Project D2 S8 (FL) 01E Conversion.

[Nollywood]

I haven't lifted my carpet yet - I've always assumed it was aluminium behind, forming the "bulge."

[SyncroS8]

Any news on your conversion Nollywood?

Which code 01E are you using?

MG

[Nollywood]

Originally Posted by SyncroS8

Any news on your conversion Nollywood?

Which code 01E are you using?

MG

I haven't done much, I've picked up my custom pedal box though.

I've got two 01E trans - a DSY from a 2001 S4, with modified 4th, 5th and 6th from a 2002 Allroad 2,5 TDI, and a standard DGV from a 1999 European S8.

I'll most likely use the DGV for my S8, and the modified DSY to mate with my S8 motor that's destined for my Audi A4 DTM Race Car.

[ainarssems]

Speaking of A4 have you considered moving radiator to boot? That would add overall weight but move it from front to back giving better balance and give more place in front for V8. And also save from radiator damage in frontal collision and leave space for intercooler if you decide to add forced induction at later date.

[Nollywood]

Originally Posted by ainarssems

Speaking of A4 have you considered moving radiator to boot? That would add overall weight but move it from front to back giving better balance and give more place in front for V8. And also save from radiator damage in frontal collision and leave space for intercooler if you decide to add forced induction at later date.

You must be reading my mind. Yes, I'm mounting the radiator at the rear, the stock B5 radiator is 25" between the end tanks, so you can only fit two 12" fans. It still runs hot, even with both fans running constantly, as I've experienced in the past.

Most of the hot running is due to space constrainsts in the B5 engine bay. It's the same size as a C5 A6 non-V8 bay. I'm going to run a 30" wide aluminium radiator in the rear, with deeper twin 14" fans. This means I won't need to cut up the front panel, I can then leave the electric air con fan in situ to cool the engine bay.

[Goran]

Nollywood you have a custom pedal box, excellent.
Please post a picture up I'm really curious to see.

I'm still scratching my head over how to customise the stock pedal box.
I recently got a used A6 1997 clutch cylinder, the clevis on it is perfect for the 8mm steel pedals the A8 used. Not sure if the cylinder itself is goint to be of use.

I took some pictures to show some of the little problems to be solved. Hopefully its usefull to someone.

I dont know how to put text after each picture so here is a little explanation:

Picture 1 - steel pedals go all the way into the bushing, so will have to be cut along with the bushing. Probably not a problem.

Picture 2 - LHD brake pedal on RHD pedal box. about 12mm has to be cut from the end of the bushing.

Picture 3 - 1997 A6 clutch cylinder, clevis fits LHD brake pedal. A hole needs to be drilled in the pedal for the pin. Will it need a metal bushing like the brake clevis?

Picture 4 - LHD brake pedal and RHD brake pedal together. Separation 73mm. Approx 25mm needs to be removed so they will be separated by just under 5cm when mounted. Is this too close?

Picture 5- LHD clutch pedal and RHD brake pedal together. Separation 98mm.
Again 25mm needs to be removed from the bushings, so mounted separation will be approx 73mm.

Picture 6 - I was thinking about using the existing hole on the LHD brake pedal for mounting the clutch cylinder. Unfortunately it is 20mm further out from the axle than the LHD clutch pedal cylinder mounting hole. This will introduce more travel to the clutch cylinder, or reduce clutch pedal travel. Also the foot pad would not line up to the same position as stock clutch pedal.

Picture 7 - LHD manual pedal box. Clutch to brake pedal separation 75mm.

Picture 8 & 9 - LHD brake pedal and LHD clutch pedal lined up. Unfortunately if the stock cylinder mounting point is to be kept, it would overlap with the brake spring slot, so that would have to be welded up first before the hole is drilled (i dont like this solution).

Other problems not pictured:

1) mounting the clutch cylinder
2) location, mounting and design of over-centre spring. Can we use a stock spring from another vehicle?
3) stock clutch pedal is aluminium to prevent pedal riding the clutch, will a heavy steel pedal cause a problem?
4) brake spring needs to be moved to the right of the brake pedal, it needs to be a mirror image of stock spring. Custom spring?
5) LHD clutch cylinder to slave cylinder hose starts off on the inside, then exits the body through a hole. Is there such a hole on the right footwell, probably not. If not how long will it have to be to go around the firewall to reach the gearbox.
6) clutch pedal sensor mounting has to be welded onto the RHD pedal box.

There are probably more problems, those are the ones I can think of.

[thebluewhale]

I dont know how to put text after each picture

Goran this may help you out.

[Goran]

Thanks!

Here is a picture to show that the A6 1997 clutch cylinder is useless. Its too long to fit the clutch pedal and not foul the brake booster. A8 clutch cylinder should be ok, I cant be bothered to buy a metal audi A4 cylinder (which feeds the slave cylinder hose on the outside of the footwell)



If you're going for a 8mm thick pedal like me, just get the 1997 A6 clevis and pin from Audi.




I wonder how much it would cost to get a custom titanium clutch pedal made, perhaps by these guys?

http://www.force-racing.co.uk/front-suspension/

[SyncroS8]

Originally Posted by Nollywood

I haven't done much, I've picked up my custom pedal box though.

I've got two 01E trans - a DSY from a 2001 S4, with modified 4th, 5th and 6th from a 2002 Allroad 2,5 TDI, and a standard DGV from a 1999 European S8.

I'll most likely use the DGV for my S8, and the modified DSY to mate with my S8 motor that's destined for my Audi A4 DTM Race Car.

Interesting, I have been looking at TDI gearboxes with a view of using the whole gearbox... Any reason not to?

MG

[ainarssems]

I can't see why not. Difference is basically in the gear ratios. TDI boxes will give longer gears and better economy, petrol boxes shorter gears and better acceleration. Needless to say that each box needs to be paired with suitable ratio rear diff.