86 Rocco / '87 XR4Ti / '93.5 SLC / '94 SVT / '95 RS / '03 GC Limited

  3. #53
    Regular Member alxdgr8 will become famous soon enough
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    Armed with some light reading...

    IMG_20150402_193223961 by alxdgr8, on Flickr

    I started a first of a series of several date nights with the wiring harness. A glass of tasty porter is a requirement!

    IMG_20150402_201020614 by alxdgr8, on Flickr

    Progress is immanent! Labeling all connectors on both the engine and fusebox side. Got about halfway with the engine side harness tonight.

    IMG_20150402_230629141 by alxdgr8, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  4. #54
    A Somebody Mr.Nobody is a jewel in the rough Mr.Nobody is a jewel in the rough Mr.Nobody is a jewel in the rough Mr.Nobody's Avatar
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    Looks like fun!

  5. #55
    that's some serious work... wow
    tell all of your local car enthusiast friends where the best place is to meet other local enthusiasts!
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  6. #56
    Regular Member alxdgr8 will become famous soon enough
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    Harness is 100% labeled on the engine side. Not entirely confident on the interior side, I'm hoping things make more sense when I pull out 10v harness. I plan on pulling the CGT into the shop this week to start tearing out the motor!
    Working in the aviation industry, some of the wiring OCD wears off on you. Most of the sticky fabric tape was falling off, so I used the 2nd best wiring invention (after Scotch 70/self-fusing silicone tape), lock-stitch...also known as lacing tape (http://en.wikipedia.org/wiki/Cable_lacing" onclick="window.open(this.href);return false. It's wax coated fabric cord that's used for tieing wire bundles. Helps clean up the wiring a lot, and much better than conventional tape or zip ties.

    IMG_20150405_214316849 by alxdgr8, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  7. #57
    never heard of.. or seen (?).. cable lacing
    tell all of your local car enthusiast friends where the best place is to meet other local enthusiasts!
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  8. #58
    Regular Member alxdgr8 will become famous soon enough
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    Say so long to the 10v! Car came into the shop for surgery Saturday night.

    IMG_20150411_215237621 by alxdgr8, on Flickr

    Few hours later and the drivetrain was out!

    IMG_20150412_024544582 by alxdgr8, on Flickr

    IMG_20150412_032217032 by alxdgr8, on Flickr

    So much grime!

    IMG_20150412_205031439 by alxdgr8, on Flickr

    Started round 1 of cleaning, a few more to go. My OCD is really starting to show.

    IMG_20150412_223014541 by alxdgr8, on Flickr

    IMG_20150412_223000718 by alxdgr8, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  9. #59
    Regular Member Helios is on a distinguished road Helios's Avatar
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    Boy the lift sure looks like it makes dropping a motor out cake.
    -Chris S.

    "If they ain't a little too wide, they ain't wide enough!"
    '76 Mk1 / '86 Rocco / '87 XR4Ti / '93.5 SLC / '94 SVT / '95 RS / '03 GC Limited

  10. #60
    Regular Member alxdgr8 will become famous soon enough
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    Quote: Originally Posted by Helios View Post
    Boy the lift sure looks like it makes dropping a motor out cake.
    Indeed, engine was out in under 4hrs after pulling it into the garage.
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  11. #61
    Regular Member alxdgr8 will become famous soon enough
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    Battery box was rusty, so it was the perfect reason to cut it out and relocate the battery to the trunk. Going to get a spraycan or two of Alpine White to touch up this and a few other scratches in the engine bay.

    IMG_20150413_234537141 by alxdgr8, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  12. #62
    Regular Member alxdgr8 will become famous soon enough
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    Trans after a degrease and pressure wash, not as clean as I would like but it'll do. Gotta stay on schedule!

    IMG_20150414_204432099 by alxdgr8, on Flickr

    Gotta love PNW cars. Can you believe this car did 200k miles in 15 years and then sat for over 10 more? Subframe and suspension cleaned right up with degreaser and pressure washer, I didn't even scrub them.

    IMG_20150414_192709017 by alxdgr8, on Flickr

    Once again, the engine bay isn't as clean as my OCD would like, but it'll be good enough. Only way I could get it cleaner is to bring the pressure washer inside and make a mess...or put the suspension back on and roll it out, but once again there are other priorities. Going to pick up some custom spray paint cans from NAPA tomorrow to go over some deep scratches and the battery box welds. Also need to try and remove the adhesive on the passenger fender, hopefully I don't have to sand it and paint it.

