Good stuff man. You should have called me, I didn’t leave until yesterday morning. I would have definitely come by to help, seeing as you helped me twice in a week.
Noticed you had that same runner flap actuator as my mom’s q5 3.2.
Really curious why on the 2.0t its an electronic motor and on the 3.2/4.2 its a vacuum actuated unit.
To make things even more complicated it’s a vac on the S4 electric in the RS4.
Electric seems like the way to go, less vacuum lines means less potential for vacuum leaks
Yeah the motors are kinda bulky but when you think about all the vac line needed and then the vac reservoir it is a much more simple system having the electronic motors. It should also be more precise.
So here’s what I was able to do today. First, I cleaned… naturally. Then I installed the oil cooler plate and the Improved Racing oil cooler thermostat that they include with the kit. I just want to say that it was a major bitch to get those lines through the motor mount bracket and then wrapped back around in lieu of the starter being placed right there where the lines need to go. I ended up taking the motor mount bracket off entirely, routing the cables and then reinstalling the bracket. Here’s a picture I snapped of the JHM oil cooler plate.
http://i.imgur.com/8a2siGX.jpg
Then, Josh (Evildsmer) came over and we hung out and did the check valve service as well as the valley pan gasket and the front crank seal. I’m actually pretty concerned about my front crank seal as it’s supposed to be a major pita to get in but once I had the lip of the seal around the crank, I was able to just push it and it slid all the way in. I should mention it was a Victor-Reinz seal and not an official OEM seal. SHould I be concerned with the ease that I got it in? (Innuendos aside)
I removed the old idler pulley, belt tensioner, and the alternator pulley with it’s spacer. I intalled the new alternator pulley and the bracket for the JHM automatic tensioner and I fully intended to finish the 6-rib kit install but I ran into a spot of trouble when it came to removing the old crank alignment dowel. I sprayed it with a ton of PB Blaster on the old crank pulley but I just couldn’t remove it! I tried for quite a while but all I succeeded in doing was sort of mangling it. Does anyone have any suggestions as to how to remove it?
http://i.imgur.com/Lkcvt5B.jpg
Lastly, I’ve been working on this on and off for the past two days but I finally finished wrapping up the lower half of my intake manifold and throttle body elbow in some serious heat shielding. I know, I totally copied JimmyBones but I really liked the idea from the moment I saw it. Just like him, I used Heatshield Products 1/8th inch thick heat shield rated to 1100 degrees constant and 2000 degrees intermittent. This mod, along with the JHM intake spacers, should seriously help eliminate the heatsoak issues that these motors have. I’m excited to see if and how much it helps.
http://i.imgur.com/JCEFOxH.jpg
http://i.imgur.com/KEuDwlo.jpg
http://i.imgur.com/95g2CxW.jpg
So now I just really want to figure out how to remove that dowel from the crank pulley so I can finish the 6-rib kit install.
Nice progress you are cruising!
I’m gonna go down to the PP airstrip attack this weekend, you and josh want to come?
Thanks man!
Josh is busy, but since my car will most likely still be missing a heart on Saturday Matt offered me a ride down there. Not sure how I feel about going down that early but it might be nice! What time were you thinking of driving down?
This exchange happened on Audizine a few hours ago and I think it’s changed my mind about the SAI delete
[quote][quote]looks great, if i were you id do secondary air delete and inspect all the vaccum hoses, regret not doing it when i did my engine. now i have a leak somewhere in the pcv valve area and it pisses me off ! 
[/quote]
I will regret it too… and will continue to regret it while doing the rest of this project because I don’t want to pay an extra $50 just to have to reflash my car again to get the JHM tune with SAI delete. I really really really should’ve done it when I bought the tune because blockoff plates would be soooo easy to make utilizing the old ECG’s or whatever they’re called but… maybe I should stop being a little bitch and do it… I’ll decide later …lol
[/quote]
So I think I might actually just delete the SAI system and pay JHM for the SAI delete reflash later on. It’ll suck to drive around with that CEL right after doing all this maintenance but hey, masking tape over the CEL icon has always taken care of that problem for me in the past.
Has anyone else on here fabbed up some plated for the SAI delete? I figure that all I’d have to do would be to grind off the ECG mounting brackets and stick some aluminum behind them to block off the holes.
im in no rush. Might leave around 8 or 9 or 10
Or 11 or noon. Lol I’m not too huge on car meets but I am interested in meeting Matt
Imitation is the greatest form of flattery. You did a good job and it looks great. I also did a tiny strip down the sides of the manifold that goes between the sides of the intake manifold and the cylinder heads just because I had a lot of material left over. It seems to make a big difference on my car and it should help on yours.
