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  #11  
Old 18th July 2018, 10:54 PM
MikkiJayne MikkiJayne is offline
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Limited progress over the past couple of evenings as the cam chain tensioners needed changing which took a while.

Flywheel on - this is a custom lightweight unit from TTV Racing. Its a little over half the weight of the stock one, and a little over half the price! It also takes a nice cheap B5 RS4 clutch.





Gearbox going on.



This is from a C5 A6 2.5TDI quattro. The ratios look 'plausible' and they're relatively easy to come by.



Always the little details



Engine and gearbox bolted together



The manual ECU files which I've obtained from Vera and Goran (thanks both!) have the secondary air injection coded out, which is handy because its pointless and just adds weight and plumbing.

Pulled all this rubbish from the engine, and I'll remove the pump from the airbox before it goes back in.



Made up some blanking plates for the ports on the back of the heads



I pre-modified a spare engine harness, removing all the automatic gearbox and ecu wiring and also the SAI stuff. Still some work to do for the sensors on the manual gearbox - I couldn't do the reverse switch and speed sensor until I had the gearbox attached so I could check the wire lengths so I'll sort that tomorrow.



Where I finished tonight:



20 hours.
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  #12  
Old 18th July 2018, 11:02 PM
Regulus Regulus is offline
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Another "What's in the workshop?"

I already learned something. The rear bumper bolt that was seized
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  #13  
Old 19th July 2018, 09:58 AM
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The_Laird The_Laird is offline
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Proof indeed that higher-intellect aliens have infiltrated our humble human society!
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2002 Final Edition S8. Ebony black with Silver Grey leather and myrtle wood trim.
Current mods: solar sun roof, 20mm rear spacers, 15 mm on front, red brembo callipers, 6k headlights, rear view camera, engine remap, alloy dash dial rings, alloy navi rings, tt/phaeton pedal upgrade, (and custom matching foot rest) dension ipod interface & parrot hands free kit (both fully hidden), av input, tv in motion switched thro' PF switch in blanking plug right of steering column, Audi 'quattro' sill covers, repositioned centre console switches, radio clock, .
Planned mods: auto-dimming rear view mirror, dash cam (as steamship's), fit the ski hatch, refit philips drl's (or maybe not - nope, definitely not - horrible botch!).
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  #14  
Old 19th July 2018, 10:21 AM
MikkiJayne MikkiJayne is offline
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I'm the monster's mother

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  #15  
Old 19th July 2018, 10:51 AM
HPsauce HPsauce is offline
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Someone photoshop that with red hair...……
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2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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  #16  
Old 19th July 2018, 10:46 PM
MikkiJayne MikkiJayne is offline
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TDI rear diff:



Original diff in the background



Cleaned up the CV joints and replaced the gaskets



Installed



Sorted the wiring for the reverse switch. New connector and wires to extend the original N75 wires over to the other side of the gearbox



Re-used some sleeving from the autobox harness



Wrapped up with tape and complete. Ideally I would have liked to sleeve all of this, but that would have meant cutting off the original connectors for the engine mount and speed sender so tape has to do in this case. I may use some split corrugated sleeve on the next swaps.



On to the gearbox oil cooler lines. The originals (of which I have a reference set) are no longer available so I cut the autobox cooler lines apart after the engine mount





I couldn't get the phone to focus to get a decent pic, but I welded a couple of little pips on the end of each pipe to function as a barb to stop the hoses pushing off. There's no pressure in these, but best to be safe. You can just see the bumps in the hoses. I'll crimp these in place once I'm happy with lengths and routing.



Mounted on the engine. They cross under the bellhousing...



...and attach to the gearbox here



I'll need to work out some brackets to support the hoses since the originals are hard lines after the engine mount. I'll be able to produce these in advance for the next conversions using spare autobox lines.
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  #17  
Old 20th July 2018, 11:08 AM
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27litres 27litres is offline
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I've been waiting for this!

Was expecting the Grey FE to be the prototype though - that will have to be the 'pre-production' model!

What are you doing about the gearbox mounts for the production models? The ones you're using for Bert's look like those "last ones" you got from Audi...


Lastly, when are you coming to Australia with one of those kits in your carry-on?
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2002 Audi S8 - Project
Replacement head coming arrived thanks to MJ
Silver with Black interior. All features as the '01, with the 'S' mode auto shifter. Dodgey rear tint (need to find a way to get rid of that).
Family:
2009 Volvo XC90 V8 R Design
- has a louder more obnoxious exhaust than the S8, sounds great! Love this thing - Q7 was double the price, and certainly not double the car!

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  #18  
Old 20th July 2018, 11:58 AM
MikkiJayne MikkiJayne is offline
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I started off prototyping on the Avus FE, but then Bert's gearbox went pop and he didn't want to spend £3K having it rebuilt only to take it out again once I figured out the swap so we agreed to prototype on his instead. Unfortunately it has taken considerably longer than we expected but hopefully it'll be worth the wait.

Bert's is using the genuine gearbox mounts for simplicity, although I did have to modify the left hand one to clear the shifter. They are pretty simple to copy though so I will redesign them using laser-cut flat plate and make an assembly jig for the pieces so they can be tig welded together. Its likely that's going to come out considerably cheaper than the genuine ones in the end anyway, just like all of the other custom parts.

Not sure I'd get away with a propshaft in a ski-bag on a trip to Australia I'm sure we can figure something out if you want a conversion though
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  #19  
Old 20th July 2018, 08:46 PM
awolfinsheepsclothes awolfinsheepsclothes is offline
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Hi MJ nice to see you've started shouldn't take you long now! i expect you be 99% finished before the end of the month. keep up the good work
Dave
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  #20  
Old 20th July 2018, 10:33 PM
MikkiJayne MikkiJayne is offline
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Sadly that is unlikely since I've only got tomorrow left on it, then Mike's Murple is in on Monday for a fortnight. I can't believe its Friday already I've only spent maybe 2 days of 5 doing actual conversion stuff. The rest has been engine maintenance or cleaning conversion parts, and obviously wasting a few hours taking the engine out the wrong way!

I finished off the oil cooler lines tonight. This is where they join the original hard lines, now crimped in place.



They curve under the bellhousing in roughly the same way as the original hardlines



Pump output



Return at the back (apologies for the focus ). I need to make another support halfway along this when I build the exhaust support bracket. On the next ones I might actually use the C5 return hardline at this point and join the hose where the pump union is.



I covered the hoses in adhesive-lined heatshrink to hold them in place and to give them some protection. This should hold its shape even when the lines are hot. If not, I'll consider some more support.



New lines top, originals bottom







All I managed after this was to put the other engine mount and starter back on and then fill the gearbox with oil. Lots to do tomorrow to get it rolling again so I can push it out of the way to work on Mike's.
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