Brendan's 07K CQ rally car

[KTM990]

It's time to start documenting this build. I got an itch to go play in the dirt with an Audi rally car again and I have: 1 x '90 CQ, plenty of suspension and drivetrain parts, a built 07K bottom end - Why not?

The starting point:


Starting operation weight reduction:


I've tried direct dry ice, crushed dry ice with rubbing alcohol slurry in various ratios, inverted air cans with various hammers, but I can't seem to find anything that will work ANYTHING like the myriad of you tube videos showing this stuff come off in whole chunks/sheets. Back to the heat gun - seems to work better than slowly chipping away.


After a few evenings of that grueling noise, I chose to do the only logical next step; to start cutting up an 01E to fit an 07K and truly commit to this project... I grabbed the closest GBE transmission in the garage and got this:



And just for fun, a preview pic of a TTRS head vs 07K:


I haven't decided which head I'll run, probably the 07K and save the TTRS head for a build that doesn't require a piddly 34mm restrictor

[KTM990]

It only took 2 tools to score that SOB trans, LOL


Here are some more pics documenting the transmission bellhousing mods for the 07K:



Test fitting the rear timing cover. You can see the sharpie outline of the bellhousing i traced onto the timing cover.










Made a a couple 1/8" plates to fit the openings, prepped the bellhousing and TIG'd them in place. Welded really nicely with just some abrasive cleaning. Everlast 255EXT FTW!
Done Done.



Including beer time, the total job probably took 1.5 hours and most of that was spent futzing, measuring and test fitting.

[KTM990]

While the trans was on the ground and "dry", it is always a good idea to pull the Torsen and swap it for a high bias unit from Scotty. The FYF/GBE Torsens can't be modified by Scotty at Advanced Automotion so I sent one out of an EDU (B5 S4) to be modified. Also test fitted the AK Motorsport trans mount. Decided to try this nice part out - the last time I did this, I made a similar mount out of plate steel and two pieces of angle, welded up, but this seemed so much more fitting :-)






Note, the AK Mount needs 6 x M8x1.25 x 100mm bolts. The rear flange of the 01E is held on with 6 bolts, 2 of them are 100mm length for the heat shield, so 4 more long bolts must be procured to run the AK mount.

[Afterthought]

Nice work!
A couple questions for you.
how much were those GBE’s ? I’m
Only a couple hours north of you and the cheapest one I could find was $700

On the AK mount . It appears as if you have to “make” a place on the bottom of the car in the tunnel for it to bolt to?

[alxdgr8]

Awesome, can't wait to check it out in person sometime!
Good to know about the FYF/GBE diffs.

Did you get a pan from Hank already?

[KTM990]

@Afterthought: Yes, the trans tunnel will need mounting provisions fabricated and welded into the tunnel. The mounting bolts will be installed from inside the car. As for FYF/GBE/EDU 6 speed prices, expect to pay $600-800 unless you can score one at a pick-n-pull ;-)

@Alex: The GBE/FYF Torsen is PN 01E409751F. The EDU diff is PN 01E 409 751E. I believe any of the other 01E diffs can be modded. The diffs on the left and middle are the same PN and came out of FYF/GBE. The diff on the right is from an EDU. I circled the primary different feature.

[ChrisAudi80]

Wow those are some opening posts!

Cool to see you are using AK MS parts. I have a bunch of their bushings. Overall good quality.

Any ideas about what turbo, injectors and ECU you are going to use? What about wiring? Are you going to do that yourself?

[audifreakjim]

Yes, Yes and Yes. Glad to see this picking up steam

[Afterthought]

Yeah stoked to see this stuff popping up. I guess Ill have to start a thread

[vt10vt]

Yeah stoked to see this stuff popping up. I guess Ill have to start a thread

I was planning on starting one Sunday but now this and yours popped up...

Love this and will be watching closely, like was already said, helluva introduction!

[Lucky]

The FYF/GBE Torsens can't be modified so I sent one out of an EDU (B5 S4) to be modified.

The Fyf torsion can be modified, mine is done. Jhm offers the service for them.

[PRY4SNO]

Great project and work so far. I like where this is heading.

[FFF]

This is looking very good. Keep the updates coming.


Sent from my iPhone using Tapatalk Pro

[KTM990]

Yes, Yes and Yes. Glad to see this picking up steam

"07K the world" is a Jim Green quote that has firmly stuck in my head :-)

[KTM990]

The FYF/GBE Torsens can't be modified so I sent one out of an EDU (B5 S4) to be modified.

The Fyf torsion can be modified, mine is done. Jhm offers the service for them.

Thanks for pointing that out. I've updated the above to say that Advanced Automotion can not modify the late 01E diffs.

[KTM990]

Wow those are some opening posts!

Cool to see you are using AK MS parts. I have a bunch of their bushings. Overall good quality.

Any ideas about what turbo, injectors and ECU you are going to use? What about wiring? Are you going to do that yourself?

Turbo: Probably a GTX 2860R or the EFR 6258. Ideally I would build a smaller displacement motor, but the 07K is too tempting. With the larger displacement the choke flow power band gets narrower due to the godforsaken restrictor. I'm honestly tempted to just try using a junkyard 07K motor with a TTRS headgasket to drop the compression a little and save the built motor for fun street project. Step 1 is to get an 07K in the car and get everything fabbed up around it.

Wiring: Yep, I'll be wiring the whole mess myself. Automotive wiring is sort of a soothing pleasure of mine - when it's new/fresh harness building

ECU: Maybe a VEMS for the rally car and save this bad boy for something more, or I may say F it and just go for it

[Afterthought]

34mm restrictor ... damn that’s small.
One of Those Indy turbos would be cool since they have the bolt Holes for a restrictor

[ChrisAudi80]

Wow those are some opening posts!

