My Audi project

[Jehannum]

A guy has an clutch again.



Not pictured: the tears, swears, and back pain from fitting the pin blindly through the pedal and clevis, or the additional finger pain, swears, and additional disassembly of the HVAC running across the bottom of the dash so I could fit my fat hands up in there and get the pin retainer on.

I'm a bit glad I pulled the manual down from the shelf, because I wouldn't have known that it's supposed to be 109.5mm from the mounting flange to the center of the hole for the pin in the clevis.

Followed that up with a gin and tonic.

 

[Jehannum]

Made a replacement for the plastic adjuster on my passenger side headlight. It disappeared some time ago.

New one's made from some aluminum round bar that I shoved in the lathe. It's knurled, edges chamfered, and the shoulder fits down in where the original plastic gear fit.



Fits like a glove.

 

[Xti04]

Couldnt 3d print one with your feet?

 

[Jehannum]

So, I've been chasing 100C+ temperatures all summer. The conventional 'wisdom' at the forums was to put a 70C thermostat in. The lower temperature thermostat did exactly what I thought it would: lowered the minimum operating temperature. However, it didn't lower the maximum operating temperature, so I decided to go harder after it.

First up: new radiator.



Second thing I did was put an 80C thermostat in, because I wasn't comfortable with 70C being the operating temperature in the winter.

Then I pulled out the Golf R/SQ5 aux radiator I bought some time ago and made a mount for it with an 8" Derale fan. I added some helicoils to the pin fits on the bottom of the radiator so I could have some M5 fasteners positively attaching it to the mount.



I need to make one more mounting strap, for the back, and add another 90° elbow so that I don't kink the hose.



The wiring will come off the solid state relay on the other fender well, and it'll run the old after-run coolant pump (which I've swapped for a C5 unit that is beefier internally). The Derale fan runs 4.8A, and the pump pulls between 1 and 2A, and I have a spare 20A slot, so I should be good.

 

[CapriMikeC]

The last pic doesn't have your foot in it for reference.

 

[Jehannum]

I got the frame and fan installed, got the first iteration of plumbing set up, drove it around the block and found some leaks, addressed the leaks.



It's still sitting out on the ramps, I'm going to change my approach on the plumbing with some 90 degree silicone elbows that run out to the frame rail and join the inlet of the pump and outlet to the main radiator. Might drive it to work tomorrow, might play it safe instead, since I spent a shitload of money on that engine.

Still have not done the wiring, I ran out of time and steam today.

Though it wasn't a fair test, as it wasn't an absolute burner of a day outside, I did drive it around the block which involved a 2 mile fairly steep uphill pull, and the temperature did not exceed 95°C.

 

[zimman]

This is me driving my 100 in Germany and a little too fast for the local police. Ugliest car I have ever seen but 125mph all day on the Autobahn. This was in town. LOL
My Chief was not happy.
Zim.

 

[Jehannum]

Put the silicone elbows in, moves the unions and clamps out where I can easily tighten, remove, or replace them. I need one more, on the pump inlet end of the hose run, as the angle is causing some seepage.



Beat the piss out of the car, and it held steady at 90C at the CHTS, with the AC on, the lower air guide in place, and the turbo force-feeding it all the air, going up a hill.

Still have not wired the pump or the fan. I am, as the kids say, le tired.

 

[Jehannum]

85-95°C the whole way home from work in traffic, and it was 40°C outside. This stupid idea might actually work.

Need to make the system less lossy, as I leaked about a quart from the junction of the pump and the aux radiator. Gonna wait for the car to cool down and then replace the clamp with something wider.

 

[CapriMikeC]

Here in the land of saguaro cacti, I often remind myself automakers supply vehicles to law enforcement and utilities with no trick parts. The vehicles sit idling for hours with a/c on full and never over heat. Despite knowing that, I still install larger radiators and "better" fans on my vehicles trying to control temperatures.

 

[Xti04]

Put the silicone elbows in, moves the unions and clamps out where I can easily tighten, remove, or replace them. I need one more, on the pump inlet end of the hose run, as the angle is causing some seepage.



Beat the piss out of the car, and it held steady at 90C at the CHTS, with the AC on, the lower air guide in place, and the turbo force-feeding it all the air, going up a hill.

Still have not wired the pump or the fan. I am, as the kids say, le tired.

Was wondering when your feet would make another cameo in this thread !

 

[Jehannum]

Here in the land of saguaro cacti, I often remind myself automakers supply vehicles to law enforcement and utilities with no trick parts. The vehicles sit idling for hours with a/c on full and never over heat. Despite knowing that, I still install larger radiators and "better" fans on my vehicles trying to control temperatures.

I did also just find that there's an aluminum 40mm radiator for my car available on eBay from someplace called "Winner Racing" that is somewhat intriguing. Not sure whether it's an upgrade on the Nissens unit I just put in or not, but it's certainly a way to go, if I'm flailing about again soon.