[Project] 2.1L A4 Avant & V-Band GT3076R

[iloveturbo]

Hi all,
I been browsing the Audizine forum for some time now. Many of the projects I read here are quite amazing and inspirational. Anyway, I figure it's only fair that I pay my share by documenting my own project. Please do keep in mind that this is a project that would take a long time and I am in no rush of things. This is my weekend car and I want to do it right.

Project car: 2005 Audi A4 Avant (B6)


Current Mod list:
Oettinger front, side skirt
S4 rear bumper
Sportec cat-back exhaust
KW V3 coilover
Porsche Cayenne six pot calipers with floating type 355mm cross-drilled rotors
320mm rear rotors with upgraded pads
19x8.5 ET35 3pc forged wheel with step lips / 225-35-19 all around (soon to be replaced with Rays Progressiv ME 19x8.5 ET31 front 19x9.5 ET37 rims. I had them sitting in my basement for few months now)

Phase 1 - Custom Audi A4 Tubular Manifold
Markku custom built me a manifold, downpipe, wastegate reroute and a support brace. They are amazing quality but don’t take my word for it. Let the pictures speak for themselves.

























Phase 2 - Engine
Issam of INA is commissioned to build up a 2.1L longblock consist of following,

CP bore: 83mm stroke: 95.5mm Compression ratio: 9.0:1 (coated)
Brute Rods with EDM
MK4 TDi Crankshaft
Supertech inconel exhaust valves (+1mm)
Supertech valve springs and retainers
main bearings (OEM)
Rod bearing (Calico + 0.000in)
SEM intake manifold (large port)
RS4 type 70mm throttle body + Adapter harness
phenolic spacer
ARP main studs
ARP head bolts
big bore gasket
CAT CAMS 3658
Brand new Block
Brand new AEB Cylinder head
OEM Timing belt & water pump

I have asked Issam to start a separate complete write-up of the installation process so others may benefit from it. Once again, prop to him for everything.

Phase 3 - Fueling and tuning
Undetermined yet.

That's all for now. I am sure there are plenty of other things I must have missed. Feel free to correct me if i made a mistake somewhere.

*admin please move this to project section. It doesnt allow me to start up a thread there. Thanks!*

[nananana4k]

I've seen the manifold on other threads. Such a sick build.

[Sandeman]

very nice... i always thought the custom fabrication far surpass any mass production made parts.... i wasnt really a fan of the B6s, but urs is pretty mint! now i have to convince the fiance to like the avants so itll be her next car lol

good luck man, and nice work

[dirtybrd]

Awesome!

[Papachristou]

you are dropping some $$$, you must be in the banking industry!

[dougyfresh]

same engine exhaust hardware as jet jockey

cool beans!



Need to figure out tuning to take full advantage of that hardware configuration. I'm sure Issam has something good up his sleeve...

[mtbrider]

nice

[RLB6]

B6 community is steppin' UP!!!!

[texasboy21]

Thats fuckin awesome!

[Issam@INA]

To anyone that is asking.Howard,Alex & Michel are all running the Stage VI turbo kit.

[Jarim]

RAw!

Gnarly build!

[A4ringedONE8T]

Markku's fab work is unreal!!!

[A4 TSCHUSS]

Agtronic is bad ass. Guru's S4 and this stuff. Definitely a "go to" place. Wish I had the money and they were close for some nice stuff like that. Looks like they have a jig made for that downpipe though. Did they just make all this stuff on a spare engine (manifold, downpipe, wastegate reroute) so they could make them for anyone without the car being there?

[iloveturbo]

Thanks for the positive comments guys and no I am not in the banking business (yet...)

A little background on this project. The inspiration came after seeing so many projects here trying pushing the envelope of B6, especially Michel aka JetJocky's built. I contacted Markku right away and few days later we agree to a price that he is happy with. The only condition I asked him was to give the his 110%; his masterpiece so as speak. Since time was none issue, he took all the time he needed for the custom fabrications (two~three month) and delivered just what i asked him to - true art in mechanical form.

The turbo of choice for me is polished/v-band GT3076R .63 with a TiAL 44mm v-band WG. After seeing Jake's built for his dad, I am confident 400+whp would be attainable with GT3076R series giving the right formula.

On the sidenote, keeping my fingers crossed. I may have a shot finishing the build before Clint (j/j... keep up the good work! don't let anyone bring you down)

-Howard

[A4 TSCHUSS]

On the sidenote, keeping my fingers crossed. I may have a shot finishing the build before Clint (j/j... keep up the good work! don't let anyone bring you down)

-Howard

LMAO I think a baby still in their mothers belly could grow up, get their drivers license and build a car before Clint

[dougyfresh]

Good to hear Howard. I like your attitude

Proper engine management software and fueling will bring out the true capability of this hardware package you have put together. Have you given any thoughts into this? Sticking with motronic tuning or stand-alone engine management? Custom fuel system like Michel or factory returnless system?






Looking forward to the outcome of these projects, Issam

[Sales@RAI]

On the sidenote, keeping my fingers crossed. I may have a shot finishing the build before Clint (j/j... keep up the good work! don't let anyone bring you down)

-Howard

Im at the shop right now Howard, and guess what I'm doing? .......

Anyway, your build looks absolutely awesome, I look forward to the numbers. What software are you going to be running? I may have missed it

[Dan[FN]6262]

yes! this is awesome!

ive been wanting to do something similar, but i want to keep it 1.8 just to see what power i can get out of it.

looking forward to see how this unfolds!

[Issam@INA]

so they could make them for anyone without the car being there?

