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Written by NEO September 06 2009 at 14:02.

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I have a really really crappy camera so sorry about the quality on these pictures. But I realised I don't really have many pictures of the car here on irry, there's mostly just close ups of various parts. So I snaped a few pics on the cars and uploaded. Once again, sorry for the poor quality of the pictures.

When I took the car out from the garage for the first ride with the new wheels I noticed that there was a nail in the left front tire. =( Just my luck.

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New 19" wheels!

Written by NEO August 30 2009 at 22:16.

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Since my 18" wheels wouldn't fit over the new brakes I needed to buy myself a set of 19"s. I found these ones on a Passat over at www.garaget.org. I e-mailed the owner and asked where he bought them and a few e-mails later I bought them from him. =) I just love these wheels! They have this old design that I think works verry well with the S2 and in particular with my whole RS2 obsession.

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Reason for the cut outs found! And new brakes, again!

Written by NEO August 23 2009 at 20:49.

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A while ago I was over at Kroegarns place and tried my car with his ECU since I suspected that the reason of my cut outs could have something to do with my ECU. Kroegarns ECU has the same chips and same modifications as mine with the exception that his has an external MAP-sensor. Unfortunately it ran jut as bad with his ECU as with mine. But the trip was not all in vain. I got some good advices from Kroegarn and he lent me a spare coil pack he had lying around. The moment I removed my coil pack I spotted the problem. Both cables to the third cylinders coil had cracks in them. So at full load it has shortened out with the result of the car only running on four cylinders. With Kroegarns coil pack the car feels like a freakin’ rocket! =) Though it’s still running to hot on the exhausts. =/

I also happened to buy new brakes again. I stumbled across a set of the calipers used with the ceramic setup on newer performance Audis (RS4/RS6/R8). They were bundled with a set of 380 mm MTM steel discs. And it just happened to turn out that they fit perfectly with my adapters I had manufactured for the 8 pot calipers. So now I have to buy me a set of 19” wheels. =)

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Leak test of crossmember and IC, again

Written by NEO June 21 2009 at 15:12.

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Today I did a leak test on the IC and crossmember. The biggest problem was that the custom hose I used leaked. I wasted three tape rolls and a shitload of plastic bags on it. Couldn't get it to keep the pressure. Manage to get 1.5 bar into it and couldn't see any leaks in the crossmember or the IC. Would have preferred to get 2 bar into it. I will see if I can get a better steel pipe manufactured for it because I'm still not convinced that it's leak free since there was such a huge difference with my IC and crossmember compared to Kroegarns.

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155555km and intercooler swap

Written by NEO May 10 2009 at 12:52.

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While testing the car a bit more today I passed 155555km on the speedometer. Still problems with it cutting out on full boost. A fellow Swede named Kroegarn (thanks a bunch mate!) lend me his original ABY intercooler and crossmember so I could test with that one. Have had an odd feeling that it might be either the IC or crossmember that's leaking on my car. The car for sure ran better with his parts but not 100% ok. It could be that his stuffs leaks where the IC connects to the crossmember. Since there was such an extreme difference compared to mine I have to pressure test my crossmember and IC. Will try to build something so I can do that while they're not mounted on the car.

Oh... The car have also passed the annual MOT without any problems. =)

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Rear calipers and first ride of the year

Written by NEO April 26 2009 at 12:47.

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I have done some more measuring on the rear brakes. Seems like I must space the discs out 4mm on each side. And too do that I need to get new hubs manufactured. Damn! =/ Also kinda odd that the carrier isn't all parallel to the disc, as seen on the first picture here. =/

Once I realized that I must space the discs out I got sick of it. I mounted the wheels and lowered the car down on the ground. I drove it out of the garage for the first time this year. I drove it home and washed it, it was dusty as hell since a yellow rally Golf have been sanded down in the garage over the winter. I can also just confirm that nothing I did this winter solved the overboost and cutting out problem. It's still doing it! Man I start to get sick of that shit. Once it was washed I drove it back to the garage.

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Front caliper brackets are manufactured! More work on the rear brakes

Written by NEO February 04 2009 at 12:25.

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Fräsarn/Fraesarn aka Danne manufactured the final brackets for the RS4 8pot calipers. He did an excellent job! It took a while for me to get the measurement correct but now they are perfect. I will probably anodize them so they'll resist weather and wind better. The calipers centers perfectly in the wheels!

I have also fitted the rear carriers with timesert thread inserts. If timeserts are good enough for airplanes they should be good enough for my little S2. =) Though the next issue is that it seems like I must space the disc out from the wheel hubs. =( Plus that I'm not sure on how to solve the handbrake wiring.

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Rear RS4 calipers

Written by NEO January 11 2009 at 11:21.

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Been looking a bit at the rear calipers and ran into some problems. The CC for the mounting points is a-ok. But the holes on the brackets are M12 and on the wheel bearing housing they're M10. Frustrating problem. Looking into various solution involving thread inserts.

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Caliper brackets and crank house breather.

Written by NEO November 27 2008 at 11:06.

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I got the metal caliper bracket back from the manufacturer. He modified it for me since it still didn't meet my requirements. It was faster and cheaper to modify it then manufacturing a new one. Though the modifications didn't go as good as I've hoped, it's still off.

I have also removed everything related to the crank house breather. Thought I should replace all the small hoses for it. That's also a step in my search for what's causing the overboost and problems I'm having.

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AC leak, airbox, caliper brackets and boost leak

Written by NEO August 01 2008 at 00:25.

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Just out of pure luck I accidentally stumbled across that AC leak that I have been searching for for a long long time. A year or two ago I had the car over at a firm that repairs ACs. They couldn't find the leak then but added some trace fluid to the system and this is what caught my attention today. The pipe that connects to the firewall had a fairly large hole in it. I have bought a new pipe and radial seals.

In the continuously search for the boost leak and the reason why the car cuts out I have been filming the exhaust temperature gauge, the boost gauge and a lambda meter. I had to build a little box for it which can be seen up here. I have also been testing with a adjustable boost pressure valve but that didn't to much good. After those attempts I once again pressure tested the whole system without finding any leaks. Frustrating!

I have also received a new prototype for the caliper brackets, now in metal from another manufacturer. Though it's still off! Can't really understand how da heck am I measuring. Am I constantly drunk in the garage?

During the pressure test session my brother came over in a sweet Audi TTS. Really awesome car! Can't wait for the TTRS!

I snapped a few pics on the ECU as well. Had that opened again to see if there were any leaks in there. Couldn't see anything odd but snapped a pic of the resistor you have to change when you rebuild the box to RS2-specs. =) Oh, the chips on one of the pictures are labeled 380hk, that's not correct. It's 350hk.

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