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Author: Subject:  hellVWrx.......EJ20 notch
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posted on March 26th, 2008 at 02:10 PM



Quote:
harden up princess


^ :lol:

loving my stock NA motor now. you can keep your haltech and turbo if it's that much stress. :spin:




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posted on March 31st, 2008 at 06:02 PM



yeah, all for a laugh guys :fakesniff:.....you may come to realize all the pictures will provide me a reliable, accesable reference to connections etc, should disaster strike and i loose my way;)

trailer plugs would be a nice addition, but it won't be me cuting into those looms:no:

..... the bench full of removed bits and pieces.....

http://i31.photobucket.com/albums/c365/dumone/31032008003Medium.jpg

........job done!


http://i31.photobucket.com/albums/c365/dumone/01042008001Medium.jpg


http://i31.photobucket.com/albums/c365/dumone/31032008001Medium.jpg

"why did i get this job:!:..".......... oh that's right, i fried the clutch :smilegrin:

http://i31.photobucket.com/albums/c365/dumone/31032008005Medium.jpg

flywheel will be removed and "ground"..........to remove hardened hot spots and uneven surface.

http://i31.photobucket.com/albums/c365/dumone/31032008008Medium.jpg

we estimated the standard 228mm pressure plate and clutch had done only two hours work:crazy:.........but that's solid HARD work! (several years of racing)........very sticky tyres, tall 1st gear, shirt loads of torque + horsepower and not enough clamp force, combined with a total lack of mechanical sympathy........results in a little bit of heat :lol: :post:

http://i31.photobucket.com/albums/c365/dumone/31032008004Medium.jpg

undoubtedly the replacement will last much longer........


http://i31.photobucket.com/albums/c365/dumone/31032008006Medium.jpg


clamp force will be over three times as much on previous set up...........

http://i31.photobucket.com/albums/c365/dumone/31032008007Medium.jpg

that's life in the hellfast lane :yes:
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posted on April 1st, 2008 at 05:45 PM



well, that was easy!.......

just undo the six bolts and off the flywheel comes........no 8 dowels and interferance fits and pullers to contend with :no:

i'm starting to dig this subie stuff!

flywheel has survived the ordeal ok and resurfacing will be fine

http://i31.photobucket.com/albums/c365/dumone/01042008002Medium.jpg

took some measurments of the new clutch and pressure plate to compare to the old set up..........flywheel will be ground to provide maximum clamp force by adjusting pressure plate height relative to the clutch plate surface
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posted on April 1st, 2008 at 05:52 PM



Hi

Kennedy make nice stuff, I just got my G50 stuff today from them. So you were running a stock 228 pressure plate with the puk clutch?

Steve
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posted on April 1st, 2008 at 06:23 PM



yeah stocka Steve, never worked........suffering from slip from day one

the puck clutch injested so much heat it is warped very badly and has a build up of metal that came off the pressure plate on the pads. closer inspection of the pressure plate sees gourges 5mm deep!..... we knew it would need replacement and just tried to get it down the track for the spectacle:rolleyes:..........i'm very suprised the flywheel has survived

i'm looking for the dyno sheets for the motor.......new set up is good for up to 500H.P so should be A.O.K

nice to meet you at Oran Park by the way
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posted on April 1st, 2008 at 08:31 PM



Hi

Nice to talk to you as well. I'm hoping for about 260 - 280 hp at the wheels, 500 should be insane.

Steve
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posted on April 1st, 2008 at 08:51 PM



o i see..........no, new clutch is rated to 500hp..........

.... engine currently makes 260hp at the wheels and will stay at that for the moment.........
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posted on April 2nd, 2008 at 01:16 PM



I too pulled my motor out last night. Only took 2 hrs. I guess I've had a bit more practice than you. :td:

BTW, love those EFI ida manifolds on the bench there. must be time to install them on something don't you think? ;) [pete the broken record] :smilegrin:




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posted on April 8th, 2008 at 09:03 PM



oki doki....

got the flywheel done. looks heaps better! you may be able to see the swirl pattern from the grinding. checkout the operational surface area provided by the 228mm surface:punk:

you can see the lip near the ring gear (pressure plate seat)
is also ground to keep the height correct.

http://i31.photobucket.com/albums/c365/dumone/08042008001Medium.jpg

further more to the plate seat being ground the matching amount, it had more taken to account for the thinner pads on the new clutch (opposed to standard plate) and also extra to lower the plate down onto the clutch to get even more "clamp".........

with the pressure plate sitting "relaxed" you can see the fingers of the diaphram rising up to the center........


http://i31.photobucket.com/albums/c365/dumone/08042008002Medium.jpg

now with the plate bolted down, the fingers should still be ever so slightly higher in the middle compared to their outer diameter mounting points..............this is a great indicator that the pressure plate installed height is good ... maximum clamping force with minimum pedal pressure:ninja:

http://i31.photobucket.com/albums/c365/dumone/08042008003Medium.jpg
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posted on May 13th, 2008 at 08:57 PM



ooorkay, so i've been quietly achieving progress on this machine, with an aim of just having it in storage , "race ready", for whenever the opportunity arises............

with the flywheel refitted and new clutch in place, the motor was ready to go back in. the bellhousing was cleaned up, necessary's greased (throw out bearing pivots, guide etc) and new thrust bearing (german) installed.

the standard liberty pipe from turbo to intercooler was long since blown apart, repaired track side, but never replaced. there was no way i could leave it. so a few options were sorted, as it's nice to arrive at race meets far from home with spares at hand...........

