kcfoxie's "lets rebuilt that bitch" thread... [Archive] - NCDubs | VW Audi Porsche Performance News & Tuning Forums

kcfoxie

June 25th, 2009, 08:36 AM

I'm waiting on some photos from the pinky, but here's the nitty gritty:

So about 3000 miles ago my car started to make a funny rattle. As usual I didn't think a thing about this and drive it over 2000 miles round trip to Mississippi and back.

Then we realized that I'd sheared off the bolt screw hole off the alternator bracket.

And the dog ear locking tab off the block for the aft motor mount bolt. eek.

So the car was driven 2k miles with a single bolt holding up one side of the engine, with the motor mount rotated and trying to take out the timing belt housing cover.

We all know how the foxie drives......

Anyway, I've got the timing belt kit, and the van gough block repair kit... engine has to come out to grind away some crap in the way to make the van gough block kit work on the BRM TDI.

Once that is done it's a t-belt job, new coolant, new lube in the gearbox, maby some brake pads.

I also ripped off all the VW logos in an emo fit of rage. I bought a black badgeless grille. I intend to make the vehicle sound like a boeing 747 before it is buttoned up (via home made CAI and just a straight pipe). Oh and I got a peace emblem for the trunk lid.

Alls well that ends well; but this was rather untimely. On the up side we checked the cam and the cam looks really good, don't think I'll be having failure any time soon (should be able to get to 150-175k before needing to worry I'd guess). But I want to do a visual inspection on the cam every oil change going forward.

So, yeah... this is why teh foxie has been absent from GTGs and the like.

djwhiplash2001

June 25th, 2009, 08:49 AM

Whatcha doin with your old grille? Donate to DJ? :p

Getting a hood with the notch filled for the badgeless grille?

JessaBug

June 25th, 2009, 08:58 AM

Oh cmon...just bring out the Escalade! :p

kcfoxie

June 25th, 2009, 12:57 PM

$20 @ 2.69 = 111.45 miles .. that's why I'm selling my grilles and stuff. To feed the beast.

pinky

June 25th, 2009, 03:14 PM

i only got pics of the cam.. they are probably not very good (cell phone, weird lighting) and they are still on my phone.

kcfoxie

June 26th, 2009, 09:33 AM

jah, I want those. if you get them off the phone post them in this thread, i'll grab a copy.

kcfoxie

July 2nd, 2009, 11:20 PM

http://lh5.ggpht.com/_N1d6GLR2rZg/Sk14IaeK-8I/AAAAAAAADHc/rFfaqu92a6c/s400/2009-07-02%2018.38.25.jpg
http://lh4.ggpht.com/_N1d6GLR2rZg/Sk14IaXtkkI/AAAAAAAADHg/3X9PQG_4zxU/s400/2009-07-02%2018.38.35.jpg
http://lh6.ggpht.com/_N1d6GLR2rZg/Sk14Iis-gLI/AAAAAAAADHk/3gVtJBhfO24/s400/2009-07-02%2018.54.11.jpg
http://lh3.ggpht.com/_N1d6GLR2rZg/Sk14Iy8ie7I/AAAAAAAADHo/biJPa0BUOZw/s400/2009-07-02%2018.54.48.jpg
http://lh5.ggpht.com/_N1d6GLR2rZg/Sk14JDJfiTI/AAAAAAAADHs/yG9GYTvliYo/s400/2009-07-02%2018.56.10.jpg
http://lh4.ggpht.com/_N1d6GLR2rZg/Sk14TwYzrdI/AAAAAAAADH0/-AF1F9QWGag/s400/2009-07-02%2018.56.43.jpg
http://lh3.ggpht.com/_N1d6GLR2rZg/Sk14UEVVqQI/AAAAAAAADH4/ljDHVqqn5y4/s400/2009-07-02%2019.02.57.jpg

Vampire Cockroach

July 3rd, 2009, 12:05 PM

http://lh3.ggpht.com/_N1d6GLR2rZg/Sk14UEVVqQI/AAAAAAAADH4/ljDHVqqn5y4/s400/2009-07-02%2019.02.57.jpg

oh now i see how it broke. you are one dirty boy foxie. :gt-ogb-spank: :eek: :hiya:

kcfoxie

July 3rd, 2009, 01:20 PM

my name shall now be "wheel hop foxie"

jnecr

July 4th, 2009, 01:28 PM

wow... you don't play around do ya?

kcfoxie

July 4th, 2009, 08:34 PM

Well I guess the answer to that is no, I don't.

The irony is most of the EGR needs to be removed to make the fix kit work. Oh how sad that I must remove my EGR system. Boo Hoo. Boo hoo hoo hoo.

