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1.8t 20v conversion RX8 track build.

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Tue Mar 01, 2016 12:45 am PostPost subject: 1.8t 20v conversion RX8 track build.
Rexy-racer
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Don't know if this will intrest you guys. But I've started to put a 20v turbo in an rx8, the help I've received from rubjonny & toyotec, has been invaluable & convinced me to join the club.

I'll start by copying the first few posts from another forum to get us upto date.
I've decided that I'm going to do an engine swap in my track car project. More out of curiosity than anything else.
I've seen a few projects done, but with no real world feedback.

Here's some of the things I'll try show.
•REAL & FULL cost of conversion.
•Time actually spent working on car.
•How car compares once finished (if finished) have my other RX8 to compare it with.
•Cost of any engine modifications. (Again if finished)

I'll keep editing this first post with costs & times.

COSTS.
•RX8 £200
•Transporting RX8 £90
• Audi engine, loom, ecu & gearbox(will be sold on) £200
• 2 sheets of cardboard for adapter plate £4
• sheet of MDF (mock up adapter plate) £10.38
• steal plate for adapter £26.38
• taper bit for adapter plate £10.99
• SAI blanking plate £12

Total so far = £553.75

Upgrades parts costs, not required for swap but I want them
•Exhaust manifold £99

TIME.
•Removing engine & box from Audi 1:15 (was just over an hour, will round things up to the nearest 15 mins)
• Remove engine from RX8 2.30 (lots of swearing involved [-X )
• Sit block in place & take some measurements, experiment with what clutch could work. (Time including picking up parts 2.30
• draw up adapter plate on cardboard 0.45
• center engine in the bay & start to cut the bulkhead. 2.00
• Remove dash & air con unit. Was a pain, but now I've done it I recon I could do it in have the time now. 3.30
• Cut some more from bulkhead. 1.00
• Cut even more from bulkhead to get inlet, cam cover & exhaust manifold on. 4.15
• bulkhead made 5.15
• passengers side engine mount made 4.30
• adapter plate 3.30
• drivers side engine mount 3.30
• loom work so far 4.15
• remove bumper & radiator 2.30
• crank pulley modification & trigger wheel mount. 1.30
•better engine mounts made. 2
•rx8 alternator fitted to VW bracket. 1.30
•flywheel & clutch fitted, engine in place. (time includes freeing off a lot of bolts for subframe, rack & anti-roll bar). 6.15
•modify metal water pipes to fit. 3.15

TOTAL TIME SO FAR. = 55.45


If you can think of anything else, just post up & I'll add it on.
I have no time limit on this, but will do my best not to let it drag on forever. Finishing off a xr2 turbo track car for a friend over the next week then this is top of the list. Wink

Engine I will be using is the VAG 1.8 20v turbo, not my first choice of engine. Cheap & plenty available. Massive market for tuning & one of the main reasons was, easy to use standard ecu.

This is the RX8 I bought with low compression for £200




Got the car dropped off to remove the engine from.









I'll do my best to answer any questions as I go. Wink

Cheers John


Last edited by Rexy-racer on Fri Apr 08, 2016 4:45 am; edited 7 times in total
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Tue Mar 01, 2016 12:46 am PostPost subject:
Rexy-racer
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Finally got the xr2 I was restoring & convering to a turbo finished & MOT'd last month.







So after taking a few weeks off the REX has finally made it into the garage. Mr. Green

Cheers John
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Tue Mar 01, 2016 12:47 am PostPost subject:
Rexy-racer
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Removed the engine. Lots of seized & snapped bolts, as the car has been lying by the sea in Wick for 2 years before I bought her. #-o











Now the hard work starts. Collect a loan of a mockup block later this week.

Cheers John
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Tue Mar 01, 2016 12:48 am PostPost subject:
Rexy-racer
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Well picked up a lone of a scrap block for mock up, so stuck it in to take a few measurements.


