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jimbo

project 600/600

starts noon tomorrow, details tba..  
andream88

Uhhhhh... great news jimbo
S4twiggy

wots this all about then.....

not looking forward to getting up at 4.30 now for GTI lol looking forward to the action from some of your bad boys S/RS's
StumpyRS4

Jealous much? Nah...!!

Another build to watch
5potmad

Pics Jimbo!!
quattrokid

He's off again!!

Respect Jimbo
dace

Stop tampering man......

Still won't get past me at CC in October  
mikeyquattro

dace wrote:
Stop tampering man......

Still won't get past me at CC in October  


That's down to driver skill.............. Or just out and out loonyness cos Jimbo likes to 'go in hot'!!
StumpyRS4

mikeyquattro wrote:
Jimbo likes to 'go in hot'!!



Yeah... Flaming hot...

mikeyquattro

StumpyRS4 wrote:
mikeyquattro wrote:
Jimbo likes to 'go in hot'!!



Yeah... Flaming hot...



Ha ha! You're not wrong stumpy! I was thinking more about the way he went into corners, more not the way he came into the pits!!!
Juice

spill the beans then.......
MarkB

Juice wrote:
spill the beans then.......


Spill the beans Jimbo if you want a slot in P&B forum
jimbo

right back home now, me and gordon made good progress today, started at 12.30 , by 3.30 the engine was out and by 6 the box, turbos , manifolds wiring loom etc were off, i noticed the cambelt was pretty baggy so thats gonna be changed, the studs that hold the turbos to the manifolds were impossible to remove so they came off as one, had to stop for light refreshment during the afternoon. tomorrow will see the heads off and the block stripped down ready for the new rods.






mikeyquattro

Piccys please Jim. Fair play to you
jimbo

thanks to phil (shobe) for sorting me out with a hoist, job would have been a bitch otherwise
mikeyquattro

mikeyquattro wrote:
Piccys please Jim. Fair play to you


My Bloody phnone.... Slow, a bit like me!
ScottR

Good on you Jimbo.  Just don't lose any bits whilst the engine is out!
LDN ED

Hi Jimbo are u going to modify the engine wat do u reckon its going to hit at the end meaning specs
davey

LDN EDD wrote:
Hi Jimbo are u going to modify the engine wat do u reckon its going to hit at the end meaning specs


I think the answer is in the title
LDN ED

davey wrote:
LDN EDD wrote:
Hi Jimbo are u going to modify the engine wat do u reckon its going to hit at the end meaning specs


I think the answer is in the title


Sorry every1 my bad i think i am a bit blind
shobe

jimbo wrote:
thanks to phil (shobe) for sorting me out with a hoist, job would have been a bitch otherwise


No problem    goodluck with the build, looks like your motoring on well.
StumpyRS4

Looking good Jim - gimme a shout about you know what  

Another question - you're running 9.5J - what ET ?
Stigter

Quality Jimbo! Can't wait to see the next installment of this fine project.

PMSL at the power figures in your signature  
LDN ED

I love these project builds really interesting
Virdee

Good progress.

Look forward to seeing the next installment!
Alps

Nice one Jimbo. Rated for doing it yourself

Looking forward to hearing the full spec.
andream88

hey jimbo what about those MTM manis?

I've seen a pair recently for sale on the bay(.de), which were snapped in half and resoldered!
Do these show any cracks etc?

cheers
Andrea

Good luck with your build.
MarkB

jimbo wrote:
right back home now, me and gordon made good progress today, started at 12.30 , by 3.30 the engine was out and by 6 the box, turbos , manifolds wiring loom etc were off, i noticed the cambelt was pretty baggy so thats gonna be changed, the studs that hold the turbos to the manifolds were impossible to remove so they came off as one, had to stop for light refreshment during the afternoon. tomorrow will see the heads off and the block stripped down ready for the new rods.