So once we put it back together, you + me at rockingham? :D

evan@absolute

July 4th, 2009, 09:11 PM

only seven pictures??? What the hell kind of build is this?

kcfoxie

July 5th, 2009, 09:18 AM

Its called I was running to get Red Vault and no one else had a camera because they were busy pulling a motor kind of build.

Now that I'm getting ready to come back to Raleigh I'm curious what may be missing off the engine now. Tho I told Gerich that it's the holiday, don't work too hard, so it may not be touched... which would be fine, I want to take more photos with a real camera with macro mode.

still evan admit that i broke it good.

pinky

July 6th, 2009, 04:22 PM

fwiw, the engine mount bracked on the pass. side also bolts to the aluminum alternator bracket, which was broken similar to the tab on the block.

evan@absolute

July 6th, 2009, 04:47 PM

fwiw, the engine mount bracked on the pass. side also bolts to the aluminum alternator bracket, which was broken similar to the tab on the block.

fwiw do you mean bracket or broke when you say bracked?

And Foxie you did a good job. I have only seen the tab broken twice before. One where a pan was run into a curb and one where the bolts were left loose during a timing belt install.

pinky

July 6th, 2009, 05:16 PM

wolfsburged

July 6th, 2009, 10:33 PM

I guess both good and bad to see that engine out.. .Good that there is progress, bad that there is I'm sure a ton left to do!

kcfoxie

July 7th, 2009, 09:19 AM

engine mount bracket bolts to the alternator bracket... broke the alt. bracket where the bolt goes in (similar to the tab on the back of the block)

(what i meant, now improved with proofreading!)

yes, there was only one bolt holding up that side of the engine and it was loose.
So the last remaining bolt was also lose? So it's less likely overtorqued and more likely none of the bolts were to spec? (Like the bolts that hold the outer door skin to the door frame?)

Lovely!

I've got some picts I'll throw up later, of the Van Gough installed + the new Alternator bracket.

pinky

July 7th, 2009, 10:05 AM

i dont know, but when the engine came out the bracket was flopping around. i dont think you can really say they were undertorqued, you did drive it after it clunked for at least a couple days, right? who knows what could have happened with that side of the engine being allowed to move that much (only one bolt holding it up)

and i think saying they were overtorqued is purely speculation. once one of the tabs let go, i'm sure the other was quick to follow. whichever one let go first could have broken for several reasons.

kcfoxie

July 7th, 2009, 12:53 PM

Yes but the veterans of TDIClub say this failure occurs in only one fashion:

After a timing belt job where the aft bolt is over-torqued, snaps the ear tab, and takes out other locking points after it.

More like I drive it 2000-2500 miles with the rattle. I went to Mississippi and back with it like that.

pinky

July 7th, 2009, 01:53 PM

yeah, aren't you on the original timing belt?

so, in theory, this never happened. (that's not an excuse to get out of the bill)

kcfoxie

July 7th, 2009, 03:14 PM

I am. Hence why I say the drunk mexican overtorqued it on monday morning when he or she assembled my car.

The car was built on either the 13th or the 20th of November 2006, I want to say the 20th, which was a Monday.

The Monday rule applies here; I knew this early on when bolts holding my outer door skin on started falling off the car at 2,000 miles.

pinky

July 7th, 2009, 03:21 PM

how long, on average, does it fail after the bolt is overtorqued during a timing belt job?

kcfoxie

July 7th, 2009, 03:26 PM

Depends. Some folks reported 20k miles before it broke. Being chipped or stock seems to play a role.

I think it was a combination of things. Chip, stiffened dogbone, driving like a bat out of hell, burn outs, and a not to spec or overspec torquing of that bolt lead to the failure. What gets me is that no time did it ever seem lose when we had it on the lift (I did look at those things, and it'd be kind of obvious).

I'm guessing it broke between 87 and 88k miles, between oil changes. I checked at 80k and everything seemed OK (I started checking these things a little after the doors starting to come apart).

wolfsburged

July 7th, 2009, 10:25 PM

Took a look at this thing on the engine crane today... damn that thing really took out some chunks!

Also Chris your turbo is so tiny! I think we need to trade ;-)

kcfoxie

July 8th, 2009, 09:26 AM

My turbo is tiny. I was surprised how little it is.

Did you notice how little gunking the turbo had on the exhaust side? The ULSD really does reduce sooting, I was impressed. I'm not going to clean the intake for another 100k because of how the exhaust port looks.

jnecr

July 8th, 2009, 04:37 PM

Did you notice how little gunking the turbo had on the exhaust side? The ULSD really does reduce sooting, I was impressed. I'm not going to clean the intake for another 100k because of how the exhaust port looks.

