Just Another Plain-Jane Build Thread.

[chris164935]

So, this build has been off and on for the past 3 years, but now that I'm finishing up school, I now have more time and money to put into this thing again. Some of these parts I've had for the past 3 years sitting around collecting dust or in use preventing various paper documents from blowing away. So, I've started this thread off with those parts first. Also, nothing in here is set in stone, so expect some changes to the build over time. Anyway, my goal now is to have it running before the end of this year. [wrench]

PARTS LIST*
HEAD
AEB Head With Massive Port And Polish
CAT Cams 1003756 Solid Billet Cams [confused]
CAT Cams Gold Valve Springs
Supertech 1mm OS Intake Valves With Single Groove Keeper
Supertech 1mm OS Exhaust Valves With Single Groove Keeper
Rosten Solid Lifter Buckets
Rosten Lash Caps
Rosten Titanium Retainers
ARP Exhaust Studs

TURBO/EXHAUST
Precision Turbo PT6266 CEA T3 .82 Turbine With Ported S Cover
SPA T3 Manifold
Borla Muffler
Custom 3" Exhaust With V-Banded Sections

BLOCK
06A Block Bored To 83.xxmm
9.25:1 83mm ?? Pistons
144mm Pauter Rods
ARP Custom Age 625 Rod Bolts
Knife-Edged Forged Transverse 86.4mm Crank
ARP Main Studs
ARP Head Studs
Fluidampr Harmonic Balancer

DRIVETRAIN/BRAKES
034 Track Density Motor Mounts
034 Track Density Transmission Mounts
034/Apikol Track Density Diff. Mount And Bracket
Clutchmasters FX700 With Steel Flywheel
JHM Solid Short Shifter
Adam's Rotors Drilled/Drilled/Slotted, Gold Zinc Coated Rotors

INTAKE
2.5" Charge Piping
Custom A/W Intercooler Setup
SEM Large Port Intake Manifold

ENGINE MANAGEMENT/FUELING
Autronic SM2
Autronic 500r CDI
Innovate LC-1 Wideband
Racepak IQ3 Display
Racepak IQ3-To-Autronic SM2 Harness
Bosch 1600cc Low-Impedence Injectors / ID1000 Injectors
Twin Bosch 044 Pumps
IE Dual Pump Surge Tanke
-8an/-6AN Fuel Lines
ATP Fuel Rail
Fuelab Adjustable FPR

*Parts list subject to change without notice. [>_<]

First, the car: a 2001 Audi A4 1.8tQM. Nothing too special; Hibiscous Red (one of my favorite colors [:D]), stock wheels, Eibach lowering springs, and Bilstein shocks.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/car1.jpg

Now, for the head. Basically, we took an AEB head and had it ported and polished. The seats were also cut to allow for the bigger valves as well as had brand new valve guides installed. Also, according to CAT Cams, some machine work may be required to allow free rotation of the cams. This had to be done for the exhaust cam. Assembly for the head has already begun, unfortunately, no snapshots of the work in progress just yet. In the end though, this head will be capable of 10,000+ RPMs, no sweat. Hopefully, the block will be able to keep up!
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/cams1.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/head1.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/head3.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/head2.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/head4.jpg

As for the block, I had a forged 1.8t crank sent off to Jared at SCCH for knife-edging and balancing. I have the main caps and am just waiting on the arrival of my ARP main studs so that the rest of the machine work can be done. Pauter rods are also in the mail right now as well. When they arrive, assembly of the block can begin. I already have the pistons and brand new rings and wrist pins.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/002.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/004.jpg

And finally, some random pics of other go-fast parts.
Piston Rings and gaskets.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/007.jpg
Autronic SM2.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/003.jpg
Wiring harness laid out and ready to be wrapped.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/001.jpg
Injectors.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/006.jpg
Various mounts.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/005.jpg

That's it for now; however, I still have plenty more packages coming in the mail this week!

[CrtchRktRcr]

soooo jealous. Looks great so far.

[flynnr]

http://i263.photobucket.com/albums/ii155/flynnr1/d33288b8.jpg

awesome

[anmagro]

MORE PICKS OF THE CAR! great color.

[A4Rob]

Great build. Moved for you

[DonnieDark0]

Cant wait to hear what it sounds like , especially at full boost. goodluck to you sir.

