Most liked posts in thread: Late Nights at TyrolSport

Some shots of the clutch job, as promised.

Bumper off




The worst part of the job, getting the tie rods off.



Subframe out



axles



trans



trans out



flywheel



Old clutch, not bad for 100K and 30 track days.



Old throwout bearing and guide sleeve compared with new



New output shaft seal



Lots of grease



Back together



Not too bad for a weeknight, starting at 7PM

 

Crank pulley out:



New parts. Crank bolt, seal, and TEMPORARY 4% overdrive pulley (it's a band aid)



Front crank seal needs to go as well:



New seal in, compared with old seal:



Still waiting on the more exciting parts to roll in the door

 

A test of patience

 

The mystery box remains. In the meantime, I started breaking down this nice 5k mileage lifecycle charger:



All that peeling coating...



Breaking down the Rotor assembly:



Removing the coating:



Looking the business:



Ready to be sent out Monday morning :wink:

 

Started porting my M45 housing tonight, then was asked to build a front bumper support for Mr.Rictus' build in the VW scene. It's a 24V GTI with dual GT28R turbos and a water to air intercooler setup.




The bar I made will protect the Water to Air heat exchanger.


Bent at 35 degrees from some roll cage tubing we had laying around. Its bent from Mild Steel DOM tubing and TIG welded to the plates for the factory bumper support. I then mixed up some paint (Black Sapphire Metallic, a BMW color) and sprayed it.

They now owe me big time for taking me away from my MC40 project

 

Made a cat-back
Need to warm this thread up to the exciting stuff on the way.

 

Likewise :beer

The goal was to make it quieter than the Borla race w/resonator that came off, hence the 9" straight through muffler that barely fits the tunnel. The end result was a deeper tone, and almost as loud (but with no drone between 55 and 70 mph). I may create a helmholtz resonator to cancel some of the 3K drone that comes with speeds 70+. Will have to wait and see how it sounds when the header is completed.

 

[ame="http://www.youtube.com/watch?v=_tw8HgH1ODk"]Hear it here[/ame]

 

News:

Changed my low-speed fan:


Changed my leaking hydraulic mount with a new hydraulic mount (third one :eek6



Other news:

Added an exhaust tip to complete the cat-back section
(pic coming soon)

Installed WMW 15% pulley to replace my Alta 19%.
(pic coming soon)

The theory here was to leave the 4% oversized crank pulley on while retaining a back to more normal boost level (4% plus 19% = overboost and 180F IAT's, logged!). I also gain more belt area on the supercharger, so the chance of belt slip is reduced as well.
BTW 23% reduction spells death and was only done on E85. Now that the pulley ratios are closer to normal, I can go full throttle again for the first time since you saw me replace the crank pulley in this thread, which was sometime before the Dragon.

I am also going to the Glen next Mon/Tues (July 16/17), and will be bringing some E85 along, as the car has responded in a night and day manner while running a 40%-60% blend. Throttle response, and power are greatly improved. It almost feels like I added a pulley to the car again.

Track days would not be possible with a 23% compressor reduction (although if you calcualte it, that figure grows slightly), as the engine internals would likely chernobyl in about 3 laps, as well as the bearings in the M45 from the increased RPM and heat. Of course by the time this thread actually launches and I stop building hype, IAT's will be a thing of the past.

That is about up to speed More to come!

 

As I type this, I am at Watkins Glen (or "The Glen") expecting 99F temps tomorrow. I had the car out today running an E85 blend (about 3 gal/tank or 25% (not accounting for the 10% already in our gasoline)). Anyway, it is working great. I am experiencing trememdous heatsoak, however the cooling effect of the E85 is really aiding in the retention of power, not to mention increased throttle response and modulation.
Will have a few pics up in the coming days. My exhaust tip is a nice shade of ash/white from the ethanol:lol:

 

This is what E85 does to the exhaust:


Please ignore the sugaring on the inner welds :wink: it was getting late and I wanted to go home, so no back purging.

 

Not true again!

I replaced a lot of sheetmetal on my classic Mini about a month ago, and have also made some much needed repairs on the beater (Grand Cherokee ZJ).

Also Recently transported my GTI from the future in-laws place to my parents place so I would have some heated garage space to work on it in the fall/winter. On top of all that I am about mid-renovation on my apt :eek6:

The better half just got a job in Manhattan with a minimum 2yr commitment (and an express-bus commute), so my R55 may be up for sale within the next month or so, as much as I want to mod it!

Things I have changed on the MC40 since my last M/A post:



Coming soon:

Control Arm bushings
Steering column universal joints
Refinished R90s
W11 Short block (maybe)