I’ve been spending most of my time getting the car together, but I do have some updates on the turbo system as well. This stuff is “in process”.
Intercooler water plumbing:
I deliberated on where to mount the pump and eventually settled on putting it on the engine. It fits well here and none of the noise will get transmitted to the cabin. The pump is a Pierburg CWA100, which is substantial overkill. I can, however, control the speed of the pump with a PWM signal from the ECU. The plan is to run it nice and slow and then adjust as things heat up.
The bracket is making use of the three bosses used for the throttle linkage plate. The pump needs amount further back so the bracket got a little bit exotic. The plan is a 3D print this out of aluminum.
Yes, that's an Audi coil sitting on there too. Turns out when you twin plug your heads, you can't fit the lower coil on cylinder 3 without the stock heat exchangers. There's just not enough room. I will remote mount that coil and fabricate a spark plug wire to that lower plug. I have not seen this done before but I don't see a reason why it wouldn't work.
Fuel rails:
The plumbing will all be AN6 with PTFE fuel line. I plan to run mostly gas, but I will also run E85 especially when tuning the engine. The original plan was to braise AN6 fittings onto the stock fuel rails. I had no experience doing this and I was pretty sure I’d screwed it up. So, I designed a set of custom fuel rails that I then 3D printed in stainless steel.
I’ve just started doing the detail work on these like tapping the holes and finishing the bores, and it looks like they’re gonna work. I might end up printing them out of aluminum because they’re much heftier than they need to be in stainless. I’ll share once they’re all finished.
The stock injectors are just for fitment. I have a set ID 1050 injectors that I will use. Each end of the rail has a M10 x 1.5 thread for the AN6 fitting. I actually printed the threads and they weren’t too bad. It made tapping them a lot easier.