[chris164935]

MORE PICKS OF THE CAR! great color.
This is all I got... She's covered in dust right now. The other A4 is my daily.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc1/hs121.snc1/5211_101124529898879_100000039986997_32138_4667278 _n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc1/hs121.snc1/5211_101124533232212_100000039986997_32139_6866245 _n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc1/hs141.snc1/5211_101124536565545_100000039986997_32140_7584888 _n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc1/hs141.snc1/5211_101124539898878_100000039986997_32141_5158652 _n.jpg

[AudiSportB5S4]

Awesome color for so much HP. Real understatement!

I have the Apikol rear diff mount in street density, I wonder how much worse the race density is. I have T/D motor/tranny mounts everywhere else, but was told to stay away from the red bushing as its really harsh.. Probably just opinion though.

[chris164935]

Awesome color for so much HP. Real understatement!

I have the Apikol rear diff mount in street density, I wonder how much worse the race density is. I have T/D motor/tranny mounts everywhere else, but was told to stay away from the red bushing as its really harsh.. Probably just opinion though.
Oh, I'm sure it's gonna be rough. But I'm not really worried about all that. This is gonna be my fun car; not really a daily driver.

[Jc61990]

very nice build. just one question this is the first time ive heard of it or seen it done, whats the purpose of knife edging the crank?

[John Gutmannnn]

That's what the color of my car is supposed to be when its all shiny....*Sigh*

[GaroBlu]

Looks like a killer build! Glad to see that you actually have a knife edged (or boat tailed as I learned) crank. That shows that you are paying attention to detail and I respect that.

Good luck!

[sean1.8t]

good to see all this going into a Quattro car this time [up]

[onemoremile]

Just make sure that crank is still perfectly balanced if you are intending to spin high revs.

[Oceanside]

We Can stop here, Florida is BAT country!

[chris164935]

I suppose it's time for an update... Haven't been able to get too much done since I've been super busy recently with school, work, and a wedding (not mine, although I'm sure my girl wishes [:D])! Mostly, I've just been waiting on more parts, which some have arrived.

But, before the pictures, I do have a quick question: Did the FSI motors not run thrust washers? My #3 main cap does not have a provision for them...

Okay, now some pictures!
Some friction shims; one for the crank nose and another for the flywheel.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/010.jpg
CATCams cam gear.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/004-1.jpg
ARP head studs.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/002-1.jpg
ARP main studs on the block. Was using them to make sure the main caps would fit. They don't. Lol. A tiny bit of shaving to the block will be needed for the caps to fit.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/011.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/013.jpg
And here is what I'm talking about with the thrust washers.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/014.jpg
But enough of all that, here's the stuff that I'm really excited about!
RacePak IQ3 digital display dash.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/006-1.jpg
Also got the interface cable so it will work with my Autronic setup.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/005-1.jpg
And lastly, my brand new Pauter rods with rifle drilling and ARP Custom Age 625 bolts.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/007-1.jpg

[lowandslow4now]

Nice build so far. I am assuming its going to be a drag car. If it is what times are you shooting for?

[chris164935]

Hmmm... I know what I'd like to run, but I don't want to speculate yet.

I am looking to get into the NSCRA Outlaw Street class though based on my car's setup: http://www.nscra.com/outlaw-street
And the IFO: http://www.importfaceoff.net/race_rules.htm
Probably run in the Forced Induction Sport or Forced Induction Pro class.

[Gaberossi]

i cant wait to see this car at NSCRA....I am at almost every event in south florida....good luck man i will be watching your build as it goes along...do werk son

also where do you go to school and what career are you shooting for?

[shokwav09]

the race pak is an awesome touch. im using aim sports

[chris164935]

Figured I'd throw you guys a bone. So, here's a quick update. Progress on the build has slowed again (what's new...) because the holiday season sucks me dry! But, it's slowly but surely coming along.

First, got this in the mail a couple weeks ago, but been too busy or lazy to take pictures of it.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/034.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/033.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/035.jpg

And now, another exciting new twist on this build. Going a new route with the intake manifold. This build may be slow but the release of the SEM manifold is even slower... Soooo, I picked up this little gem:
ADR intake manifold with 1600cc fuel injectors and ATP fuel rail bolted up.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/029.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/032.jpg

The inner diameter of the runners are 40mm each, so my best options so far are GSX-R 600/750 throttle bodies or CBR 929. Between a used set of ITBs and the manifold, it's only about ~$300 versus the SEM's $800+ manifold.

