The Project Pad

First off we'd like to thank the following people for their input/help so far: Marc Swanson, Dave Jones, 034, Eurospec (see post), Eric@Competition, and Mike in Buffalo

I'll be adding more to this later (with pictures of progress and more deets), but for now a quick history:

My dad has owned URS cars since 2004, when he picked up a bone stock 96 Europa/Ecru sedan. From there he bought a 95.5 Green/black sedan with an RS2 6 speed, MTM 2+ (chip, 3bar MAP, RS2 mani), suspension, and brakes. We swapped all the goodies to the 96, and then he sold the green car. Things were fine for a while, but then my little sister crashed the 96. Thankfully it was a low speed crash, but still needed a bumper and some other front end stuff. The car has been patiently waiting (as have I, as I'm inheriting it). Then he picked up a 1997 S6 which was owned by the owner of Competition Motors in Belleville, Ontario. The car was fairly heavily modded by Dave Jones and Autosport Werks, using an ITS T04E/K26 46 trim turbo. Dad took the car and added VEMS, larger injectors, and the plan was an FMIC before //S-Fest last year (specs in sig here). The FMIC didn't arrive in time, and on the way home from //S-Fest he lost cylinder 3. Made it home fine, just slowly. Just before //S-fest, he picked up a spare motor which had a basically brand new head on it - less than 500km on it, was replaced by dealer for $3800 by the PO. Then he crashed the car.

The plan:

Full boost at 3800rpm was okay, but dad wanted the car to be a bit more street friendly. And he likes the idea of having something unique. So, the hunt for a 92.8mm crank began (after doing quite a bit of reading we decided it would be the best and easiest solution for a stroker). Finally, one was acquired through Eurospec after a huge runaround of "no we don't have any 92.8s" and "yeah, we have one. We'll ship it out" and "no we don't have any cranks, we swear!" - just crazy stuff. Got the crank shipped to Mike in Buffalo who picked up lowlyoilburner's GT42R'd 550whp S6. That was a fun ride! Anyway, the plan is to build the spare motor to the same spec as the one in his 97 now, but as a stroker and then swap it in.

Specs:

VEMS
92.8mm stroke crank
SCAT rods (moving to a new set of 160mm rods)
83mm coated pistons (moving to Weisco)
copper 83mm head gasket (moving to bored MLS)
ringed block (moving to tall block)
Wagner Sport Quattro exhaust manifold (moving to Hank's)
Comp Turbo CT3-6465 triple ball bearing/billet turbo w/ v-band outlet, 1.0AR (swapped to .82A/R)
N75 operated Sound Performance Quickspool valve
AEM dryflow air filter
ARP head/main studs with new bearings
ID1000CC injectors
044 fuel pump
7A cams
NEW head with lightweight lifters (less than 500km on it, PO then totaled car)
ported head head/intake mani
custom 3" downpipe (moving to Hank's)
034 phenolic spacer
big FMIC
South Bend stage 4 clutch w/ 7A flywheel - 900ftlb!
034 catch can
entire build cryo-treated
AEM water/methanol injection

Won't be high revving so valvetrain stuff isn't needed.

Comments and suggestions welcome!

Album of pictures of work completed on 97 pre-//S-Fest: linky
Album of pictures dedicated to stroker build (only "joke" pix so far): linky

Update on the cause of no cyl 3, some more turbo info, and pics of build bits

when we pulled the head, this is what we found:




brutal. Not sure exactly how it fried, a few things were suggested on QW, one of them being a crap injector. Those will be tested/balanced before the rebuild. Now onto the GOOD stuff

JE 83mm pistons, coated obviously


The lifters out of the "old" head and the new one - both ended up weighing around 67 grams with oil. 034 says lightweight are 63 grams and normal are 85. Nice that these were free!


Ahem... hard to admit this one. Note: shaft threads MAY be reverse. Do not talk about stuff while taking apart. do not assume it's a locking nut. Lastly, check the dang threads!


Other than that, we found some interesting info on the coldside after measuring:

inducer: 50.8mm
exducer: 74.9
trim: 46

Based on this site, it is a T04E 46 trim (map link). Anyone have any experience with these/know what they're capable of? I found one site that said 300-420whp... great. lol.

Current status of the build is: block being sandblasted, then everything goes off for cryo treatment! Then the block should be bored/skimmed soon after.

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box of goodies for the build shipped yesterday, BTW

Thank you Marc, I'm sure we'll be sending you an email or two. And thanks for the consulting w/ VEMS and everything else thus far. It seems like it's been taking forever, but hopefully it'll all be wrapped up quickly now that the parts are starting to come together

I am following this build! Major S6 fan here.

Why is there so much rust?

ChrisAudi80 wrote:Why is there so much rust?

96 and 97's are normally from Canada IIRC...

Mmmmmmmmmmm salty Ontario.

sweet!!!

Made some headway with cylinder 3 yesterday and this morning. We changed the batteries in the fiber optic scope and took another look at the cylinder and top of the piston. On the exhaust side it looks like there's some deformation. We hooked some air up and can feel air coming out of the exhaust. We're pretty sure without absolutely knowing that it's an exhaust valve that burnt up, but we're going to be taking the head off tomorrow to find out. Tomorrow we also plan on prepping the block (sandblast, POR20, skim). Pictures to follow!

Whats the update Matt? Seen the shots of the valve on qw. When do you two plan to assemble the motor?

Not exactly sure what happened with the valve. Right now the block is being blasted, then everything will be cryo treated, then painted/assembled after the block goes for boring/skimming. See post up there for pics!

where do you get the cryo done? and is it a euro van crank?

We have two options for cryo in Ontario, but I forget what they are off the top of my head. One is in Toronto and one is near Niagara. I think for the entire engine in pieces - everything we can throw in there - it's $850.

Just a small update... currently talking with Marc about going with Comp Turbo, the SQ manifold, and a quickspool valve. We'll see how everything turns out

Block is now bored and ready to build.

Awesome... soo looking forward to the build

quickspool valve 8) very cool, will be watching this!

build specs updated above...

Just a quick update - Marc finally has all of our stuff to ship to us! Except for one little thing... Comp sent the turbo with a divided T4 housing. LOL - of COURSE they did!

So the entire order will probably ship to us by mid week. I asked Marc for a pic of the turbo... we'll see if he can find some time to take one

Also, dad's been busy getting a Saab 9-3 ready for my mom to drive will the rest of the build is finished. This is why there's been no progress on the stroker. Soon there will be pics of the head porting and intake manifold cleaning out. Also of the block once it finally gets o-ringed, as that's all it needs before it can be rebuilt.

Sweet! Cant wait to see everything come together.