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Thread: Alex's CGT - 7A Swap Prep

  1. #76
    That looks like such a huge project.. really impressive to just see all of the wire..
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  2. #77
    Regular Member alxdgr8 will become famous soon enough
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    Painted the fuel rail and the timing cover in a gunmetal that looks much nicer than the gloss black.

    IMG_20150509_202630235 by Vex Art, on Flickr

    IMG_20150509_202212132 by Vex Art, on Flickr

    New clutch. Ordered a Luk for a 200 20v on the recommendation that it was just a rebadged Sach for $100 less. Looks like the clutch disc is indeed Sachs, but the pressure plate is Luk. Still should do the job just nicely. Had to use the Coupe GT throwout bearing due to the differences in the transmissions. The CGT TOB is slighly different from the AWD 016 trans TOB, but it should work. The 016 version has a slight cup in the mating surface, but it's also plastic where the CGT one is metal.

    IMG_20150512_205438072 by Vex Art, on Flickr

    IMG_20150512_190503982 by Vex Art, on Flickr

    IMG_20150512_201342087 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)

  3. #78
    that engine looks so pretty...
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  4. #79
    Regular Member alxdgr8 will become famous soon enough
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    Box of goodies from Hersh Performance and Racing. Poly engine/trans/subframe mounts.

    IMG_20150517_183243166 by Vex Art, on Flickr

    Engine mounts are in

    IMG_20150517_202528850 by Vex Art, on Flickr

    Trans mount

    IMG_20150517_202519332 by Vex Art, on Flickr

    034 firewall brace to stop the cracking

    IMG_20150517_183049273 by Vex Art, on Flickr

    Installed

    IMG_20150517_191500316 by Vex Art, on Flickr

    And the engine is in!

    IMG_20150517_210318423 by Vex Art, on Flickr

    Need a 20v throttle cable as the 10v one is too long

    IMG_20150517_210448012 by Vex Art, on Flickr
    Last edited by alxdgr8; 2015.05.17 at 21:52 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)

  5. #80
    Regular Member benny_mech will become famous soon enough
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    Sweet!
    “Religion is a defense against the experience of God.”
    — C.G. Jung

  6. #81
    that firewall brace is kind of cool
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  7. #82
    Regular Member alxdgr8 will become famous soon enough
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    Injectors (Bosch 0280155759) and adapters installed. $88 for a set of 5 that were cleaned/tested and come with a 5yr warranty!

    IMG_20150527_201530788 by Vex Art, on Flickr

    Mounted in the fuel rail. I think I want to find some clips to hold the injector adapters into the fuel rail. I'm guessing that with the car N/A, the fuel rail bolts will be plenty, but it's just an extra safety factor. I think most people don't even use the lower injector clips like i did.

    IMG_20150527_203817159 by Vex Art, on Flickr

    New to me radiator installed and shroud painted.

    IMG_20150527_203845117 by Vex Art, on Flickr

    Starting to look more like an engine!

    IMG_20150527_203832815 by Vex Art, on Flickr

    HPR poly subframe bushings installed.

    IMG_20150531_185920753 by Vex Art, on Flickr

    10v brake booster line didn't reach the 20v intake port and the 20v didn't come with a vacuum booster, so....found one off a 1.8T New Beetle at the junkyard that worked perfect! Also got some new OEM-style cloth braided vacuum hose.

    IMG_20150530_145727055 by Vex Art, on Flickr

    More goodies to install. Brass distributor gear and silicone crankcase breather hose.

    IMG_20150529_202217280 by Vex Art, on Flickr

    The cardboard radiator ducting was deteriorated so I made some new ones out of thin aluminum.

    IMG_20150531_213533323 by Vex Art, on Flickr

    IMG_20150602_203651172 by Vex Art, on Flickr

    Got the breaker and terminal lugs to build my battery cables, still waiting on the 1/0 SGX cable to arrive. Also ordered some 4AWG SGT cable for smaller stuff.

