roortube's UrS6 Avant...now playing with Alfas

[roortube]

Been on here a while now, mainly reading and asking questions, so I guess it's time to let people know why. I had a '91 200 for a couple years and loved that car, but it was beat. Body was rusty, suspension was shot, trans made a whining noise in 4th and 5th, cluster was wacky, 350k + miles, etc. It ran great, still does, and made a steady 24psi on stock turbo with a Ben Swann tune. I sold that car to a buddy and needed another quattro.

Enter the S4. I found it online in Loch Haven Pa, and went to check it out. The paint(emerald) is badly oxidized, but it is rust free, sorta low mileage (150k), new (ecru) leather, everything works, and every receipt since new (one owner). Not bad, so I picked it up in October.

Future plans include Wagner RS2 turbo manifold, gt2871r or 3071r turbo, Apikol FMIC, 034 short shifter, and call it a day. I do, however have a low mile 7A that I got for a song that may get built to allow a gt30r and lots of revs, but who knows about that.

[roortube]

The last few months have been fun. I have been testing chips with Ben Swann to the point that my fuel pump and clutch were failing. For those interested, his stg. 2.5 AAN chipset for stock injectors seems to work best with a 2.7bar vmap setting at 70ish psi fuel pressure at idle.

Speaking of clutchs and fuel pumps failing, it has been time to replace some parts for several weeks now. Fuel pump replacement is quick and easy, but clutch replacement isn't. I also had a punctured condenser and cracked radiator, so it seemed logical to pull the engine for clutch access and replace those parts while it's out. And you know how it is when the engine is out.

Current build spec:

Engine:
HMS gt35/billet 60-1
HMS header/DP
034 cat back exhaust
034 silicone boost hoses and clamp kit
034 billet bypass valve
034 breather can
034 phenolic intake spacer
IMS intake mani
Apikol FMIC
EFI express crank gear
Pauter rods
JE pistons
coated bearings
ARP head and main studs
Full balance to <1g
Supertech .5mm over valves
Supertech valve train

Fuel:
044 pump
FIC 1100cc injectors
Eurospec adjustable fuel pressure regulator
Swanson MAFless Motronic dyno tune
Innovate wideband to keep tabs

Ignition:
034 H/O coil kit
Magnecor wires
Bosch FR5DTC

Driveline:
Southbend stg 4+ clutch kit
JB 8lb aluminum flywheel
034 street density motor and trans mounts
034 poly snubber and bracket
Apikol rear diff mount

Brakes:
Big Reds w/ Hawk pads

Suspension:
stock, beaten, and next on the list.

Future plans include either Bilstein/H&R or DIY coils and haps rear sway along with more Apikol urethane.


<<<Pick up oringinal post from back in the day here>>>

We just got the car running today after the upgrades, and I still have some details to sort before hammering it, but around town driveability seems unchanged aside from a lighter clutch pedal. I have no leaks, be they fluids, intake, or exhaust. I need to go back and check torque on a few things now that they've heat cycled, and button up my passenger footwell. Then I need to break in the clutch and slowly work the throttle application up.

[naudi80quattro]

This car has to be sweet but where are the :pics:

[Beny]

:stupid:

[roortube]

pics will follow soon. I dunno if I'm gonna hold off on those till I paint the car or put some up now. If you check the thread I posted in the abnormally aspirated forum there are a few iphone pics my buddy posted from the engine removal.

I took the car on it's first significant drive this evening, 40 miles from work to home. It ran flawlessly, and still no leaks of any sort that I can find. I'll daily drive it for the next week to break in the clutch. My paint is badly oxidized and the hood is a different color than the rest of the car (from a '92 100), so I'm gonna start sanding it soon to get ready for some krylon flat black. If I like the look of a flat black car, I may rhino line the whole car.

[roortube]

Half a year later I guess it's time to resume this thread. The car has been running flawlessly for 12k miles. Lots of fun, and very comfortable. A few minor changes since the original post: Apikol front mount and more rear urethane, krylon flat black paint and grimmspeed gold fuchs. How do I host pics for here?