I will regret it too… and will continue to regret it while doing the rest of this project because I don’t want to pay an extra $50 just to have to reflash my car again to get the JHM tune with SAI delete. I really really really should’ve done it when I bought the tune because blockoff plates would be soooo easy to make utilizing the old ECG’s or whatever they’re called but… maybe I should stop being a little bitch and do it… I’ll decide later …lol
[/quote]
So I think I might actually just delete the SAI system and pay JHM for the SAI delete reflash later on. It’ll suck to drive around with that CEL right after doing all this maintenance but hey, masking tape over the CEL icon has always taken care of that problem for me in the past.
Has anyone else on here fabbed up some plated for the SAI delete? I figure that all I’d have to do would be to grind off the ECG mounting brackets and stick some aluminum behind them to block off the holes.
[/quote]
Since I have the JHM SC, my SAI pump is already deleted but I want to make block off plates while I am doing my timing service right now too. There isn’t any need for the additional hoses and the combination valves since they don’t do anything any more. I figured that I can cut out small pieces of thin steel that I get from either Home Depot or if I can find some scrap around the house. Use the SAI gaskets as templates for the basic shape and the material doesn’t have to be very thick. Then drill holes in them for the bolts to go through and reuse the old gaskets. There was a local guy that replaced his engine and he made block off plates out of pieces of an old license plate that he had laying around for example.
So I think I might actually just delete the SAI system and pay JHM for the SAI delete reflash later on. It’ll suck to drive around with that CEL right after doing all this maintenance but hey, masking tape over the CEL icon has always taken care of that problem for me in the past.
Has anyone else on here fabbed up some plated for the SAI delete? I figure that all I’d have to do would be to grind off the ECG mounting brackets and stick some aluminum behind them to block off the holes.
[/quote]
Since I have the JHM SC, my SAI pump is already deleted but I want to make block off plates while I am doing my timing service right now too. There isn’t any need for the additional hoses and the combination valves since they don’t do anything any more. I figured that I can cut out small pieces of thin steel that I get from either Home Depot or if I can find some scrap around the house. Use the SAI gaskets as templates for the basic shape and the material doesn’t have to be very thick. Then drill holes in them for the bolts to go through and reuse the old gaskets. There was a local guy that replaced his engine and he made block off plates out of pieces of an old license plate that he had laying around for example.
[/quote]
I remember one guy making something like this for the 2.0t out of aluminum cans. Easy to cut with scissors and it worked out pretty well for him. Thought I think some slightly thicker steel would be a better long term solution.
I will definitely be doing the sides of the IM ports. Also I have plans to use a lot more of that heat shielding… 
As far as SAI deleting, I’m definitely gonna just grind off the old mounding brackets and cover the holes on the inside with some aluminium. May even weld it on if Martin let’s me borrow his welder.
What do you say man? Welding lessons?
Okay, can I just say… HOOOOOOOOOLYY SHIT!!! Jace (@BoostedAvant) is by far the most talented person behind a camera that I’ve ever seen! Here are some pics from a photoshoot we did two weeks ago
Que the pic whoring
https://c1.staticflickr.com/1/382/18514959393_aa67500002_h.jpg
IMG_3926-2 by Jace Stout, on Flickr
https://c1.staticflickr.com/1/524/19109425086_036d55acc9_h.jpg
IMG_3973 by Jace Stout, on Flickr
https://c1.staticflickr.com/1/522/18949445399_200ce40751_h.jpg
IMG_3898 by Jace Stout, on Flickr
https://c2.staticflickr.com/4/3932/18949630769_a26e3085a1_h.jpg
IMG_4183 by Jace Stout, on Flickr
https://c1.staticflickr.com/1/498/18948043750_b0f84f9bcd_h.jpg
IMG_4162 by Jace Stout, on Flickr
https://c1.staticflickr.com/1/371/18949617929_654c6256c9_h.jpg
IMG_4093-2 by Jace Stout, on Flickr
https://c1.staticflickr.com/1/465/19135752135_5fe47e24a5_h.jpg
IMG_4080 by Jace Stout, on Flickr
A few of Josh’s amazing Imola too
https://c2.staticflickr.com/4/3791/18949469569_f7402c9f7b_h.jpg
IMG_4046 by Jace Stout, on Flickr
https://c1.staticflickr.com/1/258/18514973173_8fcc4f599e_h.jpg
IMG_4007 by Jace Stout, on Flickr
https://c1.staticflickr.com/1/436/19135597105_e823651e9c_h.jpg
IMG_3994 by Jace Stout, on Flickr
Absolutely stellar work. I couldn’t be more impressed! Thanks again Jace [up]
I wouldn’t weld the pieces on. It would be better to just have something small that covers the holes and bolts on. Aluminum can be a bitch to weld since it melts at such a low temperature. It can be almost as frustrating as stainless steel.
Guess I’ll just make brackets out of the old mounts and stick metal underneath. Maybe put some JB Weld on them to hold the metal cover in place.
Ha no…we will fabricate something. Lol get outta here with your jb weld
Fine 