    IMG_20150531_221444724 by Vex Art, on Flickr

    Started work on the front coilovers and got the lower perch off. The fronts need new Koni struts, which won't arrive in time for Audi Expo so I'm going to reassemble with the stock struts for now.

    IMG_20150602_210546190 by Vex Art, on Flickr

    IMG_20150602_212201109 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)

  8. #83
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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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    !! wow, looking great!
    -Tyler-

  9. #84
    holy... the car's radiator is on the side?

    what are the injector adapters needed for?
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  10. #85
    Regular Member alxdgr8 will become famous soon enough
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    Quote: Originally Posted by joel View Post
    holy... the car's radiator is on the side?

    what are the injector adapters needed for?
    Yep, there no room in front of the engine.
    Car came OEM with a Hitachi EFI system with very badly designed injectors, the adapers allow you to run much more reliable Bosch injectors.
    -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. #86
    gotcha
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  12. #87
    Regular Member alxdgr8 will become famous soon enough
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    Well the marathon to get the car ready for Audi Expo is over and it won't be there Attempted to start it tonight, but it looks like I've still got some wiring to troubleshoot as it's not triggering the fuel pump. The final nail in the coffin came when I jumpered the fuel pump relay and found a leaking fuel line. I won't be able to get a replacement or build one before next Saturday. The 20v fuel inlet line is leaking at the crimp going to the fuel rail and it's also not sealing correctly with the 10v body fuel line.

    So some updates on the progress thus far...

    A thread restorer kit has been invaluable for this build. The car is super clean since it's been a PNW car it's entire life, but there's still some crust on nuts/bolts so this tool has been great for cleaning them up.
    IMG_20150610_193656628 by Vex Art, on Flickr

    Front coilovers installed
    IMG_20150608_210852191 by Vex Art, on Flickr

    Rears installed
    IMG_20150610_212601162 by Vex Art, on Flickr

    16x7.5 TSW Hock's, tires need replaced so I'll run my ABT's for now
    IMG_20150608_214511994 by Vex Art, on Flickr

    IMG_20150610_212609949 by Vex Art, on Flickr

    NAPA sent me the wrong driver's side axle so only the passenger was replaced. Going to order a rebuild kit for the driver side since it seems to be in pretty good shape minus the boots.
    Undercarriage shot:
    IMG_20150610_215729994 by Vex Art, on Flickr

    Brass distro gear installed with roll-pin:
    IMG_20150613_162142062 by Vex Art, on Flickr

    1/0 SGX battery cables
    IMG_20150610_223014699 by Vex Art, on Flickr

    IMG_20150613_225532453 by Vex Art, on Flickr

    Battery box temp mounted in trunk
    IMG_20150614_242111010 by Vex Art, on Flickr

    Got a 7A throttle cable since the 10v was too long. Sadly, the firewall and gas pedal connections of the B3 chassis are completely different from B2. So, I modified the 7A cable with the B2 firewall and gas pedal connections. Use some thin aluminum tubing to crimp the two together; tested it with quite a bit of weight and it held.
    B3 top, B2 bottom:
    IMG_20150613_142609083 by Vex Art, on Flickr

    Crimped modified cable
    IMG_20150613_173632270 by Vex Art, on Flickr

    Cable was still a little long (I think I need to shorten it on the pedal side), but for the time being I flipped the intake bracket and it works great:
    IMG_20150613_185123077 by Vex Art, on Flickr

    Intake with a simple sheet metal heatshield
    IMG_20150614_242031270 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)

  13. #88
    Regular Member alxdgr8 will become famous soon enough
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    Spent the last few weeks waiting on getting the correct adapter for the fuel line. Ordered the wrong one, then got sent the wrong one twice despite ordering the correct one, finally have the correct one on the way.

    In the mean time I threw the fuel line on with a crush washer and wrong flare adapter and installed the 7A fuel pump relay and it fired right up.