    IMG_20150414_204333120 by alxdgr8, on Flickr

    IMG_20150414_204340134 by alxdgr8, on Flickr

    IMG_20150414_204527567 by alxdgr8, on Flickr

    IMG_20150414_204520368 by alxdgr8, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  13. #63
    Regular Member benny_mech will become famous soon enough
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    Your garage floor looks like a superfund site!
    “Religion is a defense against the experience of God.”
    — C.G. Jung

  14. #64
    Regular Member alxdgr8 will become famous soon enough
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    Quote: Originally Posted by benny_mech View Post
    Your garage floor looks like a superfund site!
    Yeah, it's going to need a good cleaning after this. I've been shop vac'ing it up every night. I might as well bring the pressure washer into the garage and spray the engine bay since I've already made a mess.
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  15. #65
    Regular Member alxdgr8 will become famous soon enough
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    Primered and rattle canned the spots where the battery tray was ground off and some other scratches. Got rid of the surface rust spot on the hood too. Paint matched pretty well with a small test area, but with the large area it obviously doesn't. The engine bay itself is about 10 shades of white since a lot of it has yellowed, so I'm not sure there's anything I can do about it. Maybe it'll look better with the engine in it, or maybe I should spray the whole engine bay.

    IMG_20150418_220845638 by alxdgr8, on Flickr

    IMG_20150418_222256307 by alxdgr8, on Flickr

    IMG_20150418_231451552 by alxdgr8, on Flickr

    IMG_20150418_234356457 by alxdgr8, on Flickr
    Last edited by alxdgr8; 2015.04.19 at 12:58 PM.
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  16. #66
    Regular Member alxdgr8 will become famous soon enough
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    As I was warned, it's pretty much impossible to ceramic coat the 'bag-o-snakes' header. So knowing that it was going to turn out shitty, I sprayed it extra heavy to reach all of the nooks and crannies which lead to it turning out shitty. Oh well, it'll do for now and I'm sure it'll start flaking off after a few miles.
    Also hacked up the heatshield to show off the not-so-beautiful header.

    IMG_20150425_214513840 by Vex Art, on Flickr

    IMG_20150425_214439275 by Vex Art, on Flickr

    Rattle canned the belt cover and I think I'm going to redo it in matte. The gloss black is just a bit too much and doesn't match the valve cover very well.

    IMG_20150425_214645439 by Vex Art, on Flickr

    Iroz Motorsport billet goodness in the form of a power steering adapter.

    IMG_20150425_224830931 by Vex Art, on Flickr

    More shiny parts. Decided I should try and mount the 10v AC stuff on the 20v engine in case I can get it working again. Don't have it all together yet, but I think it'll work just fine.

    IMG_20150425_214831301 by Vex Art, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  17. #67
    Regular Member alxdgr8 will become famous soon enough
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    10v AC compressor and lines are mounted on the engine now. It's missing the lower rear bracket as the 10v doesn't fit due to the oil filter housing and the 20v one sits an inch or two too low. Should be fine with the other 3 attachment points though. If not, I'll fab up a bracket down the road.

    IMG_20150426_172726361 by Vex Art, on Flickr

    Lines clear everything just fine. Probably going to fab up a heat shield or wrap them in fire sleeve.

    IMG_20150426_185028700 by Vex Art, on Flickr

    20v doesn't have the mount for the AC line 'hook', but it fit perfectly at the end of the alternator adjustment bracket.

    IMG_20150426_185048311 by Vex Art, on Flickr

    The 10v PS pump adapter doesn't allow you to run the 20v engine hook. Chopped off a small bit and drilled a new hole and it fits just fine. It's a little taller now, but hopefully it clears the hood.

    IMG_20150426_175448979 by Vex Art, on Flickr

    Painted the PS and crank pulley so they didn't look so crusty.

    IMG_20150426_221513570 by Vex Art, on Flickr

    Installed one side of the Jamex strut bar with Mance solid strut mounts. Looking at it now since I deleted the battery box, I could actually run a straight rod between the strut towers. This would allow me to have a much more effective strut bar than the curved Jamex piece. I might just install as is and then change it later.

    IMG_20150426_224951504 by Vex Art, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  18. #68
    Regular Member Helios is on a distinguished road Helios's Avatar
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    Yeah, definitely a semi-gloss black on the timing cover. It's coming together nicely.
    -Chris S.

