4kRR Audi 4000 Rally Rig

[mr_aj_johnson]

been meaning to read this. Cool stuff! Gotta do an audi shootout one of these days! out of curiosity when you did your cam measurements did you ever do a 7A intake and exhaust measurement?

[chaloux]

Craig, this is your insta-tq setup!

Wow that's amazing! Excellent work to all involved. We definitely need more media though! I'd love to see what this would do with no restrictor. The boost curve is amazing lol

[vbares]

AJ - I only measured 7A exhaust, I don't remember why intake was discarded, I think it was due to contributing to high lag - but might be worth looking at again.

Chaloux - that would be interesting

[vbares]

here are some weight stats on the rig:

LF 884 Front 1789 58.9%
RF 905 Rear 1249 41.1%
LR 593 LF/RR 1540 50.7%
RR 656 RF/LR 1498 49.3%
Total 3038 R Bite

A wee bit heavier than I thought - I bit lop sided on the rear left-to-right (I'll check the heights later to make sure they are even) - but overall the balance is pretty good.

This is with about 5 gal of fuel in the tank, stock location and a spare rally tire in the trunk...

[mr_aj_johnson]

how are you fitting a spare tire in the trunk? The b3 is nearly a no go. I'm considering mounting on top of the trunk!

[vbares]

I'll take some pics tonight - its a tight squeeze and I cut some body material near the lock pin...

[mr_aj_johnson]

Reminder for pics

[vbares]

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I just remembered that I moved the gas tank backwards by modifying the brackets (I'll look for those pics too) - plus you'll see that I cut the trunk a bit in a wide v-shape in order to facilitate in-out.

2 195/15 fit, but only 1 205/15 will fit

[vbares]

yep - here is a pic of how I changed the bracket - it moves the tank back a bit, but not so much that I had to change the bulkhead configuration. I don't know how this would work with stock fuel lines as I have a different implementation for the fuel pumps...

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[mr_aj_johnson]

Eventually I'm going to have to modify my fuel line like yours, For now I took the factory pickup out of the bottom of the tank, flipped it around a bit and welded it back in. It comes out very close to where your box does. I would like to note that it doesn't like fuel sloshing around when towards the last gallon or two. your little box might be ideal as a kind of surge tank.

I'll have to see what sort of persuading I can do to the latch area. My tire sits in a much more upright position when in the trunk. No chance in hell of getting 2 195's in there.

And of course I don't have any pictures of the fuel tank outlet. But it worked out pretty darn well.

[vbares]

If the tire is more in the upright position - you might be able to modify the floor some ?

[mr_aj_johnson]

Not before hood next weekend. One spare will be plenty. Gonna have to get trunk straps though, pulled all the trunk latch hardware to make things work.

[vbares]

Posting pics of my skid plate setup as several folks have asked:

FIrst I built a support frame from 1" DOM.

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[vbares]

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Also made some high mis-alignment nut holders using old sockets...this has proven to be invaluable.

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[vbares]

Square tube to the underbody

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Smaller square tube to the skid plate

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Slip square tubes into each other, 2 bolts - and you're good (I also have hitch pins that go through the square tube in case I do loose the front somehow)

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[PRY4SNO]

That's badass! How much does it all weigh?

[vbares]

Skid plate is pretty weighty - but it still got bent by a rogue baby head in Saguenay - deflected enough to bend the bolts on the oil pan extension...but the car, with 1/2 tank of fuel and a spare tire came in at 3038#'s

[deaner]

Thanks for posting how you did your skid plate! That's pretty much the same thought I had for the front support. Im thinking of adding another bar across bolted to tabs too for mounting the radiator and IC. That way the upper tube core support is tied in as well, but removable for servicing the rad/IC up front. My cage stops at the fire wall and Ive found out that with out the front end tied together, it twists something fierce with the core support cut out. LOVE the idea for the square tubing in the rear! Can I steal your idea?

[vbares]

lol - I'm sure I stole it from somewhere...I recommend tying in the strut towers to your cage. My first rally 4k did not until I hit a big hole in a winter event that pushed one of the towers back about 2"...they're not that strong on their own...

[deaner]

That's a bit of a buzz kill..... Lol. I was planning on tying in when I rewire the chassis in a year or two. If I don't rip the front end off that is lol.

[JimT]

So has there been a phase 4?

Are you happy with the suspension or suggest anything different? It's finally time to
make some changes to my 90 rally car. I'm out for the season, so its a good time to look
at making changes.

My current list -
1. fix the damage from my June hard landing. Bent front end.
2. Improve radiator mount/radiator
2. Change front calipers and rotors to ones from a coupe.
- might want to consider alternatives.
3. Upgrade from Bilsteen's
4. upgrade some wiring and general engine bay clean up.
5. Redo centre console wiring and switches.






jim

[vbares]

The suspension has been awesome!!

Inevitably, as you improve your equipment and increase speed you look for further improvement ... if I had the budget, I'd start looking for alternative that had adjust-ability in dampening and bump - but I think this would more than double the cost (think Reiger).

For brakes, I went from wilwoods in front to A4 calipers - just because they are plentiful, bolt-on to the b3 2-piece fronts and allow for a fairly large rotor that fits under 15" rims.

Good luck on the rebuild!