[chris164935]

Quick teaser: Picked up some throttle bodies for $47 shipped. [evilsmile]

[onemoremile]

Quick teaser: Picked up some throttle bodies for $47 shipped. [evilsmile]

oh hell yeah.

[onemoremile]

Are you going to fit a newer cam tensioner and do the little trick 034 did with their race car? Should help get that turbo spinning a little earlier.

[chris164935]

Are you going to fit a newer cam tensioner and do the little trick 034 did with their race car? Should help get that turbo spinning a little earlier.
I've thought about it; not sure how reliable the tensioner would be pushing high RPMs though. Most likely just end up using a non-VVT tensioner to start... Definitely got enough things going on with this build for now. [wrench]

[Seerlah]

Ummmm, update? And you are going to run 4 TBs? One on each runner?

[jaychen]

One would assume so Seerlah, Quad throttle bodies aren't new designs. Nissan GTiR's have this setup in Australia. Crazy fast cars with minimal work done, 350hp at all 4's in a car that weighs 1100kg (2400lb). A lot of boys here that are on their P License (restricted from driving turbo till they have had their license for atleast 3 - 4 years) run them on NA SR20's and do quite well.

[chris164935]

Project is on hold for a while. I am finishing up school, starting a new job, etc., etc. I am considering a simpler turbo setup in the meantime with the same motor build, just a T3-based turbo since it's simpler to get a T3 manifold, and running just 1 TB for now. I don't know. We'll see.

[Wet0willy01]

http://store.agtronicmotorsport.com/images/agms31005_01.jpg

http://store.agtronicmotorsport.com/product_info.php?products_id=122&osCsid=5c35vig3me5g8cl3hprue8lli0

[chris164935]

Very nice but is only for transverse cars...

[Wet0willy01]

shoot, I completely missed that. Sorry. But I'm sure Markku could do a t4 variant of the manifold he currently offers with a v-band. I can vouch for the quailty of his craftsmanship.


http://www.agtronicmotorsport.com/gallery/andrew_1.8t/


Good luck, looks like a solid project.

[Dan[FN]6262]

this is totally boss.

[chris164935]

Alright, here's the deal. I miss the car so much that I have decided to go with a T3 turbo setup to save some money and time with less fabrication work. Trying to fit 3" intercooler piping, a 4" downpipe, and the T4 turbo itself was going to take up a lot of time and money. So, I just purchased a new Precision T3 turbo that I think pair nicely (for a T3 turbo, anyway) with the engine build. Now, fitting a 3" downpipe and 2.5" intercooler plumbing will be a lot easier.
Also, now that the SEM manifolds are in stock, I have picked up one of those as well. This will save a lot of time, money and headache with having to build a plenum for ITBs and tuning the damn thing.

Anyway, here's a list of what is changing (also updated on the first post):
9.5:1 83mm CR Pistons
Precision Turbo PT6266 CEA T3 .82 Turbine With Ported S Cover
SPA T3 Manifold
Custom 3" Exhaust With V-Banded Sections
2.5" Charge Piping
SEM Large Port Intake Manifold
80mm Godspeed Throttle Body
Bosch 044 Fuel Pump
Custom Surge Tank

Another big change is we are going with CP Pistons. I have been having a lot of problems with JE's pistons cracking near the wrist pins (8 pistons in total, all in the same spots); these are mostly hairline fractures. So, it is time to move on to another brand. I have heard MANY good things about CP and their pistons. Plus, I was able to grab a set of their 9.5:1 83mm pistons from a place overseas for $600 shipped, which is great considering the places that sell them here in the states charge $675 without shipping and do not have them in stock (it was actually by luck that this shop had them in stock).
As a reference, when I grenaded my stock engine and melted the piston in cylinder #4 (stock piston), it got messed up pretty bad, but it did not crack in the areas where all my JE pistons have cracked.

But moving on. Most of the stuff in the new list is coming soon. However, I do have the SPA manifold in my possession. Man, is it gorgeous.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/026.jpg

Also, a box of a bunch of random parts to assemble the motor and brand new sensors for the SM2.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/025.jpg

[chris164935]

Another project we are working on putting together is called a reluctor interface. This circuit will let us use the stock crank sensor with the SM2. What the device does is converts the magnetic sensor's output signal from a spike wave to a square wave signal. The SM4 has this built into it; but the SM2 does not. These are available online or from most Autronic dealers, however, they want $150 or more for them! The device itself is relatively simple.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/036.png

Between buying the components, circuit board, etching solution, case, etc. it will cost less that $50 to make. The toughest part is going to be getting the proper resistance set on the variable resistor.