Cool to see you are using AK MS parts. I have a bunch of their bushings. Overall good quality.

Any ideas about what turbo, injectors and ECU you are going to use? What about wiring? Are you going to do that yourself?

Turbo: Probably a GTX 2860R or the EFR 6258. Ideally I would build a smaller displacement motor, but the 07K is too tempting. With the larger displacement the choke flow power band gets narrower due to the godforsaken restrictor. I'm honestly tempted to just try using a junkyard 07K motor with a TTRS headgasket to drop the compression a little and save the built motor for fun street project. Step 1 is to get an 07K in the car and get everything fabbed up around it.

Wiring: Yep, I'll be wiring the whole mess myself. Automotive wiring is sort of a soothing pleasure of mine - when it's new/fresh harness building

ECU: Maybe a VEMS for the rally car and save this bad boy for something more, or I may say F it and just go for it

Yes! Another wiring geek! I recently remade my Motronic to VEMS EC adapter and other stuff. A full harness build is something I aspire to.

That Bosch MS ECU is secks yo! Where did you get that?

What's this about a restrictor? Where?

[KTM990]

If you can build an adapter you can build a full harness! Attention to detail, confirming your crimps are solid and getting the order of operations right is all it takes.
The MS6 ECU came from Sakata Motorsports. I've been wanted to learn a different ECU platform for a long time, I figure this will be a good one :-D
Restrictor: Per all US rally sanctioning bodies, all air coming into the engine for this class car must flow through a 34mm diam. inlet restrictor - which I believe still aligns with WRC rules.
Trust me, I plan to have a non-restricted inlet and larger turbo option!

[KTM990]

Started on the suspension mods tonight.
Specs:
Cabriolet front uprights modified w/ BBSE
Koni 86.2149 Sport dampers all 4 corners
Threaded perch adjusters: Coleman Racing PN 421-700 bored out to 2.16". 3.5" length in front and 7" length in back
These are steel collars and will be welded to the strut tubes.
Springs: GKR 100mm ID coils compatible with 2.5" lower spring perches



Created a masking tape cut line and carefully cut with an angle grinder and cutoff wheel:



Left, Coleman threaded collar, bored to 2.16" ID. Center: BBSE bored to 47.85mm for Koni's. Right: Cutoff scrap from factory upright



The Koni's get held in with a supplied steel ring that centers them and the shock nut contacts the top of this part. The supplied ring is designed for the factory strut tube. I had to remove material on the OD to fit inside the BBSE. This was carefully done with my homemade lathe/grinder... Chucked the steel ring in my angle grinder and centered it. Then ran the angle grinder against my running belt sander

[ChrisAudi80]

If you can build an adapter you can build a full harness! Attention to detail, confirming your crimps are solid and getting the order of operations right is all it takes.
The MS6 ECU came from Sakata Motorsports. I've been wanted to learn a different ECU platform for a long time, I figure this will be a good one :-D
Restrictor: Per all US rally sanctioning bodies, all air coming into the engine for this class car must flow through a 34mm diam. inlet restrictor - which I believe still aligns with WRC rules.
Trust me, I plan to have a non-restricted inlet and larger turbo option!

That 6.1 is very advanced. 196 pins! Just skimmed through the datasheet. It is very versatile. You can go hog wild on sensor inputs. Temps, pressures everywhere! Might be good to put the 6.1 on your rally class spec car. That way you could run linear travel sensors on all 4 corners to dial in suspension.

What are the regulations for the restrictor? Can you make it yourself or does it have to come from the sanctioning body? If you can make it yourself, you could make the venturi transitions as smooth as possible.

[KTM990]

Here are some more side by side pics of the heads:
Most notable here is how they bored the head for the cams:



Exhaust side:
TTRS: No EGR , exhaust manifold mounting studs and provisions for sensor for cam VVT.



Intake Side:
TTRS: Direct Injection, Intake port plates.



Valve Cover Removed:
TTRS: HPFP, Exhaust cam adjuster solenoid/sensor provisions,

[KTM990]

A lot happens in life in a 1+ years! Still making diligent progress on all my projects and quarantine life has definitely increased project completions!
Been making good progress on 07K conversions since it seems I have 2 going now. 1 in my CQ rally car project and one for my '91 200 20vt that showed up in my driveway sans motor...

07K updates first: working on making CQ and Type 44 mounts as well as a Oil adapter block.

Oil block must have:
-3 M10x1 ports (oil pressure switches and pressure sender, oil temp sender. (even though some of the newer 07K blocks have extra oil pressure ports)
-Breather port
-Turbo Coolant feed
-Turbo Oil feed
-2 ports for remote filter/cooler
-Cylinder head oil check valve. not the 5cyl Audi unit. Seen too many sticky ones.

Here's what has packaged nicely. Almost finished getting the first one cut out of aluminum!

[KTM990]

For the motor mounts I settled on some good old fashioned robust steel. Laser cut base plates, the right side is formed to minimize spacers and shorten bolts. I toyed with making them out of round tubing and square. Seemed easier to knock them out with square tubing and miter cuts rather then having to play with multi-axis fish-mouths on the round. I'm getting burned out of fish mouthing tubes with the roll cage build. I still need to make up some gussets and finish weld, but getting close.

RHS mount:

[KTM990]

I also machined up some EGR blockoff plates and added some flare to the larger one :-)





The little mill I built, instead of working on car projects - BUT it lets me make fun stuff!