started mocking stuff up in wait for the head….
tried to figure out what bumper to use…I gotta hang a pretty big IC (Greddy 28r off my old Mk4) and was thinking it has to fit the rad as well…the V6 rebar seems to work (without the dampers)…I`ll have to drill some holes…
here’s the front done…
interior is ready for some cables:
hey look what I found at the local junk yard…
all of my problems are solved 
lovin the price list too: rad 40$, alu head with cams – 40$…gotta put apart a whole lot of it to get to the passenger side engine mount though – pain in my a**…
oh wait – I was wrong…the rad won’t work 
drivetrain is complete – everything is installed…had a little problem with the front diff supports – the shop welded the plates with the thought of using nuts on top – super hard when the gas tank is in to get nuts on top of the diff nose….might have been better if I had the gas tank in place when they were doing the brackets…
also got the passenger side engine mount on – needed a little trimming to the mount but get everything nice and tight at the end…had to figure out the rad and the intercooler today so I mocked it all up…installed the TB to see how things will line up with the side rad…
a few of the options are:
1. 7A rad – tilted sideways to clear the AAN intake and TB
2. 7A rad tilted in a combination with a short front mount rad to improve cooling
3. V6 rad with V6 rebar
4. 4cyl rad with 4cyl rebar
5. AAN rad with custom rebar
some limitations:
- AAN intake and TB position
- clearance on front
- Front bumper design
- Intercooler mounting
- AAN vs. 7A accessory belt setup
and this is what I came up with:
1. too much work to install, insufficient air flow, no space for stock fan, ugly as sh*t
2. still too much work, a little better air flow, looks like poop, must find a skinny rad, no space for fan behind front rad due to accessory belt
yeah…that’s not gonna work…so let’s see what else can be done here…
3. fits perfectly (sort of)…spaced the rebar 1.5″ forward to clear the accessory belt – plenty of room behind the bumper BUT still no space for a rear fan…the V6 rad is slightly taller than the AEG rad so the rebar dips down…if it was on it’s own it would be perfect – unfortunately that goes smack in the middle of the front bumper opening, which of course is reserved for the intercooler…it would look like poop and doesn’t leave me with much space for the IC itself unless I use a sidemount which would be too much work and wouldn’t be very efficient
4. Ok – now we’re cooking….there’s def difference in the cooling area of the 4cyl and the V6 rads but not enough for me to scrap the idea…the rebar hides right behind the bumper and if I tuck the IC inside of it (will need some cutting) it will line up with the bumper perfectly….the rebar still needs to be spaced out about 1.5″ (or cut out to clear the accessory belts – decided against that because there wouldn’t be much structure left to an already weak bar) but with that there’s lots of room for the belt behind…still no space for a ‘sucker’ fan, however I can easily mount a pusher on the front provided it’s skinny enough…my dad drives a Mercedes Sprinter and showed me the AC fan they use which is no more than about an inch wide and mounts to the front of the AC rad…I`m lovin it and I’m sure there’s other aftermarket solutions to that as well…
5. way too big, too much work, no space for intercooler, no space for fans
so – there you have it folks – the decision’s been made…I will try to finish all of the work today and take pictures of all the options discussed above (forgot my camera yesterday)…of course this will need to be tested – no question about it…I will be bringing an extra rad or two with me just in case we need to modify the system….I`m also planning on returning the 7A and get that skinny Echo rad and fan – they might make a good secondary rad for this setup and should have no problem fitting on the side…
while I was working on the rad setup I also finalized the accessory belt situation – I was going to try and use the 7A dual V belt idea, however looking at the brackets and the main pulley – everything gets pushed way too forward….the AAN pulley uses one big belt to drive everything (similar to my B5 actually) and keeps things tucked away….I wanted to eliminate the fan pulley bracket but I`m running out of time to make my own supports so it will have to stay for now…so I will be using the 120A alternator and the AAN hydraulic pump…i`ll have to look into the pressure differences between the B4 and the S4 pumps but I thought people said everything should be fine…
the car is scheduled for exhaust and IC piping next week…Sam@034 hopes to send the head back to me by the end of this week, which means it should all come together next weekend…I`ve also started working on the wiring – I split up the engine and chassis harness yesterday – the next step is to install the engine harness, install the B4 chassis harness and mate the two together…this should all be finished by sunday but can’t test it until the head’s back…
certainly did wonders for boostin my enthusiasm 