That makes no sense. Of course the exhaust will not have "gunking." It's got exhaust coming out at 1600 degrees!! Gunking occurs when the soot from the exhaust meets the oil from the PCV valve. They combine and at a couple hundred degrees form this hard "gunk." This will never occur on the exhaust side of the engine because everything is burnt, there's no liquid oil with which the soot can combine, meaning no gunk can occur. Don't rely on the cleanliness of the exhaust manifold to determine when you need to clean the intake manifold... Some buildup of soot can occur on the exhaust side of the engine, but it's nothing to what is on the intake side.

And I'll contribute your borked engine mount to wheel hop and not being nice to your little 1.9L. :)

wolfsburged

July 8th, 2009, 06:57 PM

If there's anything you ever wanted to clean, I'd go ahead and do it now while you don't have a pesky car around it.

kcfoxie

July 9th, 2009, 10:41 AM

gah ok, i'll take ya'll wisdom on the matter.

however if it's cleanish inside.....

I'm nice to my TDI. I don't use WVO in it :)

kcfoxie

July 17th, 2009, 09:23 AM

Updated photos of the van Gough block kit fix installed, ready for action:
http://lh6.ggpht.com/_N1d6GLR2rZg/SmB6vqjrDiI/AAAAAAAADK4/urbI76pfgkM/s800/2009-07-16%2020.25.09.jpg
http://lh6.ggpht.com/_N1d6GLR2rZg/SmB6vzyWSII/AAAAAAAADK8/LFKRBWSha8E/s800/2009-07-16%2020.25.29.jpg
http://lh6.ggpht.com/_N1d6GLR2rZg/SmB6wMcZwqI/AAAAAAAADLA/_md2axx3f8I/s800/2009-07-16%2020.25.37.jpg
http://lh5.ggpht.com/_N1d6GLR2rZg/SmB6wK_oQZI/AAAAAAAADLE/Py6x64s3hpE/s800/2009-07-16%2020.25.56.jpg
Timing belt has been changed. Waiting on Unitronic to see about EGR Delete; otherwise we have to get creative in how the pipe works, the oil return line from the Turbo is certainly in the way with the van gough and we're not grinding into the van gough to put the EGR back on! Hopefully have the car back on the road by the 25th (next saturday)!

evan@absolute

July 17th, 2009, 10:00 AM

did you guys try bolting the egr back on? It looks like with a 10mm spacer where it bolts to the engine and you have plenty of room.

kcfoxie

July 17th, 2009, 10:35 AM

We didn't, we're attempting to delete it entirely.

I was thinking similar but we'd have to bang on the outlet pipe that feeds back up to the intake, and Gerich was nervous about doing that. Also it would cause the cooler to rest less than a few MM from the oil return pipe, and the fear of two pressurized, high temp pipes being near each other suggested that we just remove EGR entirely.

Not that I'm complaining.

One way or another, tho, it'll come back together.

Major

July 17th, 2009, 04:48 PM

when your finished with the CAI and straight pipe, I would like to hear it in person. For personal reasons lol. My 1.8T is accused of being a Dodge Cummings in the dark after straight piping from the cat. I am positive yours will also be louder and seeing and hearing something like that in person on someone ELSE'S car would be nice for a change.

kcfoxie

July 19th, 2009, 10:15 PM

not gonna have a straight pipe yet; can't wait any longer -- need the car back for a while. however with the large air intake it should sound more truckish.

Major

July 20th, 2009, 08:33 PM

very nice. Living out in the Docks' now I think people just consider me to be a truck when i pull through late at night

kcfoxie

July 22nd, 2009, 10:41 PM

Looks like I managed to avoid deleting it (for now)...
http://4.bp.blogspot.com/_N1d6GLR2rZg/SmetcN6mt2I/AAAAAAAADME/FeHtLW2idGs/s320/2009-07-22+20.16.07-791817.jpg
http://2.bp.blogspot.com/_N1d6GLR2rZg/Smetb-slMaI/AAAAAAAADL8/9X4ChCQ0YTc/s320/2009-07-22+20.16.00-790756.jpg
http://4.bp.blogspot.com/_N1d6GLR2rZg/SmetbSxdDLI/AAAAAAAADL0/o82Fg19qe4s/s320/2009-07-22+20.17.05-789594.jpg

We also are going for a new look.... I don't feel bad about it given the built-in advertising on VWs part (that is really cool).
http://i31.tinypic.com/f1z4vc.jpg

I have some other goodies in store... will post those as I make them/mod the car with them.