Moved to Projects and Builds
jimbo

cheers mark ive finally reached the holy grail in p+b. just for info im still in old money so the target is in hp and lbft, not this ps and nm nonsense. the manifolds have done 20k and look fine all thats happened is the zircotec coating has gone a bit yellow and has started flaking off underneath, i also want to replace the wiring loom if anyone has one lying around. im looking at 3 weeks turn round time for this job. more pics tonite.
DW

Good luck Jim, you deserve a good outcome after the run of bad luck over the last couple of years!
MilkybarKid

DW wrote:
Good luck Jim, you deserve a good outcome after the run of bad luck over the last couple of years!

+1, good luck man, should be an interesting thread this onje to see how you get the extra horses in there  
jimbo

DW wrote:
Good luck Jim, you deserve a good outcome after the run of bad luck over the last couple of years!


cheers daz thats why ive decided to do all the work myself with help from  my mate. once the engines out its really not that complicated to work on. im not looking forward to opening the bottom end though.
mikey-s

jimbo wrote:
im not looking forward to opening the bottom end though.


I hope you've got a haynes manual??    
jimbo

no but i know a nice chap who lives on a little island who will be sick of all my phone calls before we are done.  
5potmad

mikey-s wrote:


I hope you've got a haynes manual??    


DOES NOT cover S4 RS4.




   
MarkB

jimbo wrote:
no but i know a nice chap who lives on a little island who will be sick of all my phone calls before we are done.  


Be good if you have yours finished before I start mine. I don't want you hogging the line!
jimbo

todays progress has been pretty slow, eventually got all the head bolts out some were feckin tight, some werent very tight and 4 had rounded off heads but after a lot of swearing they all came out. about six weeks ago a new set of plugs were fitted and the tip of one decided to fall off as soon as the engine was started, this has caused a bit of damage to the head and piston on the back passenger side, hopefully this can be mended theres also been some detonation on the pass side middle and rear cylinder and as you can see from the colour of everything its been running really rich which maybe explains the terrible fuel economy i was seeing , dont know if that was due to the water/meth or the reduced boost its been running.

im also still convinced the inlet cams are different so im going to try and find someone to identify the timing ,lift and duration and put this thing to bed. the heads are going off this week to be ported out, refurbed and fitted with uprated springs so we can up the rev limit. the turbos will also be going away for a bigger compressor wheel and ported hot side with a cut back turbine wheel and 1 bar actuators, the bolts holding the turbos to manifolds are seized solid, anyone know how i should split these?.

lastly the oem intake pipes are now redundant as bigger ones will be going in there place. thats it now until the heads and turbos are back.













grizz

Jimbo , Try some "Plus gas " On the cap heads bolts  ....They can be a fecker to undo ..
jimbo

ta ive got some mapp gas on my blowtorch, all the exhaust bolts were a bitch to undoo. il try it tomorrow.
viperbl

Good work Jimbo

check the head bolt holes in the heads mate, I know that they mushroom over after the bolt being torqued down, this could be the tight effect on some, worth having them reamed out anyways ...

Measure the total height of the inlet cams, easiest way to check if they are the same, the s4, rs4 and 2.8 are different heights ...
grizz

I've got a full set of 2.4 cams spare if you want to measure them up.
PaulyRS4

This looks like a good project, good work hope all goes well bud.
jimbo

done some more today, got the new rods in ,cleaned all the pistons up and replaced one then fitted them with new rings. fitted the new aircon compressor and oil pump then put the sump back on, il do some more work on it next weekend and hopefully get it built back up.  