Also got donated a few old flywheels & clutches to have a play with. Have found a mix that might work. 1.9 tdi a4 solid flywheel (if I can find one at a reasonable price) with a 4x4 Sierra Cosworth friction plate & Audi pressure plate. Fly would need a lip machined on it to take the rx8 starter ring gear. Or get a custom fly made to take rx8 clutch. Once adapter plate arrives I can take final measurements & make a decision.
So most of my time has been spent like this. Rolling Eyes


Another 2 1/2 hours spent. Including picking up parts donated.

Cheers John
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Tue Mar 01, 2016 12:49 am PostPost subject:
Rexy-racer
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Broke out the CAD (cardboard aided design) to make a start on a mock up adapter plate. First plate will be made out of wood, just to check fitment & I can take all measurements from that. Saves money on wasted steal if it's not right. [-o<



Cheers John
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Tue Mar 01, 2016 12:49 am PostPost subject:
Rexy-racer
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Offered the wooden mock up adapter up to the VW engine. So far so good. Just need to see if it fits both together. [-o<



Cheers John
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Tue Mar 01, 2016 12:50 am PostPost subject:
Rexy-racer
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Engine & box bolted together using mock up adapter plate. Time to get engine mounts made, then make room for the head. #-o



Cheers John
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Tue Mar 01, 2016 12:50 am PostPost subject:
Rexy-racer
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Spent some time, got the engine centred & at the proper hight in the bay. All measurements taken from gearbox on my rotary powered rx.


Sat the head on to see how much I'll need to cut the bulkhead. Shocked


Some more clearance required, could just use a bigger gearbox adapter, but want engine as far back as possible.


Cheers John
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Tue Mar 01, 2016 12:51 am PostPost subject:
Rexy-racer
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Unfortunately I didn't manage to make the road trip this weekend. Rolling Eyes But did put some time to good use.

Dash looked so nice at the start of the day.


But it had to go.






Gave me the acess to cut the bulkhead so I could get the engine as far back as I want. Still lots of clearance needed & then work out how I get a heater back in her. :-k


Cheers John
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Tue Mar 01, 2016 12:52 am PostPost subject:
Rexy-racer
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Most of the engine physical in the bay today. Lots had to come out the bulkhead. Need to put a bit of strength back into it next.


Inlet on.


Exhaust manifold on. This isn't the one I'll be using. Proper one I have has the turbo further forward.


View from inside the car. Might not need fancy gauges. Passenger could just lean forward & feel intake & exhaust temps. Razz




Bonnet even fits. Very Happy


Cheers John
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Tue Mar 01, 2016 12:52 am PostPost subject:
Rexy-racer
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Didn't get a chance to work on the car today. But sat the strutbrace back on, just to show how far back the engine is sitting.


Could even put the standard cover back on. Wink


Cheers John
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Tue Mar 01, 2016 12:53 am PostPost subject:
Rexy-racer
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Sorry guys not had much time to spend on the car. But managed to get some time during the week to make the adapter plate.


Made the new bulkhead this weekend. Have left a removable inspection plate, to allow access to the rear of the engine.


Should be enough room for the engine now.


Plan of action for this week is to get engine back in with proper plate, make engine mounts & take final measurments for flywheel.

Hope to keep this post moving & updated now.

Will update time spent ASAP.

Cheers John
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Tue Mar 01, 2016 12:54 am PostPost subject:
Rexy-racer
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Passengers side engine mount tacked up.


All welded up.


Cheers John
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Tue Mar 01, 2016 12:55 am PostPost subject:
Rexy-racer
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Got the drivers side mount tacked up.


All welded up.


Mock up engine in, sitting on its own mounts. Still have proper spacers to make to replace washers.




What do you think so far guys?

Cheers John
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Tue Mar 01, 2016 12:55 am PostPost subject:
Rexy-racer
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Made a start in the loom last night. Note to self, if someone who knows, tells you to try & avoid a loom from a Passat or A4. Next time listen. Most of loom is invaded in a foam/tar, that has to be removed. #-o

Started like this


Got it this far before I needed a break, it really is a nightmare. Sad


Everyone in work thinks I'm mad, sitting doing this on my teabreaks. Razz

Cheers John
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