A4 Rebuild 2014

Rebuild Start.  The head is frozen stuck on the two thermostat studs.  It overheats reliably.  It

2013 troubleshooting...  tip of the iceberg,as it turns out

Head removed - blocked passages - no surprises

Hurricane Sandy.  A4 salvage with MMI SS waterlift - $500  :&gt;)  The copper standpipe is sculpture, but I can

Salvage engine port side - it

Salvage engine starboard side - clean water jacket!!!

Springtime.  Almost.  What

Painted port side.  High-temp aluminum pant on manfold - we

Painted and starting to go back together.  Stainless studs for the water jacket, JB Weld, and nutted on the inside.

Coming together...

Badged.  Shameless bling.

Case hardened heavy flange nuts

Timing mark at TDC drilled and painted onto flywheel tooth in line with hole in housing.

How to make a standard thermostat fit without the spacer block and extra gasket.  Take a big countersink to the bypass stub....

Stainless water jacket cover.  I

The irrational response to a lot of rust and cooling fears - multi-port stainless steel.

Water jacket side plate.

Water jacket side plate inside - final fit will include drilling caps for water direction.  The caps fit neatly between the cylinders.

Water Jacket - Full Monty.  3/8&quot;NPT to 3x 1/4&quot; NPT brass air hose adapter

Water Jacket - plumbing with Russell ProFlex.  Serious PITA, but bulletproof.

Water Jacket - inside drilling

FinishedLarge

Coil heat shield - 0.062 aluminum 4&quot; on legs, 5.25&quot; tall, mounted on original holes, spaced off on the block with thick washers.

Zinc.  Temp sensor moved to tee off a manifold

Studs JB Weld into the soft aluminum pot metal...  Nutted on top.  Fuel pressure at the point of no return.