    IMG_20150722_203547307 by Vex Art, on Flickr

    IMG_20150725_203054498 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)

  14. #89
    Regular Member alxdgr8 will become famous soon enough
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    Glamour shots

    P1160021 by Vex Art, on Flickr

    P1010064 by Vex Art, on Flickr

    P1010075 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)

  15. #90
    Regular Member alxdgr8 will become famous soon enough
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    Alright, finally made some progress! Was out of town for work for a few weeks, then some vacation, bought an UrS6 Avant, and a few other things. Countdown is on to BBQ '15....

    Tachomter works. Used the tach signal from the 7A ecu, with a 220 Ohm voltage divider.
    CLICK TO PLAY
    VID_20150905_193037857 by Vex Art, on Flickr

    Converted the gauges to LED. Lots of people haven't had success at this, but I think I figured out a selection that works great. Everything was purchased from superbrightleds.com I'll post up a DIY with all the details.

    IMG_20150902_210406685 by Vex Art, on Flickr

    IMG_20150902_225538347 by Vex Art, on Flickr

    IMG_20150905_150324766 by Vex Art, on Flickr

    Protizmo AILD-1 created by a fellow Porsche enthusiast on Rennlist. This is a high side LED PWD dimmer that auto learns the rheostat. Most of the current PWM dimmers employ a low-side driver that doesn't work with a common ground circuit like a car. To use these dimmers, you'd have to wire a dedicated circuit just for the LED's. This is the only high-side PWM dimmer I've found that allows you to use the OEM rheostat.
    I built a simple wiring harness for it that plugs into the rheostat. Going to make a video of the dimming, but haven't yet.

    IMG_20150905_184600269 by Vex Art, on Flickr

    And the results.
    LED on the left, incandescent on the right.

    IMG_20150905_155319168 by Vex Art, on Flickr

    Very bright, even in a lit shop.

    IMG_20150906_220457022 by Vex Art, on Flickr

    Messed around with fitting some Porsche Cup 1 17x7.5 for future reference. I won't be running these at BBQ. Looks like they'll clear the steering arm and fender.

    IMG_20150906_141701603 by Vex Art, on Flickr

    IMG_20150906_141546109 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)

  16. #91
    Regular Member benny_mech will become famous soon enough
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    Lookin' sweet! Your video on Flickr is private, so I couldn't watch it.
    “Religion is a defense against the experience of God.”
    — C.G. Jung

  17. #92
    Regular Member alxdgr8 will become famous soon enough
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    15 days to go (for the first deadline, 23 until BBQ journey begins).

    The Coupe has always been a WA car, so it didn't get the CEL like CA cars. So, I wanted to add one in order to easily flash codes. This ended up taking a lot longer than I expected, probably spent 8 hours on it trying things. Had to run wiring from the OBD1 ports for power and ground from the 7A IC connector. The CEL gets constant power and is triggered by the ground. This doesn't work well since the CEL in the CGT cluster shares a common ground with everything else. I had to remove the board contact prongs from a dash light and solder the wires directly to it. I had to do this twice since the first time I used an LED. The LED always has power, and even after key off there's low enough resistance in the wire that the LED will continue to glow. So I had to swap in a normal incandescent and this solved that problem.

    Try #1 with the LED, didn't take a pic of the second try.

    IMG_20150917_191628737 by Vex Art, on Flickr

    Working code flashing! (click for video)

    VID_20150919_162104280 by Vex Art, on Flickr

    Never been so happy to see so many warning lights! Still don't have the oil pressure warning light working, but the oil pressure gauge works so that's the most important.

    IMG_20150919_175507782 by Vex Art, on Flickr

    I'm glad I wired up the CEL as it helped me diagnose some bad ISV wiring (forgot to plug in the power supply for it on the relay board). Figured this out after I cleaned the ISV.

    IMG_20150920_174105126_TOP by Vex Art, on Flickr

    Fabbed up an exhaust with what I had. It's not pretty but it'll do the job for now. It's still a little loud, I don't really like the muffler choices (cheap straight through) but it's an unknown SS catback. Cat is hollowed. I'll do a better one done the line, especially since this is mostly 2" right now.