I have sold the 7A to a friend who needed it, but last week picked up a spare AAN that seems to be freshly rebuilt, and it came with a free 7a block. I've torn the block down and cleaned it. It's at my machinist now for more cleaning and honing, followed by measurement to see if it's suitable for a build. I've got some Scats, and will be ordering more internal parts over the next few months. Planned engine build spec is:

Scat rods
ARP main and head studs
new bearings and rings
034 high rate valve springs
034 ti retainers
034 oversize valves
7a cams

zero balance the motor and possibly port/polish the head.
I'm not sure yet what I'm gonna do for lifters. My machinist is a fan of solid lift, but I don't know how I feel about pulling the cams every few thousand miles to adjust clearance on a daily driver.

[85oceanic]

Photobucket or upload! Lets see some pics!

[roortube]

viewtopic.php?f=14&t=33026

no current pics, but here are some from the turbo upgrade last winter. more pics of the current motor build coming soon...

The block work is done, bearings and pistons are back from coating and the assembly is out for balancing. I have next week off. I hope to get my engine together then. I'm still waiting on the valve train to arrive from 034, but no worries there, plently left to do yet before bolting the head on. I'll hopefully learn how to use a camera over the weekend so I can post some current pics of the car in all of it's salt covered krylon glory and the shiny new engine bits.

[jcarrick]

This project sounds awesome! And i too really wanna see pics How much did it cost you too have your pistons coated? Do you think its really necessary to have done?

[roortube]

It was $250 to coat the domes with PC9 and the skirts with anti friction coating through Swaintech. It's not necessary, but from what I've read it reduces ring and wall wear as well as giving a bit of detonation resistance. As my goal is a high boost, high power daily driver that will last I figured it's worth it. I don't wanna have to crack the motor open again for at least 100k, hopefully around 200k miles. We'll see how that works out.

[jcarrick]

Ah, good to know. I may do the same as I too don't wanna open mine for AT LEAST 100k

[roortube]

Update time...

My engine is at the builders place for assembly. Plans have changed a bit, so here's a new list of stuff going inside:

IE rods, small ends honed for fit by 034
stock pistons, swain coated
kilbenschmit bearings, coated by swain
Goetz rings
ARP head studs
034 main girdle kit (in the mail)
head ported, polished, and flow benched
supertech complete valve train kit (over size valves, high rate springs, ti retainers)
AFC lifters
MLS head gasket
7a cams
034 adjustable cam gear
EFI express crank cog
new cam chain
new balancer, zero balanced by 034
block honed, deck polished, align honed
crank polished by 034
complete assembly balanced at 034
034 billet clutch kit with steel flywheel, zero balanced

All of these parts are purchaced and at the builders place, only waiting on arrival of the girdle kit.

Next up is a tube header with full vband, either a tial MVR or a synchronic wastegate, and a bigger turbo. I just closed on a house, and my wife will be giving birth to our first (a girl, Maya Rose) so my car funds are a bit tight, but this WILL happen soon.

[aesthetics]

WOW Rob!, some real nice improvements since i saw you last. Im glad everything has been running good. Are you still running Ben's 3.0 chipset?

im sure you have answered this in your other posts, but for the sake of it being info in your project thread: How was Ben's chipset with the 034 HO coil kit? were there any issues? or did it run fine?

[roortube]

Whats up Erol-

There weren't any issues directly related to the chipset/coil combo. I did have some issues getting AFR dialed in, and it took some injector swappage along with fuel pressure adjustments to get it right. After that it ran well. I've been on a version of 034s stg 1 chipset for the 3071r that Nate tweaked for more midrange response for a while. It has better idle resolution, but a bit less kick up top than Bens stg 3. I figured it's a bit safer that way. Once the new motor goes in Ben and I will probably play with some more stuff to see how his stuff runs at higher boost levels than the 26 I currently feel safe running on stock motor.

[aesthetics]

oo ok, I remember the AFR issues because that is when I met you. Currently I am running the stock ECU on my S6, so I just wanted to make sure using Ben's 2.5 chipset will work ok with the 034 coils. I still want to get an 044 fuel pump, adjustable FPR w/gauge, and wb02 before I chip the car anyway....so im sure I will be contacting you for some more info

My projects have all been put on hold since im either never in the country or im at school. But I am very glad to hear the updates on your car, and keep me posted!

[aesthetics]

btw, how are those Blausports holding up? I am sick and tired of a stiff suspension on a daily driver, especially when the daily driver is a huge boat-like, comfy car. I want to just sell my H&R/koni setup and get stock springs and thinking of the Blausport kit.