Yup,
that was the intention but you would probably have to purchase the turbocharger and lines through us as it is not really worth it for us to just sell a manifold and downpipe.
Not on a kit of this caliber....we do offer HTA turbochargers as well for those that are interested so if you have any questions please feel free to email me :
iabed[at]inaengineering[dot]com

[iloveturbo]

Doug - I haven't decide it yet. Returnless system would probably work but more efforts would be required to bring out most of it. As for the factory ECU or standalone, I think I will try to keep things sensible try keeping an Audi what Audi is, factory ECU wins this time.

[AudiA4_20T]

Doug - I haven't decide it yet. Returnless system would probably work but more efforts would be required to bring out most of it. As for the factory ECU or standalone, I think I will try to keep things sensible try keeping an Audi what Audi is, factory ECU wins this time.

Unitronic is currently working on the 830cc returnless file for the B6 through a customer of ours. I will be running that file to begin with on my car as well, and seeing where it goes from there

[Agtronic]

Howard, I'm so happy to see this finally come together! Can't wait to see it in action! :)

[iloveturbo]

Howard, I'm so happy to see this finally come together! Can't wait to see it in action! :)

Hey Markku! good to hear from you bro. I need to get your manifold sealed in a closed glass window display.

Amazing weld + amazing guy = just can't ask for more

[dougyfresh]

Doug - I haven't decide it yet. Returnless system would probably work but more efforts would be required to bring out most of it. As for the factory ECU or standalone, I think I will try to keep things sensible try keeping an Audi what Audi is, factory ECU wins this time.

Sounds good. I am pretty sure you are going to run into fueling limits when really trying to take advantage of that hardware configuration. Keep that in mind as you move forward.

[dougyfresh]

Unitronic is currently working on the 830cc returnless file for the B6 through a customer of ours. I will be running that file to begin with on my car as well, and seeing where it goes from there

What about the return-style system on David's car? Why is Unitronic developing two separate files? Doesn't sound like a good business model to me.

[Sales@RAI]

What about the return-style system on David's car? Why is Unitronic developing two separate files? Doesn't sound like a good business model to me.

Because Mike is a beast and can write anything. Why not have two files? We've been plagued with nothing for the past 3 years

[B6Lovin]

Probably because lots of people said they'd rather run the stock fuel system and see how far it can be carried..... there's a couple of us ready to pony up right now (just a FYI)

also, it seems to me that the less modification needed to still safely achieve results above and beyond the current 630cc file the better (from a business standpoint anyways)

[B6Lovin]

P.s. Both of you two have paypal coming when I go on lunch today. Pm me email addys for paypal

[Sales@RAI]

P.s. Both of you two have paypal coming when I go on lunch today. Pm me email addys for paypal

AudiA4_18T@yahoo.com

[jbrown7815]

In on this build :D

[bernB5]

looks sick

[NetLogic]

Pretty cool thread Markku started about him starting his shop and so on. A long read but very cool.

http://www.honda-tech.com/showthread.php?t=2267900

[Issam@INA]

Because Mike is a beast and can write anything. Why not have two files? We've been plagued with nothing for the past 3 years

plagued?be real Clint....
You did not even run the Eurodyne 1000cc file so how can you say you have been plagued with nothing for the past 3 years when there are B6 files floating around like flies.

[Sales@RAI]

plagued?be real Clint....
You did not even run the Eurodyne 1000cc file so how can you say you have been plagued with nothing for the past 3 years when there are B6 files floating around like flies.

I did not run the Eurodyne 1000cc file because my ECU is fried, I never even got a chance to run it. We plugged it in to do a throttle body adaptation and it wouldn't wake-up. I don't like bashing anyone so I never said anything on here, Chris did say he would check out the file and I have respect for what he does.

The B6 community only had the Revo 440cc file for the longest time, Unitronic did surface on cars like Josh's (mtbrider) and Dan's (B6Lovin) pretty early, but the files are stronger than ever now. GIAC had their 28R tune but it failed miserably. Now, the Unitronic tune has put down the best two times on B6s in this forum, replacing the outdated Revo files

[Issam@INA]

I did not run the Eurodyne 1000cc file because my ECU is fried, I never even got a chance to run it. We plugged it in to do a throttle body adaptation and it wouldn't wake-up. I don't like bashing anyone so I never said anything on here, Chris did say he would check out the file and I have respect for what he does.

The B6 community only had the Revo 440cc file for the longest time, Unitronic did surface on cars like Josh's (mtbrider) and Dan's (B6Lovin) pretty early, but the files are stronger than ever now. GIAC had their 28R tune but it failed miserably. Now, the Unitronic tune has put down the best two times on B6s in this forum, replacing the outdated Revo files

I am all for Unitronic support considering we are a dealer for them but what you typed above is what I would expect from some marketing VP trying ....
If you have respect for what he does then run the file?

[Sales@RAI]

I am all for Unitronic support considering we are a dealer for them but what you typed above is what I would expect from some marketing VP trying ....
If you have respect for what he does then run the file?

Thanks Issam

I can't though my ECU is fried. I'm sending it back but I do want to get the car running soon and my availability for the Unitronic is unmatched here.

[Issam@INA]

With Howard's permission we will be starting a new thread

[B6Lovin]

With Howard's permission we will be starting a new thread

i think he gave you the "go" for that in post #1

so get to typing, i wanna read allllllllll about it

[coran nariman]

Good stuff!!! cant wait to see what this car puts down!

Coran

[coran nariman]

Issam. Whats considered a Stage VI turbo kit? haha