Mihnea

The scoring on those pistons is NOT detonation, if it had been detonation marks, all the outside of your pistons would have been eaten away

Doesn't sound like that engine was too healthy, yet it still made half-decent power
jimbo

the tip of a new plug came off in the combustion chamber thus trashing said piston.
ZeroK66

Do the Peroni give extra BHP?
supersi

Jimbo did you or will you  hone the bores for the new rings ?
andream88

supersi wrote:
Jimbo did you or will you  hone the bores for the new rings ?


i've honed mine, old pistons with new rings going on.

cheers
Andrea
supersi

andream88 wrote:
supersi wrote:
Jimbo did you or will you  hone the bores for the new rings ?


i've honed mine, old pistons with new rings going on.

cheers
Andrea


What honeing tool you use was it the bead type or the spring loAded flat bar type ? Did you use hand drill your self or use a machine shop
andream88

i've brought the block to a machine shop as i don't trust myself that much!!!!
jimbo

i used the spring loaded flat bar type in the end of a drill, the original honing marks on the bores could still be seen.  
supersi

jimbo wrote:
the original honing marks on the bores could still be seen.  


thats a good sign jimbo   ,what about sides of pistons ,also what sort of mileage is on your bores

si
jimbo

the sides of the pistons have some kind of black square on each one at each side which i can only assume is some kind of anti friction material. i dont know the actual mileage of this block but the crank is mint and was good on the comp test before hand.

wrapped up the downpipes last night and went mad with some stainless welding wire in the process.

got a set of large bore intake pipes too , these are 10mm dia bigger than std, new cold side inlet on the turbo will be this size.




Virdee

Looking good, and liking the updates!
jimbo

cheers. thought no-one was intetrested.        
davidhodgkinson

jimbo wrote:
cheers. thought no-one was intetrested.        



JohnnyB

What rods have you got Jim? New intake pipes look good. Who is doing your heads for you? Looks to be coming on well we will have to go on another trackday soon.
Juice

im always interested Jimbo, good to see you got the large bore intake pipes, i looked into it too but only worth fitting if your taking the engine out.

keep the updates coming.
Virdee

I'm always liking stuff like this!

As Juice has said now is your chance to do whatever you have been itching to!!!
Matt_D

I love these threads

Turbo's wise are you going for RS6's or Tials ?
StumpyRS4

^^ RS6 Stage 2 I believe.

Awesome work Jim.  Keep it all coming.

Do the DPs actually need wrapping?  Have heard mixed reviews?  I believe Doug mentioned once he never wraps DPs.  Also the S/S wire - is that overkill, or do you think the wrap is likely to come off over time...?
jimbo

il put some before and aft pics of the turbos when i get them back. dunno about the heat wrap, i had it so thought id use it, gonna do the ex manifolds and intake pipes too, has anyone seen those turbo blankets?
supersi

Yes I've seen the turbo blankets  jimbo and I reckon are good idea , I also think the wrapping of any super hot surface is good , a amazing difrance in temp after wraped , so much so you can touch the wrap after or while  beeing used and not get burnt,

Doug said before its just he has never done that's all not that it's not a good practice ,
jimbo

you want the turbo and manifold to be as hot as possible to make the gas speed as fast as possible, once the gasses are out of the turbo you want them to cool as quickly as poss but you dont want the under bonnet temps to be sky high either, thats why i wrapped them about the first foot and np more, would a blanket interfere with the wastegate?
supersi

Yes understand the reasons for wrapping manis I've done before on bikes and karts . Not sure on waste gate maybe work around waste gate ( leave anoth room to allow function )
Doug

it is a good idea to protect WGs from heat - they have diaghraphms inside.

you have to be careful not to spill oil or other fluids on the wrap - so it doesn;t go on fire.
andream88

Doug wrote:
it is a good idea to protect WGs from heat - they have diaghraphms inside.

you have to be careful not to spill oil or other fluids on the wrap - so it doesn;t go on fire.


maybe worth spraying it with a hi-temp coat to protect it from oil or other fluids?
davidhodgkinson

Doug wrote:
it is a good idea to protect WGs from heat - they have diaghraphms inside.

you have to be careful not to spill oil or other fluids on the wrap - so it doesn;t go on fire.


I'm sure he's tried that one before  
mikey-s

davidhodgkinson wrote:
Doug wrote:
it is a good idea to protect WGs from heat - they have diaghraphms inside.

you have to be careful not to spill oil or other fluids on the wrap - so it doesn;t go on fire.