    IMG_20150920_155135883 by Vex Art, on Flickr

    Got the brakes/clutch, cooling system, and power steering filled and bled. Everything feels great.
    Threw the ABT's on the car to roll it around, new tires come tomorrow to put on the TSW's.

    Once I fixed the ISV problem, the car seemed to start and run pretty decent. I need to adjust the idle again after I messed with it troubleshooting the ISV.
    I also think I have faulty plug wires, or at least the coil to distributor one. If I jiggle the coil wire while the car's running it'll die. Also if I turn the wheel while it's idleing it'll die as the power steering pump puts load on it. Dave is sending me some new plug wires, hopefully that fixes the problem.
    Rolled it outside for the first time in over 6 months and took a family picture.

    IMG_20150920_191921490 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. #93
    Regular Member alxdgr8 will become famous soon enough
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    Got the replacement IC for the LED dimmer with new programming specifically for the Audi B2 dimmer (21 ohm). Works great! Does a fade up to the current rheostat setting when powered on. There is a slight flicker when it first turns on, but doesn't bother me. I had Ed at Protizmo also setup the dimmer to completely shut off at the minimum since this is sometimes handy. He's now added this configuration to his website. He should have another batch ready to go in shortly if anyone is interested.

    *Click for video*
    -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)

  19. #94
    Regular Member alxdgr8 will become famous soon enough
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    Status update, 16 days before I leave...

    Quote: Originally Posted by alxdgr8 Still to do:
    -Cleaup wiring, install drivers side lower dash *COMPLETE*
    -Fill/flush powersteering *COMPLETE*
    -Bleed clutch master/slave/brakes *COMPLETE*
    -Fab up exhaust *COMPLETE*
    -Hook up shifter *COMPLETE*
    -Uninstall front suspension to install new Konis *COMPLETE*
    -Uninstall/reinstall rear Konis to adjust them since I don't know what they're currently at *Still Needed*
    -Fill cooling system, warm up, check for leaks *COMPLETE*
    -Mount front bumper *COMPLETE*
    -Wire up and mount H1/H4 headlights *Mounted, need wiring, parts in hand*
    -Mount new tires when they get here later this week. Cleanup the wheels too; sadly won't have time to powdercoat them. *Getting done tomorrow*
    -Test drive and hope for the best! *COMPLETE*
    -Get an alignment. *Scheduled*
    -Reinstall rear seat. *Still Needed*
    -Vacuum interior. *Still Needed*
    -Reseal sunroof. *Still Needed*
    -Troubleshoot cruise control. *Still Needed*
    Have taken it around the block a few times and it's running pretty good. I think I need to try another ISV, mine is still acting a little funny. Also leaking a little bit of oil, but nothing alarming.
    Looks like a car again!

    2015-09-28_12-49-39 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)

  20. #95
    Regular Member alxdgr8 will become famous soon enough
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    Tires mounted and coilovers lowered. Going to drive it to work tomorrow and see how bad the alignment is and find out if it has any issues with 35 miles round trip.

    P1010735 by Vex Art, on Flickr

    P1010745 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)

  21. #96
    Regular Member Helios is on a distinguished road Helios's Avatar
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    Sweet!
    -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