djwhiplash2001

July 22nd, 2009, 11:51 PM

Grille looks good, fill that notch :p

kcfoxie

July 24th, 2009, 10:22 PM

had a few other updates. yes, it's supposed to be off-center. the other emblems are going to have their orientation changed tomorrow to match the driver's (i.e. not straight). :)

http://lh5.ggpht.com/_N1d6GLR2rZg/SmplyikY58I/AAAAAAAADNo/xYjuL3ZZhmo/s800/2009-07-24%2018.33.52.jpg

and, finally, a reason to pop my hood at GTG! (that used to be on the trunk)
http://lh3.ggpht.com/_N1d6GLR2rZg/Smply7Clh-I/AAAAAAAADNQ/qfhsbfEP2Cg/s800/2009-07-24%2020.06.33.jpg

Major

July 25th, 2009, 04:00 PM

What is the crag thing for? or octopus or whatever it is. Can't really tell.

evan@absolute

July 25th, 2009, 04:35 PM

Mr. Chan

July 25th, 2009, 06:23 PM

What is the crag thing for? or octopus or whatever it is. Can't really tell.

http://www.venganza.org/

kcfoxie

July 25th, 2009, 06:48 PM

Ok I have to ask.... Why the hell did you take the entire engine out to put a belt and that mount on? That seems crazy looking at the mount. It looks like a timing belt job plus an hour maybe two to fit that mount on there and you are good to go. There is plenty of room to grind away in there if you pull the axle which you did anyway to take the motor out. Seems like a lot of wasted time and effort or I am really missing something.

The developer of the van gough said that it would be best to remove the engine and work with it out of the car, especially since the EGR would be an issue. The EGR has to be twisted to get it out of the way (unless you remove the turbo and maniford), I can't image doing that with the engine in the car, let along trying to get the grinder down into the tight creveces to bring away at the block to get the bit to fit.

It might have been done but it would have been harder work for everyone involved, especially the one doing the grinding.

Major

July 28th, 2009, 07:22 PM

http://www.venganza.org/

WOW.................
I may start wearing a pirate hat now

kcfoxie

July 29th, 2009, 07:13 AM

WOW.................
I may start wearing a pirate hat now
I am often seen with a parrot on my shoulder, but I still need the hat...

http://lh5.ggpht.com/_N1d6GLR2rZg/SlLQyhPAVQI/AAAAAAAADIY/ChPJa3cc59c/s400/67b589-1-9d65bd-c411-full572x572.jpg

kcfoxie

July 30th, 2009, 08:11 AM

One Step closer....

http://lh5.ggpht.com/_N1d6GLR2rZg/SnGN4F1X1kI/AAAAAAAADPo/-9Tg9_ay8L8/s800/2009-07-29%2020.33.31.jpg
http://lh4.ggpht.com/_N1d6GLR2rZg/SnGN4KiuScI/AAAAAAAADPs/iuawRs6YkaY/s800/2009-07-29%2020.33.45.jpg

JessaBug

July 30th, 2009, 08:59 AM

woohoo! So what's left until you can take her home?

Mr. Chan

July 30th, 2009, 09:23 AM

Like the new grill...

kcfoxie

July 30th, 2009, 01:49 PM

Thanks for the props on the looks :)

Electrical, piping, fluids

I hope to have it back Friday, sat at the latest...

pinky

July 30th, 2009, 02:10 PM

Electrical, piping, fluids

reconnect axles, dogbone, airbox, battery, alternator, downpipe...

kcfoxie

July 30th, 2009, 03:13 PM

oh yeah.. I always forget that stuff.

Pete-Diddy

July 30th, 2009, 04:29 PM

Like the new grill...
:plus1:

pinky

August 1st, 2009, 07:01 PM

so i guess it is working now.

chris, how's your day going? :P

2.slowduo

August 2nd, 2009, 11:48 PM

damn break shit!

kcfoxie

August 3rd, 2009, 08:02 AM

so i guess it is working now.

chris, how's your day going? :P
Well now that I see that the speeding ticket isn't going to affect shit, and I'm not wasting my money of any of Wake County's not-so-finest attorneys to handle it, it's ok. I'm still bitter as piss about the trooper, how often does that happen? I know I'm not the first; Yareka and it seems like 2-3 other people have been pulled from speed or other bullshit on a test drive.

I still have an exhaust shield that's rattling, either from a leak or not being bolted down enough, only hear it at idle and it does not bother me.

I didn't drive the car sunday but she fired up today, no bolts have backed out according to the marks, coolant level and oil level are holding... I think she's OK. I have noticed that I'm getting better economy; reported by the MFD which is known to be inaccurate one way or another. I missed having instant passing power.

No more hard downshifts, either.