*edit* living in Northern NJ means a stiff suspension is one of the worst things you can do for your daily driver.

[roortube]

Time for a long over due update here...

I have installed the built motor, and it's running. I've heat cycled it and retorqued the head studs. I have a bit of a problem with the release bearing, in that it's new, but sounds like it's shot. I get to pull the trans and investigate :curses:

Here's the project a couple hours in, with the old motor ready to come out:



this is a pic of the oil pan that didn't work. The extension on the passenger side contacted the subframe and as the motor was lowered onto the mounts broke the bolts in the block on that side. I had a spare pan that I swapped in and fit.



Here's a pic of the clearancing required to make the 034 main bearing girdle fit. Not a big deal, just be sure not to cut too deep.



This is the next evening, new motor in place and ready for charge pipes. Notice the pretty header that Hank made...I really can't say enough about how impressive his fabrication is.



I have more pics including charge and intake pipes, but my phone sucks and is still uploading them to gmail. when that's done I'll post them. I also intend to shorten and clean up the oil/coolant lines for the turbo. They can be routed differently if the lengths are correct. I love the fact that I no longer have to lift the car for oil changes...turn the front wheels left for the drain plug, reach down from the top for the filter. All of the fasteners are super easy to reach for the header, and the Vband turbo is awesome. Service to this motor will be super easy in the future.

[roortube]

This is the final routing of the charge pipes.



It gets a little tight down in here.



I was actually able to fit the MAF, air filter, and pipes through this space, and still leave the stock oil cooler. Eventually I'll mount a larger oil cooler where the stock intercooler used to be, as well as VEMS so I can loose a bunch of clutter over here.



Front bumper ready to go back on.



'Bahn Stormers, class of '91. The M5 has been my reliable daily during this project as well as before. The 200 20v Avant was recently purchaced from a friend with a bottom end knock. It will receive the AAN block that came out of the S4.

[roortube]

While it was apart I picked up a nice set of headlamps from Sam to replace my broken up ones. I put new euro lenses in them and got some 55w 4300k HID kits from VVME for the low beams and fogs, which I have yet to install. Anyone have any suggestions on how to relay them?

Hank is working on an intake manifold for me that will complete the air moving system for the engine. I can't wait to see it.

Once I have sorted the clutch release bearing I'll break the motor in and start having fun. The car is still running the modified 034 3071 chipset, but I forsee a billet 3076 turbo of some sort along with larger injectors and VEMS or a rip chip in the near future.

[ringbearer]

Nice work, will be lots of fun, I hate the last hangups like your release bearing. I know you want to drive it and not take it back apart...

[roortube]

Damn right I want to drive it. Don't get me wrong, I love the M5, but don't want to put 80-100 miles per day on it with the commute. Not to mention that I miss boOOSSST!!

Aside from the HID relay questions, I have a few other odds and ends to tie up. I need to shorten the feed and drain hoses for the turbo. What do people use to cut this braided stuff? I've wrapped it in duct tape and cut through the tape and braid with a hack saw before, but that can be messy. Any better solutions? I also need to mount the N75 and run it's hoses. Will standard rubber vac hose take the temps at the wastegate barb, or do I need something else?

[EDIGREG]

Looks great Rob... sucks about the clutch, but a day's work and you'll have her back on the road. This photo shows how to relay the headlight power...

What do people use to cut this braided stuff?

I wrap with tape, then use a dremel with a cut off wheel. It makes a nice clean cut.

Will standard rubber vac hose take the temps at the wastegate barb, or do I need something else?

Probably not for long. High temp silicone hose or something similar like the OE Audi hose would be better. I'm using -4AN hose on mine.

[Hank]

Best way to cut the braided line is with a zip tie snugged down to where you want to cut it. Cut as close to the zip tie as possible(maybe even into it) on the side that is now scrap. The heat from the cut will make the plastic brittle and just kindof break off once the cut is done. You are left with a perfect edge to put into the AN fitting!!

Looks nice!!

[Hank]

BTW, the car looks awesome

That header is golden brown ready for use!!

[roortube]

thanks for the suggestions. I'll give them a try on some scrap line and see which i like best.

Ed-that photo is worth a few hundred words, at least. thanks man!