infernosg's S5 N/A Build

[infernosg]

Even smaller Update.

Nothing much done lately. 50+ hour work weeks leave me not wanting to do anything during the week and with the nice weather I've been spending too much time at the range on the weekends...

The S5 N/A rotor housings and the S4 TII intermediate plates have all be cleaned up and resurfaced. Many thanks to Jonathan at Goopy Performance and Chip at Chips Motorsports for the service. I don't have pictures of the rotor housings at this time but see the intermediate plates below (courtesy of Chips Motorsports):



You can see more photographs in his (To_Slow) thread. All sealing surfaces have been lapped and re-nitrided and all unneccesary cooling ports have been plugged. These look SO MUCH better than they did when I sent them out. If I can get them back in my hands before the weekend I may try to take a trip to Columbus to talk about some porting and fabrication work with Defined Autoworks.

[infernosg]

Still slowly working on this.

I had everything back for a while so I decided to take some pictures of the shiny stuff. Lapped/cleaned intermediate plates (thanks Chips Motorsports!):



Resurfaced/cleaned rotor housings (thanks Goopy Performance!):



Clean rotors:



For giggles I put the plates and housings together. I actually kind of like the grey/silver theme. It will definitely be easier to spot leaks versus those on black/silver or black/grey parts.



Then I went back to work on the wiring. Engine harness this time:



Engine bay as it sits now. Every stock engine control connection is gone. The only things that remain are the charging system, lights and transmission switches.



Basically done stripping the wiring harnesses so now I need to plan where all the new stuff is going. Ideally, all the new wiring for the new gauges and control system will be loomed with what remains of the stock harnesses but I don't think that will be completely possible.

The rotor housings and plates are off getting ported now as well with Defined Autoworks. Ilve also been talking with them about getting an intake manifold, header and throttle bodies fab'd up.

[infernosg]

A few quick updates. Been working slowly as "real" work has been kicking my ass.

Used old engine parts to make a dummy engine for figuring out where stuff needs to go:



I've been going through a lot of the stock connectors and replacing them with Weatherpack connectors too.

Test fit new radiator:



Going to need to make some kind of shroud around it to force air through it.

Stock mechanical fan is being replaced by a 16" puller. Supposedly pulls 3000 CFM at 10 amps continuous. Not sure if I'll shroud this or not as the car really won't see a lot of driving in traffic.



Note Weatherpack connector again.

Made ECU/relay mounting thing out of .025" aluminum. Everything fits in the stock location and there's a thicker aluminum kick plate that covers everything up. Mounted new fuse panel behind the passenger's kick panel as well:



Temporarily installed dual wideband gauge (displays info from two sensors at once) so I can run all the wires:



Other gauges:



Gauges are Marshall Instruments SCX Pro in black/black. Pretty good for the price (~$100): 270 degree stepper motor, warning output, peak recall. Super company to deal with too. Not sure where to mount the recall button just yet.

Irons/housings are still with Defined Autoworks. They ran into a problem with the front iron and it had to be replaced but it looks like everything will be taken care of.

Need to find someone with a TIG locally to weld shut the heater port on the radiator.