Re: thoughts on breathing - long

[Chris Jung <palace_master@yahoo.com>]

I put a audi 5000 SW throttle body into my '83 1.8 8V
and I quite like the power increase.  I used a 3"
black ABS sewer pipe to replace the stock intake pipe.
It was hard work getting the stock rubber boots to fit
around the pipe.  I had to cut the pipe at an exact
angle on both ends with a hacksaw.  I also had to take
my power grinder and make the pipe a bit thinner at
the ends, so that I could get the boots around it.  In
my opinion, things would be much easier for you if you
can get some 3" copper pipe.  It can be found
somewhere, just not here in Vancouver Canada.  One
other thing, it is not as easy as other people tell
you to change the throttle linkage from your stock
throttle body to the audi throttle body.  There are a
whole whack of springs and shafts that can NOT be
pulled off of the Audi one.  It might be that the one
I got was peculiar.  Anyhow, I took the Audi linkage,
hacksawed some pieces off, and welded the appropriate
piece in the right spot.  That was a LOT easier than
trying to pull off the pieces.  It is important to
weld the bracket in the exact spot so that you have
your full pedal travel and that you don't have the
throttle binding anywhere.  It took me two tries to
get it right.  It's a bit hair trigger right now, but
it works OK.  I haven't gotten around to swiss
cheesing my airbox, so I'm doing the very nasty
incorrect thing by leaving the clips undone on my
airbox.  

Chris J.
'83 Scirocco GT

--- Colin <cwass99@home.com> wrote:
> Hi,
>      I've been thinking about how to improve my 8v
> breathing and I figured I'd
> better get opinions before I did something permanent
> and annoying.  There are 2
> basic problems to breathing on my stock CIS system
> and they each attach
> directly to the air box/fuel distributor assembly. 
> The first is the teeny
> little pipe that lets air in.  I removed the nasty
> little valve that was there
> and re-ran the hose directly from the box to the
> connection in the back of the
> air dam (yes, it stretched that far without
> difficulty and stays put). 
> I was thinking, though, that this needs to be
> improved upon.  My first thought
> was to 'swiss cheese' the box, but then I had a
> better idea.  If I were to get
> a 2 inch floor drain and cut an appropriate hole in
> the bottom of the box, I
> could attach a second pipe and run it to the grill
> for a bit of a ram air
> effect.  Done correctly and carefully, it should
> look quite neat and tidy. 
> I've also considered cutting off the hose connection
> originally there and
> replacing it with a 3 inch bit of pipe.  Again, it
> should be simple to make
> this look quite appropriate.  Any thoughts or
> comments?
>      The second breathing problem I see needing
> addressed is the pipe that
> joins the air box to the throttle body.  If you look
> closely, you'll notice
> it's somewhat skinnier in the middle than on the
> ends.  I've seen a couple
> advertised replacements for this and they all seem
> to be based on somewhat
> flattened 3 inch piping with a 48 degree bend on one
> side to make it fit. They
> also seem to be based on copper pipe.  My thought
> was to use 3 inch abs pipe. 
> Does anybody know if this stuff can be bent?  I
> would guess liberal use of a
> propane torch would be helpful here, but I'm open to
> suggestions.  I think
> staying with black abs would look most like the
> stock piece there now which is
> important when you're building a sleeper ;) 
> Besides, I don't have a pipe
> bender that will take 3 inch copper and I don't like
> the idea of paying lots of
> cash for something I should be able to build myself
> for under $10.
>      I see both those things as extremely simple and
> inexpensive things that
> should improve the air flow into the system
> substantially.  My biggest concern
> is that opening up things that much might be more
> than a basic CIS system can
> stand.  I'd appreciate any comments on this.
>      The whole point of this exercise is to make
> sure I have decent airflow for
> the bigger throttle body I'm going to try and get
> from the wrecker's this
> week-end.  Any thoughts on which TB's I should be
> looking for?  I'm also going
> to try to get a spare intake manifold for my engine
> to do the carving on to fit
> the new throttle body.  Worst case, I go get another
> and try again if I screw
> it up.
>      I appreciate any thoughts or comments (except
> on spelling or grammar...;)).
> 
> Cheers,
> Colin


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