SHOCKY'S ENGINE SWAP - APRIL VISIT

I suppose possibly as pay back (for the times Dan got dirty while I stayed clean) or maybe just as a cruel twist of irony, I got the task of sorting through Shocky's boxes and unearthing all of the engine related components that had been included with the purchase of the AWP and 02J.  Dan had some ridiculous excuse as to why he could not help -- something about having to go to work or some such thing.  If you ask me, I think he was just trying to get out of the chore at hand....

So back to the boxes....as you can see there were quite a few boxes of Shocky parts although fortunately, we had kept the engine related stuff all grouped in the same section....

Sorting through them would have been simple enough except that once I unearthed them, I was going to have to sort through each and every piece to determine what was going to be kept and what could be gotten rid of.  So step one....lay everything out.....easy enough....

Step two:  Does it look like something Shocky might want?  Yeah?  Okay, throw it on the engine (just loosely hanging there)....Shocky emphatically rejecting any notion of putting that item in him?  Well into the trash box it goes...  So I diligently set out to complete this task and got about this far.....:  That would be um....the accessory chunk 'o aluminum they call a mounting bracket (it houses the AC, power steering, and alternator), the oil cooler and oil filter housing, a couplea hoses that you can't see, and um....that was all I got to.  I did however set aside things like the exhaust manifold (got a wheels up on that one....) the notorious K03 turbo setup, all the coolant hoses, and of course the engine wiring harness conglomerate....(to which Shocky just sort of gave a very reserved sigh about).

You will also note in the picture the addition of a throttle body finally...funny story on that...you see there was one TB that I brought with me in March...but amongst several other big player items, it did not fit - bolt pattern was just a hair off of the AWP's intake manifold bolt pattern.  Why not just use the AWP TB in the first place?  Well because Shocky didn't want to use the drive-by-wire setup....so from the get go, the stock throttle body got the boot.  What we ended up going with in the end (and what you see in the picture below) is an ABA throttle body which has the same diameter throttle plate and the same mounting pattern as the stock AWP (60 mm from center to center all around).  Most importantly, the ABA's TB is cable actuated.  We found a cable for it from Futrell Autoworks - a VR6 Corrado Throttle Cable (with an included new pedal bushing! - $54).  So here is how far I got in terms of sticking stuff on the engine that we were going to keep (pretty pathetic, huh?).



This is the bottom of the mounting bracket which houses the alternator, air conditioning, and power steering pump.

Okay, so not much else got done this April visit.......

Went through some of the projects for the next visit.....   


Eh....yup it's an intercooler, and yup....it will fit just fine with the radiator that doesn't exist yet....now all that is needed is the intercooler piping....

Okay....so it is downright impossible to tell what the hell this picture is of.....but if you click on it you can get an even bigger version of darkness!!
This would be a shot of well, um the brake lines....and also the lack of fuel lines...both the brake lines and fuel lines are slated for fabrication.......

And what better way to follow up a bad picture than with another bad one?  But this one at least....I am sure of!!
This would be a pic showing where the new fuel lines will be routed.  Instead of being on the outside track, the will be moved to a safer haven further in and then bend back out to where the original line is towards the back.

And here we have yet another fabrication project...the clutch master cylinder install which involves both mounting the MC to the chassis as well as mating together the push rod and clutch pedal.....enter "the clevis" shown below and to the right....guess you will have to stay tuned to find out the plan on that one.........


The clutch MC will be mounted on the driver's side of where the brake booster lives (which would be where that gaping hole is).

And the joys of cable shift!!  Well, it may be all that and a bag of chips, but for now the cable shifter and cables are much more of an annoyance than a joy!  The shifter itself will need to be mounted in the area where the stock shifter sits (after the mounting area is widened a bit to allow for the bulkier setup) and then the cables will get routed under and up to where they attach to the tranny.



Kinda bulky and awkward to store....

Shift box and cables...







The view from beneath.  This is where the shifter box will be moving into....right where the stock shifter mounts.

Oh Boy!!!!  WIRING!!!  WooHoo!!  This is the engine bay wiring harness, which will need to be modified by eliminating all the things that Shocky doesn't want and also wiring in the DTA...

Eeny, meeny, miny, mo to which cylinder does it go?

And so I leave Shocky with a couple of additional things thrown loosely on the engine....but that is about it!  DAMN mounts!!!  They are the bane of my existence at this moment in time (well actually at that moment in time they were.......now they are yesterday's news)

Oh, one last thing I did before leaving....sold Shocky's old tranny to a Scirocco List member....(thanks Mark! Sorry about the tranny code!)...

Cleaned up nicely, dontcha think?



Ahhhh......the wonders of Purple Power.....

...and a little bit of elbow grease!



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