john-t5
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| posted on 29/2/16 at 02:22 PM |
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Rx8 1.8t 20v conversion for track
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
Total so far = £541.75
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
TOTAL TIME SO FAR. = 41.15
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
[Edited on 29/2/16 by john-t5]
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john-t5
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| posted on 29/2/16 at 02:29 PM |
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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.
Cheers John
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john-t5
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| posted on 29/2/16 at 02:31 PM |
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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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john-t5
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| posted on 29/2/16 at 02:33 PM |
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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. :roll:
Another 2 1/2 hours spent. Including picking up parts donated.
Cheers John
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john-t5
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| posted on 29/2/16 at 02:34 PM |
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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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john-t5
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| posted on 29/2/16 at 02:35 PM |
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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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john-t5
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| posted on 29/2/16 at 02:36 PM |
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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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john-t5
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| posted on 29/2/16 at 02:37 PM |
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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. :shock:
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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john-t5
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| posted on 29/2/16 at 02:39 PM |
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Unfortunately I didn't manage to make the road trip this weekend. :roll: 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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john-t5
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| posted on 29/2/16 at 02:42 PM |
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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. 
Bonnet even fits. 
Cheers John
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john-t5
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| posted on 29/2/16 at 02:43 PM |
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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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john-t5
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| posted on 29/2/16 at 02:44 PM |
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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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john-t5
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| posted on 29/2/16 at 02:45 PM |
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Passengers side engine mount tacked up.
All welded up.
Cheers John
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john-t5
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| posted on 29/2/16 at 02:45 PM |
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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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john-t5
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| posted on 29/2/16 at 02:46 PM |
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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. 
Everyone in work thinks I'm mad, sitting doing this on my teabreaks.
Cheers John
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john-t5
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| posted on 29/2/16 at 02:47 PM |
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Well the plan for this week, while I'm waiting on parts. Is to get this cleaned up & ready to put in for the first of many times this
weekend.
Cheers John
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marc_cowley
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| posted on 29/2/16 at 02:51 PM |
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Following. 
C30 T5
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Chaz
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| posted on 29/2/16 at 04:30 PM |
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Ambitious AND I'm following!
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Benzine
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| posted on 29/2/16 at 05:42 PM |
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Decent 
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big_wasa
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| posted on 29/2/16 at 06:24 PM |
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Look forward to progress
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maccmike
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| posted on 29/2/16 at 06:59 PM |
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Keep up the good work
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dinosaurjuice
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| posted on 1/3/16 at 08:45 AM |
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Really like the RX8, and even more so the concept of swapping the engine for a tried and trusted VW turbo lump. Following
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john-t5
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| posted on 1/3/16 at 09:35 AM |
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Got the engine decluttered a bit for fitting in. Also cleaned up a bit too.
Also cut down the front pulley & mounted the RX8 trigger wheel. This is needed to send a signal to the RX8 ECU & should make the Rev counter,
power steering & ABS work. 
Original pulley
Cut aircon belt drive off
Got a stroke of luck to centre it. When I put bolts through the original mounting holes, they are a tight fit into the centre of the VW pulley. There
for centering the trigger wheel. :thumbup:
All done.
Cheers John
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john-t5
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| posted on 6/3/16 at 01:03 AM |
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First part ordered turned up today, can't wait for the rest so I can get engine in.
Cheers John
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john-t5
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| posted on 7/3/16 at 09:38 PM |
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Manifold turned up today, just a cheap eBay one at the moment. Will be upgraded, if conversion turns out to be worth it.
Looks a tighter fit than it is. Engine has to go back over to the right & dropped down a bit. Have the engine mounts back off to do a small mod.
Will make a heat shield to protect brake & clutch master cylinders.
Just flywheel to come, then I can put proper engine in & start the hard work of piping & wiring.
Cheers John
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