Audi 5000 Turbo front brakes.(G60 Girling dual calipers)
Groove and oil holes in pinion bearing race.
Different angle.
Lubrication holes in main shaft.
Drilled main shaft.
External oil line fittings.
Main bearing oil spray nozzle.
Here you can see the oil channel that is drilled through the housing.
From the diff side.
Starting to fit the lines.
Drilled hole in main shaft.
Tranny in the stand.
Oil lines.
You can see some of the oil lines.
Spray nozzle aimed at pinion gear.
Front diff housing machined to accept locking diff.
Locking differential.
Front diff
Decoupler.
Audi 2.0 TD clutchplate
Flywheel from a Volvo D24
Flywheel
Installed a stainless steel sleeve in the clutch slave cylinder.
Tools for pre-combustion cup repair.
I Bringing head up to temperature.
Chamber after machining
Powder coated my wheels
Audi front brake
Adapter plate
Plate tacked onto a piece of pipe
Adaptor plate
Caliper bracket
Machining of plate.
Milling of the caliper bracket.
Caliper bracket.
Adapter plate tack welded to the adapter plate.
Caliper mounted.
Tack welded on
Almost done.
Emergency brake cable extension.
This is the ball that I made out of the old Jetta E- brake cable end
Hub,rotor and caliper in place
17" Audi S4 wheel with 215x65x17" tire.
You can see the ball on the cable end
Extra cyl head cooling fluid opening.
Welded up an elbow.
Pressurizing cyl head to check for cracks.
Valve spring compressor.
Vacuum pump.
New cylinder head.
Drilled a small hole to pressure lube the pushrod.
Steel head gasket
Difference between VW 2.4 D steel headgasket and Audi 2.0TD head gasket.
Oil filters mounted behind pre-lube oil pump, one filter for the tranny oil and one for the pre-lube pump.
Engine pre-lube pump
Saab Blackstone intercooler with home made water jacket.
I had to weld a straight connection on instead of the original elbow.
Intercooler hoses fitted
The intercooler has two pins on the end that fit into the rubbers on the mounting plate, it allows the intercooler to move a bit, also it shows that I had to remove a corner brace behind the left tail light.
This is the bracket
Engine oil cooler
Fuel injector tester.
Rear spring spacer and air shock.
Home made front shock
New faceplates
Tap bushings
Bushing puller
Bushing is out
Test fit new bushings
Driveshaft
New bushings
Corrosion and wear .
New universal joint, number is on box.
Machining shaft.
Pop Top roof conversion.
Donor roof section.
Roof conversion.
2 Aux.fuel tanks 75 liter each
Our 1989 Westy (Gas)
Mieke and I on the ferry. 2006
Tank schematic
Ball joint spacer
Angle of ball joint at end of travel ( Test fitting spacer)
Ball joint spacer with retaining plate
The ball joint spacer is held in place by 2 bolts in the original ball joint holes and by a third bolt that goes through the retaining plate into the spacer.
Retaining plate with 12 mm bolt
Retaining plate is slightly concave on bottom
The ball joint fits in this end.
Top side of spacer, this end fits in the A -arm.
Angle of spacer.
Machining the ball joint spigot
Spacer mounted on adapter
Close up
Adapter
Machine this end first in 4 jaw chuck.
Backside of adapter.
Looks fairly high off the ground
How do you expect me to climb into this thing, eh?
Syncro hasn't been out of the shop for 7 months.
Also a work in progress
This section has a second story
http://www.revelstokemountainresort.com/revelstokemtn/photo-gallery.aspx?display=videoGallery
Test fitting engine.
This is where the oil sprayers mount
Oil return opening.
TD piston with cut-out
Engine bay cut-out.
Exhaust from turbo.
Engine bay cut-out
Home made stainless muffler with Audi logo.
Complete exhaust system.
Flex joint
Exhaust section Turbo to flex joint.
Engine support bracket
I have made this out of 2" square tubing, 3/16" wall thickness.
Motor mount on turbo side is slightly offset
Made little brackets to support the engine carrier
You can see where the exhaust goes
Tranny pressure lubrication lines
Just bought another Syncro, this one is a 1991.
Ready to pull it home
Started on the gauge pod. I have cut the 2 " PVC 90 deg elbows in half.
Made a mounting plate from aluminum, and cut 1 3/4" holes in it .
I have sprayed some body under coating on it to give it some texture and painted them black with plastic bumper paint.
Test fitting gauges.
Gauges stick out a bit without the aluminum ring
Final product
Cut elbow with mounting ring and gauge
Aluminum ring
Voltmeter, Turbo boost, Pyrometer,Oil temp and Oil pressure.
Had the engine running today! The turbo charger sounds wicked through the muffler.
Some plumbing to the intercooler and engine oil cooler
Pre-lube pump and transmission filter with cooler
It's getting crowded in there!
Engine lid is raised 3"
Here I cut the eye off and pressed the rubber bushing out of it
Two pieces of tubing with a solid 1 3/8" long piece of bar and eyes welded to it
This is how the new shock slides into it and extends the shock 1 3/8"
Clearance between the new shock absorber and the drive shaft, about 8 mm.