http://i31.photobucket.com/albums/c365/dumone/P1010745Medium.jpg

to avoid reinventing the wheel at this point, it has gone back together as it was previosly run. the samco model specific hose (wrx) will allow the use of standard recirulatory style blow off valve.

in the future, we have the option of going to a aftermarket BOV which can be plumbed into either the stainless "up" pipe or the one from the intercooler to T.B

http://i31.photobucket.com/albums/c365/dumone/P1010748Medium.jpg

so here is where i'm at now..............note the "workshop manual" taped to the back window:lol: a picture says a thousand words:!:............and people wonder why i do boring threads with too many pictures, but for sure they come in mighty handy:dork:


http://i31.photobucket.com/albums/c365/dumone/P1010747Medium.jpg

the hands on experience has been great. i now understand all of the engines components and have spotted some room for small improvements with routing of fuel lines etc.............might even consider doing a subie conversion for myself down the track
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posted on May 13th, 2008 at 09:22 PM



I spot those manifolds too!!!

Daimo, you gotta put em on something.!!!




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posted on May 13th, 2008 at 10:12 PM



o.k
:cool:


http://i31.photobucket.com/albums/c365/dumone/P1000259Small.jpg


they're the ones that were on the chop top Matt?

the butterfly tops (black with sassy exhaust pipe rams) of yours are about to come back into use
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posted on May 13th, 2008 at 10:30 PM



bloody idiot:crazy:....looks goodly m8
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posted on May 13th, 2008 at 10:35 PM



the butterfly tops (black with sassy exhaust pipe rams) of yours are about to come back into use

Thats the ones !
They have been around.




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posted on May 20th, 2008 at 09:48 PM



RUNNING AGAIN

soo basically it all went back together fine. a couple of re arangments because of the new pipes, but nothing spectacular


http://i31.photobucket.com/albums/c365/dumone/20052008Medium.jpg

went to start it and no fuel pressure at the engine. so the process of elimination lead us to the primary efi fuel pump which was seized probably due to "gumming" of residue fuel after the last run..........anyways got that sorted (not easy) and so it was time to fire up.

the engine sounds quite nasty on the warm up fuel curve from the computer, as soon as the temp reaches 50' it changes completely.

anyways, try this link for a video as i do the run around looking for leaks and noises having just got it fired up for the first time in 18 months.................damn sound has got me amped now i'm pretty chuffed with the results!

http://i31.photobucket.com/albums/c365/dumone/th_20052008.jpg
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posted on May 20th, 2008 at 10:01 PM



Daimo that sounds wicked. We need to see more.....like driving would be good....:tu:



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posted on May 20th, 2008 at 10:33 PM



yeah, it's ooorsum hey.

yes, should have some paddock action to check the new clutch works on Saturday (although it went into gear fine in the shed but no time left so fingers crossed)........and hopefully hillclimb 1st June followed by test and tune for the entre following day, then fingers crossed Grafton hillclimb with the other VW crews............

for now "hear's" :dork: another;

http://i31.photobucket.com/albums/c365/dumone/th_20052008001.jpg
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posted on May 21st, 2008 at 09:07 AM



Hey Daimo, incase you didn't notice, there's an onion on your throtle cable !!!



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posted on May 21st, 2008 at 09:18 AM



Quote:
Originally posted by matberry
Hey Daimo, incase you didn't notice, there's an onion on your throtle cable !!!


I thought I saw wood chips on the ground
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posted on May 21st, 2008 at 09:36 AM



Hope to see you at grafton then..... me entrys sent off this week. Looks like the VW's will be out in force for this event.



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posted on May 21st, 2008 at 09:38 PM



Sounds great:tu:



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posted on May 22nd, 2008 at 08:18 AM



Quote:
Originally posted by matberry
Hey Daimo, incase you didn't notice, there's an onion on your throtle cable !!!


Ah you old dogs keep on falling out of the wood work




Don't let body work get in the way of real suspension travel
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posted on May 22nd, 2008 at 08:20 AM



As opposed to you young fellas falling out of your prams:lol:



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posted on May 22nd, 2008 at 08:23 AM



whaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa



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posted on May 22nd, 2008 at 08:48 AM



I used to run my brick (mini) at Grafton hill Climb many moons ago, dam good little hillclimb track for a mini :-)
Gota love that fist corner hey? :-) & the "Flip-Flop" nearly got me on my first ever run there, but i nailed every run after that :-)

i`ll be back there soon, i`m building some new toys to play with on the hillclimb scene , Yammy R1 powered special & a fastback twin cam turbo injected mini

I might even enter the duel cab kombi foir a laugh too :-)

good work & hope to see you there one day
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posted on May 22nd, 2008 at 03:30 PM



bumped back



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posted on May 22nd, 2008 at 10:45 PM



well it's actually the artist formerly known as the "onion"......

spending so much time in the woodwork he's now the "Lumber Jeff"
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posted on June 16th, 2008 at 06:50 PM



why they let us put these donks in our road regoed cars i will never know:dork:...........check out the speedo needle after a tickle on the go pedal, on dirt with no traction and barely getting into the engines sweet area!

sorry about the crappy vid quality, kinda hard to hold and grab opposite lock one handed:crazy:..........will get some better footage (on a real camera) next week when we get the "navigators" seat mounted in prep for joy rides at VALLA SPECTACULAR LAP DASH:lol:

http://i31.photobucket.com/albums/c365/dumone/th_16062008.jpg
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posted on June 16th, 2008 at 08:25 PM



not bad! still think mind sounded bett:lol:er
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posted on June 17th, 2008 at 10:08 AM



looks to me like you need to Baja that notch :yes:



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