    "If they ain't a little too wide, they ain't wide enough!"
    '76 Mk1 / '86 Rocco / '87 XR4Ti / '93.5 SLC / '94 SVT / '95 RS / '03 GC Limited

  19. #69
    Thought more about painting the rest of the engine bay? It does seem like you may as well with almost everything out of it.

    The engine looks so good with everything being out together. I especially love the valve cover and intake manifold
    tell all of your local car enthusiast friends where the best place is to meet other local enthusiasts!
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  20. #70
    Regular Member alxdgr8 will become famous soon enough
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    Quote: Originally Posted by joel View Post
    Thought more about painting the rest of the engine bay? It does seem like you may as well with almost everything out of it.

    The engine looks so good with everything being out together. I especially love the valve cover and intake manifold
    I don't have the time to pull the rest of the wiring/brake master/steering rack/etc that would be required to paint the bay. Marching towards a deadline for Audi Expo in less than 8 weeks! And even then it probably wouldn't match well. I've gotten it pretty decent so far and once the engine bay is full of an engine and everything else, I don't think the blemishes will be very noticeable.
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  21. #71
    Regular Member alxdgr8 will become famous soon enough
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    Got the other strut mount drilled and the brace mounted.

    IMG_20150427_231209726 by Vex Art, on Flickr

    Also pulled the dash and heatercore in prep for the wiring.

    IMG_20150427_232739988 by Vex Art, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  22. #72
    Regular Member alxdgr8 will become famous soon enough
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    Fresh 3B flywheel, still need to order a clutch. Also waiting on my 1.8T rear main seal to come in before this will go on.

    IMG_20150428_210613856 by Vex Art, on Flickr

    My new toy for $100 complimentary of an Ebay auction (cosigned by my company). Sun/Snap-On DGA1000 exhaust gas analyzer. Auction listings said it had a keyboard error so I figured I might need a new one. Silly idiots didn't plug it in that's why! Plugged it in and it powers up and operates perfectly. Hell even the IR remote and printer works! Should work great for troubleshooting CIS on the Merc and for getting VEMS to pass emissions on the 90 (so I don't have to keep getting re-tested every few days until it passes).

    IMG_20150428_211437401 by Vex Art, on Flickr

    IMG_20150428_211839363 by Vex Art, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  23. #73
    gosh... that's quite the tool to have in a home garage
    tell all of your local car enthusiast friends where the best place is to meet other local enthusiasts!
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  24. #74
    Regular Member alxdgr8 will become famous soon enough
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    Got both of the old wiring harnesses out, time to put the new one in!

    IMG_20150503_201954101 by Vex Art, on Flickr

    Copper exhaust manifold nuts

    IMG_20150503_172830930 by Vex Art, on Flickr

    New pilot bearing and 1.8t rear main seal installed (oil pan doesn't have to come off like I've seen mentioned)

    IMG_20150503_184517740 by Vex Art, on Flickr

    New PS reservoir filter vs old one

    IMG_20150503_175916316 by Vex Art, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

  25. #75
    Regular Member alxdgr8 will become famous soon enough
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    New engine harness is routed through the firewall (what a pain!). Also found some cracking around the clutch master cylinder, going to order the firewall brace from 034. Still working on figuring out where everything hooks up and what isn't used.

    IMG_20150506_215424059 by Vex Art, on Flickr

    New clutch master and slave

    IMG_20150506_220748271 by Vex Art, on Flickr

    Didn't like the gloss black on the timing belt cover, so I redid it in a gunmetal. PS pump cover and fuel rail are done in the same.

    IMG_20150506_214941497 by Vex Art, on Flickr

    With the 093 trans, you have to modify the bellhousing to accept the timing/reference sensors. The 016 trans in 4kq apparently has this, but not the 093 on the CGT. Easy fix with the angle grinder.

    IMG_20150506_172916172 by Vex Art, on Flickr

    Clearanced

    IMG_20150506_175821700 by Vex Art, on Flickr

    Sensor clear just fine

    IMG_20150506_175955783 by Vex Art, on Flickr

    The horror of trying to integrate two different wiring harnesses. I may be overdoing it trying to get all of the dash warning lights to still function. The wiper motor and spray pump definitely need integrated, possibly more.

    IMG_20150505_230029368 by Vex Art, on Flickr
    -Alex @vexartmedia-
    '03 Audi S8 (Avus/Oxblood - DD)
    '92 Porsche 968 (VW 07k 2.5T swap in the works) --- '86 Audi Coupe GT (2.3L 20v swap) ---'83 Audi UrQuattro (2.2L 20vt swap in progress)

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