  22. #97
    Regular Member alxdgr8 will become famous soon enough
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    Made it to work just fine, no problems. Cruise control still isn't working, gotta troubleshoot that.
    The combination of coilovers, still loud exhaust, intake, and poly engine/trans mounts make for a really mechanical feeling...I like it. It's like driving my Ducati, but on four wheels.
    -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. #98
    Regular Member alxdgr8 will become famous soon enough
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    Still to do:
    -Cleaup wiring, install drivers side lower dash *COMPLETE*
    -Fill/flush powersteering *COMPLETE*
    -Bleed clutch master/slave/brakes *COMPLETE*
    -Fab up exhaust *COMPLETE*
    -Hook up shifter *COMPLETE*
    -Uninstall front suspension to install new Konis *COMPLETE*
    -Uninstall/reinstall rear Konis to adjust them since I don't know what they're currently at *Rides fine, deemed OK for now*
    -Fill cooling system, warm up, check for leaks *COMPLETE*
    -Mount front bumper *COMPLETE*
    -Wire up and mount H1/H4 headlights *COMPLETE*
    -Mount new tires when they get here later this week. Cleanup the wheels too; sadly won't have time to powdercoat them. *COMPLETE*
    -Test drive and hope for the best! *COMPLETE*
    -Get an alignment. *Scheduled*
    -Reinstall rear seat. *COMPLETE*
    -Vacuum interior. *COMPLETE*
    -Reseal sunroof. *Need to order parts, what I thought would work won't*
    -Troubleshoot cruise control. *Still Needed*

    Built the wiring harness for the new headlight relay's. Didn't take very many pictures sadly. Used a Hella 4-relay enclosure with 2 Bosch relays, 12 AWG SGT wire wrapped with snakeskin, and ceramic H4 connectors.

    IMG_20151003_220156062 by Vex Art, on Flickr

    IMG_20151004_230401517 by Vex Art, on Flickr

    Installed an old Alpine head unit that has an aux input. Also upgraded the rear speakers to a set of old MB Quart 6.5" components I had sitting around. Should've updated the front speakers while I had the dash out, but had more important things to do at the time. Sounds decent for now.

    IMG_20151004_230326280 by Vex Art, on Flickr

    Got the rest of the interior put back together. Installed a toggle into the cubby that's wired to the OBD1 port so I can read codes without jumpering the connectors.

    Flex-sealed the rain tray and radiator cover to cover up some cracks. Forgot to take after pics, I'll do that tonight.
    IMG_20151003_161413351 by Vex Art, on Flickr

    Also gave the car a much needed wash and clay bar. Took over 2 ours to clay the car since there was so much grime on it. Gotta polish and wax it tonight to try and get rid of all the swirl marks.
    It's a good 10 footer for now. I really need to get the dents in the doors fixed in the future, hoping paintless dent repair can work.

    2015-10-05_11-12-40 by Vex Art, on Flickr

    Going to make one more revision to the exhaust to try and cut down on some drone. It's still a bit too loud for 3200 miles of road tripping. Got a few minor things left to do, but otherwise I'm ready for Battle Born!
    -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)

  24. #99
    Regular Member alxdgr8 will become famous soon enough
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    Forgot to plug in the speedo sensor for the cruise control, so I fixed that hoping for the best...no go. Gotta check for vacuum leaks and resolder the CC brain in an attempt to get the cruise working.

    Pics of the "flex-seal" on the rain tray and radiator cover

    IMG_20151006_244254925 by Vex Art, on Flickr

    IMG_20151006_244249484 by Vex Art, on Flickr

    The paint in the HVAC/fusebox tray was all kinda of messed up and was a mix of white and black paint. I first tried painting it white, but it didn't match so I got a can of black automotive enamel spray paint and did it in that. I think it blends nicely with the black fusebox and rain cover. Looks much better than the chipped white and black paint.

    IMG_20151005_221206208 by Vex Art, on Flickr

    IMG_20151006_241155224_HDR by Vex Art, on Flickr

    Had a scare at the auto parts store, came out to a pool of water under my car. Thankfully it was just a split in the radiator to overflow hose and was easily replaced.

    Brought out the heavy machinery to polish the car and it cleaned up pretty well. However it was taking FOREVER to get all the swirls out so I only got about half of the roof done right. I quickly went over the rest of the car to at least get it decently shiny. I'll have to go back some other time and do a full paint correction on it...or pay someone to do it. I spent almost 5 hours just on what I did last night.

    IMG_20151006_241247067 by Vex Art, on Flickr

    Still some swirls evident in the hood.

    IMG_20151006_241257067_HDR 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. #100
    Regular Member Helios is on a distinguished road Helios's Avatar
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    Car is gorgeous!
    -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

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