I'm sure he's tried that one before  


Below the belt..  
DavidT

How much do the downpipes expand? they're bound up pretty tight, will they be OK?
jimbo

anyone want an update???
mikeyquattro

jimbo wrote:
anyone want an update???


No

Get on with it.....
jimbo

wildoo after top gear
Graham

I like reading these project threads, even though I could never attempt anything like this myself,  please do keep the updates coming.
Juice

top gears finished now right?..c'mon jimmy, its my bedtime soon.
Virdee

LOL......keep them coming!
jimbo

sorry had to watch moto gp  
jimbo

ok. had a good time this weekend on the engine. saturday saw the heads go on and new cambelt fitted, im running oem valves with uprated springs so should be able to up the rev limit a tad  big thanks to mikey-s for giving me a lift with that job.
 today we fitted my spare gearbox, although there was nothing wrong with the one i had i thought id give this one a go. also managed to source another wiring loom so again im gonna try that after my fire at castle coombe last year it had a little damage.
  the exhaust manifolds have been a big job as they wouldnt go back onto the studs, ive done some porting work on them just to make sure the gas flows well and the gaskets have also had to be ground out as there was gasket sticking out into the gas flow so these were ground out too. the manifolds had to be put in the oven at 200 degrees for half an hour each so they would go back onto the heads.
  n249 delete done.
  thick head gaskets fitted.
 just waiting for some gaskets now    so i can get the inlet manifold back on  and also the turbos. looking to get the engine finished next sat and refitted on sunday.
















frazered

interesting aluminium and glass heatshields there Jim
jimbo

it was 3 pm matt, cut me some slack  
davidhodgkinson

looking good Jim.  

I see the engine additions look to be in the wrong positions  
Juice

woah, you've been a busy boy

whens it going back into the car?
MarkB

Juice wrote:
whens it going back into the car?


jimbo wrote:
looking to get the engine finished next sat and refitted on sunday.
quattrokid

Respect Jimbo, looking good

catch up soon

regs Rich
JohnnyB

Looking good Jim few more tinnies and it should be finished.
jimbo

yeah . gotta get pissed after each fettle. only way to get through it  
MilkybarKid

Excellent stuff mate keep it up
davidhodgkinson

jimbo wrote:
yeah . gotta get pissed after each fettle. only way to get through it  



Well, you never mentioned that      
Ash25

good stuff going on here jimbo  

well impressed on the work, and also the green can and glass additions too.....don't think it will work as well as a traditional meth kit though.

keep up the pics dude  

Ash
jimbo

got my rs6 turbos made into stage 2 hybrids. gonna be making them into a stage 3 myself this evening and fitting them tomorrow. will get some pics up on sunday when the engine will be back in.
MarkB

jimbo wrote:
gonna be making them into a stage 3 myself this evening


^^^ So what's this then ^^^
jimbo

the inlet eye has been changed for a 60mm one along with a bigger compressor wheel off the new s3 and machining to suit, the hot side turbine has been cut back along with the core being refurbished. all that needs to be done now is the porting of the hotside where the gasses exit the turbine wheel. this means stripping the turbo down and attacking the hotside with my drill and grinding stone. will be staying off the beer for this job.
MarkB

Make sure you don't touch the area that the turbine runs next to.

I've also been told to be very careful what you do around the waste-gate heatshield area...
jimbo

whats that then mark. ive been wondering weather or not to knife edge the heat sheild or just smooth it over.
MarkB

I would do nothing apart from maybe remove any harsh steps.

Main thing to avoid is the circumference around the turbine. If you damage that, you've had it!
jimbo

rodger  
jimbo

interesting times. anyone reading this      
StumpyRS4

Always Jimbo...

Any more developments?
jimbo

rs6 turbos , before and after. bigger inlet eye, bigger compressor wheel , cutback turbine wheel, 15 psi actuators instead of 6 psi. now stage 2  









jimbo

awesome eh. notice how the borg warner tags arent there any more.
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