[chris164935]

And, lastly, the issue with the forged 06F main caps. I have not worked with this motor before (it is the 2.0T FSI motor for those who were wondering), so why the #3 cap does not have a provision for thrust washers was somewhat baffling.
Pictures from earlier of what I am talking about.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/014.jpg
As it turns out, the 06F motor does use thrust washers. The block itself has provisions for thrust washer and then the main cap acts as the top half of the thrust washers. We figured this out 2 ways: searching through a parts database similar to what the dealership uses and through testing.
For the testing, we installed some old used main bearings, the crank, and bolted down the caps. Without the lower thrust washers installed, the crank was able to walk by just pushing on the nose with your hand. After we took everything apart, we put thrust washers in the lower half and re-installed everything again. This time, we could not get any movement out of the crank, even using a small pry bar. So, if anyone is interested in forged billet main caps, stealing some from an 06F motor is a viable and affordable (only cost me like $150 for all the caps) option. [up]

[chris164935]

Well, my baby just arrived today. I'm so EXCITED! [:D]
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/037.jpg

Now we are just waiting on the turbo and for my lazy ass to take the block to get the new main caps align bored.

[chris164935]

Came home from work late last night and went into the garage to find my Bentley repair manual, and happened upon this as well!
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/038.jpg

Of course, once you've owned a 72mm turbo for a few years, then every other turbo looks like a baby to you. Lol.
Top: S372. Bottom: PT6266 SP.
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/039-1.jpg

[Dan[FN]6262]

Could you take a picture of the inside of the SEM?

[chris164935]

Ask, and you shall receive! [az]
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/040.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/041.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/042.jpg

[Dan[FN]6262]

Thanks!

[EErie B6]

That manifold looks pretty nice.

Could you shoot 1 more picture looking up one of the runners towards the plenum?

[B5RiceEater]

This project is siiick bro, can't wait til it's all done, keep up on the good work

[Dan[FN]6262]

Yo, what are you doing with your ADR intake manifold?

[chris164935]

That manifold looks pretty nice.

Could you shoot 1 more picture looking up one of the runners towards the plenum?

Anything for my 2 fans. Lol. [>_<]
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/043.jpg
The money shot: AEB intake manifold gasket lined up with the manifold. And yes, I know that the gasket is not on right, I just lined it up real quick to show off the port job. [:d]
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/044.jpg

Now, for a quick update. The throttle body that's gonna get bolted to the manifold arrived. It's a Godspeed 80mm throttle body. Anybody know what throttle position sensors will work with it? Make and/or Part #'s would be great!
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/045.jpg
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/046.jpg

[Don R]

CNC Porting FTW! [:)]

Looks like a stout setup [wrench]

[v dub'n]

Sweet build!! you Sir have some good taste in parts!!

[jaychen]

What's happened to this thing?

Updates?

[chris164935]

What's happened to this thing?

Updates?
My daily driver 1.8t felt like it was being left out and wanted some attention. Anyway, now that that is all sorted out, I am trying to get this project back on track.
Currently, I am in talks with Pete at IE to get ahold of some Mahle Motorsports main and rod bearings as well as some JE FSR pistons. Other than that, a while back I picked up an 044 pump. Then, I got a GREAT deal on this a couple weeks ago:
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/047.jpg

So, now all I need are some fuel lines to the rail, a FPR, and an AWIC setup. Finally, it's just a matter of having time/space to put everything back into the car.

[jaychen]

Schhhwwweeeet.

You won't be having any trouble with fuel from now on [:p]

[spindoctor]

My daily driver 1.8t felt like it was being left out and wanted some attention. Anyway, now that that is all sorted out, I am trying to get this project back on track.
Currently, I am in talks with Pete at IE to get ahold of some Mahle Motorsports main and rod bearings as well as some JE FSR pistons. Other than that, a while back I picked up an 044 pump. Then, I got a GREAT deal on this a couple weeks ago:
http://i49.photobucket.com/albums/f260/chris164935/Project%20Build/047.jpg

So, now all I need are some fuel lines to the rail, a FPR, and an AWIC setup. Finally, it's just a matter of having time/space to put everything back into the car.

Just went through your thread. Interesting build.

One of your post, you mentioned the JE pistons have a tendency to crack(hairline) around the wrist pin area and you're gonna use CP pistons.

Now, you're looking JE's FSR. Have they fixed that problem?