Here I have made extension pieces that I still have to weld in place. I would like to use a 20 mm shaft in this pump instead of the 17mm that it came with.
Welded but bushing still has to be pressed in and reamed to size.
Both done, I am converting both pumps to mechanical TDI injection
Made the piston a bit shorter and modified the pump housing to get more advance
On the left is the original 2.0 TD 5 cyl roller cage, center is the M- TDI with four rollers and on the right is the stock 2.5 TDI cage with five rollers. It also shows that the pin in the advance piston moves further to the left after the modification.
Difference between the stock 2.5 TDI with five rollers and the modified one. The cutout is where the govenor flywheights are on the M-TDI pump.
In the center you can see the cutout that I made.
Shortened the advance pistom a bit and ground the inside out to maximize the stroke.
The pin that goes into the advance piston of the TDI has originally a slight undercut.
Camplates from 5 cyl TDI (left) and 2.0 TD
Added this plug in the pumphousing so that the pump has four rollers instead of the original three. No cold start advance anymore.
Full stroke of piston advances the timing 44 degrees (crankshaft) This may be too much but I can limit the timing by adjusting the piston stroke with spacers.
Modified timing piston slot.
I removed some material so that the timing piston can move a bit more
I am working on a conversion from a 2.0 indirect injection engine to direct injection. I am using Renault Clio pistons for this but the injection bowl in the piston top has to be enlarged. This is the tool I made to hold the piston securely in place in the lathe.
Tool
I had to make a tool to hold the piston in place during machining in the milling machine.
I made this so that I can machine the bronze connecting rod bushings on the lathe.
Piston after machining, a regular conrod will now fit in there.
This stock piston needs a connecting rod end that is tapered.
Valves barely fit in the 76mm bore.
Cylinder sleeve, I have an engine that had the last oversize pistons in it, so I had 5 sleeves installed, now it is back to standard size.
Cylinder sleeves installed
5 Cyl 2.5 TDI cylinder head that I am using for this engine conversion
Sleeves installed, ready to be put back together
New TDI piston and rod
Put the engine together today
Cylinderhead installed, have to find a valve cover for it.
Experimenting with Stainless plates to make a Hydrogen Generator, this is the Mark 2 ( I need a few projects on the go at the same time)
Plates installed in 8" pipe.
Producing Hydrogen, ran it for 4 hours @ 10 amps, temperature went up to about 40C.
This is the Mark 3, 5 sets of 6 plates in series.
I will add a sixth set of plates to try to run it cooler, each set will run at 2 volts.
Aux tank fuel transfer pump
Right Hand side tank overflow back to filler neck
Left Hand side tank
Aux fuel transfer pump with isolation valves.
This is the float assembly from a Beetle that I have used for the Aux tank.
I had to glue on the wiper assy from a Vanagon 2 wheel drive, the beetle has the wrong resistor.
Engine protection plate still has to be installed.
Here you can see the ground clearance under the engine, still 1.5 inches higher than the antifreeze container.
Still have to install plate under tranny.
Eberspacher heater
G and Reverse gear mod
Original bronze synchronizer ring
Made pins out of a special though material
In the primer
Just came back from the painter
36 LED printed circuits
All back together.
Intercooler lines
Outside in the snow
Inside the cover
Closed position
At night
I have used the Mini USB port on the right
I have filed a small notch in there to open it
Here is the opening where the Mini USB connects to the GPS
Got my new tires, Yokohama Geolandar 225/60/17
Front bumper
Winch mount
Rear Bumper with spare tire carrier
Swing out spare tire carrier
New tires
Just enough space between sliding door and the Yokohama 225/60/17 tire
Rear brakes
Extended luggage rack
Extended 11' 8" awning
BMW booster on left side
Test fitted booster on pedal frame
I have used the front section of an old roof
Roof section used to reinforce the roof rack
Intercooler radiator in extended luggage rack
Used 6" longer section from another rack
Glued and pop rivetted aluminium plates in
Prototype shower tent
Took er out for a test drive today, checked lockers and decoupler in the sand.
Syncro De Mayo 2010
Moab 2010
Grand Canyon campground
Syncro De Mayo
Grand Canyon 2010
I drilled 3 lubrication holes in the pinion bearing, this is for the transmission that is going into the blue Syncro.
Here it shows the radial groove that feeds the lubrication holes
The holes are centered between the bearing surfaces.
I drilled a hole in the main shaft to feed oil to the needle bearings of the 4th and 5th gears
This tube fits inside the drilled hole and has about 0.0010" clearance
Here you can see the oil spray nozzle, it supplies oil to the main bearing.
Another view of the nozzle.
This is the external oil feed into the main shaft.
Oil feed connection to the main shaft bearing spray nozzle.
Nozzle and fittings.
Drilling a hole into the pinion bearing housing.
This hole is centered and supplies oil into the radial groove of the pinion bearing to the 3 small oil holes.
