My stroked BT Build...

[A4DRIVR]

This whole project originally started because of this... Any idea what part of the motor this is?



So this was supposed to be your run of the mill 06a rebuild… new rings, bearings and some stronger rods, add a larger turbo, possibly an eliminator kit and be on my merry way… well, not anymore. After sending the block to the machine shop for a rehone, it was apparent that the wear in the cylinder walls was going to require an overbore. And as many of you know, the cost of overbore pistons are roughly equal to the cost of stroker pistons, and that’s where it all went down hill…

So 400 whp is my new goal.

All right, let the fun begin...

The current plan is to Bore and stroke the motor out to 2008cc…
I got all of my rotating assembly this week from Joe @ Axis Motorsports who I highly recommend. That includes Supertech 83mm stroker pistons w/ 8.9:1 compression, Scat 144mm/20mm Rods, Forged 2.0 FSI 92.8mm crankshaft, SB Stage IV Clutch/Pressure Plate/SM Flywheel. I dropped everything off including my block and cylinder head at D&D's, my local machine shop.



The machine shop will be balancing the entire rotating assembly, rebuilding the head and boring the block. And just for good measure, I rented one of IE’s torque plates for the final hone to get everything perfect.





Cylinder head:
I have chosen to keep the AWM (small port) casting. I have purchased Supertech nitride coated SS intake valves; inconel exhaust valves and the full high lift spring kit with titanium retainers. Again, I got all of this thru Axis Motorsports. I plan to run the 3652 CAT camshafts… however this detail is still undecided. I may start with the stock cams and add the 52’s later.

Edit - looks like the 52's aren't for me... too much low end loss, meant to be spun way high. I have decided on running a set of custom "Purple" cams from QEDpower.com. Here's to maximizing the area under the curve!!!



Turbo setup:
I will be running a GT3076R turbo (4in cold inlet//.82 A/R T3 with 4-bolt T31 outlet), SPA manifold, 034's 3" down pipe and v-band adapter (034), and Tial 38mm black 0.9Bar external waste gate.

Engine Management:
I have yet to determine this… however, I am starting to sway toward the Eurodyne tuning suite. ON a side note, since I have an 01, my ECU (Motronic ME 7.1) can be tweaked by some tuners.

The deciding factor here is support. I’d like to put the car on a dyno and have it tuned once finished, however i’m in Cincinnati and 4 wheel dynos are not very close to me. So basically the shop I decide to take it to will determine my software setup. This is something I need to determine soon because that will also determine my intake plumbing (i.e. MAF versus MAF-less)

Edit - Decision made! I will be running Eurodyne w/ Meastro Tuning Suite. SAHWEETTTTT!!!!!

Fuel Injection:
I have a set of new 630cc Dekka injectors, a Walbro in-line pump, Adjustable FPR.

Edit - sold the Walbro inline and upgrade to 034's drop-in Bosch 044 pump. This provides me a cleaner install without having to splice into the factory fuel lines and fuel pump harness.

I will also be changing the 630cc injectors to 1000cc injectors to assist in future fuel delivery at high RPM and boost levels

FMIC:
The 034 Motorsports B5 kit. I'm just going to have to fabricate the hot side plumbing for my setup.

I will add more pictures and developments as the project evolves.


I’d love your comments, suggestions, and/or recommendations… or just your prayers!

[A4DRIVR]

So disassembly started a few weeks back...


Once the front end was off...


I even got my dad over to the house to help me turn some wrenches! Dad doesn't usually touch cars...


So now the motor is out...


Here's me and a good friend on mine disassembling the motor... He drove down from Columbus to "help a brotha out"!




Rob taking stuff off...


And here is how the car sits currently. I rolled it out into the driveway to pressure wash the engine bay and to remove a few more items... look at that bell housing shine!


10/15 - Stopped by the machine shop tonight. All of my rotating parts have been balanced!!! I was hoping to get some pics but decided to pass since it's just a pile of parts.

10/16 - Stopped by the machine shop to drop off the torque plate...


And while I was there they went ahead started boring the cylinders. Dan (one of the D's in D&D's) told me how he was going to cut the cylinder bores in three seperate passes. Once finished, he would be within 0.005" of the final bore diameter. The final bore dimension would be made by the honing machine with the torque plate installed. I decided on a .003" piston to bore gap... The pistons called for a .00275" gap, but .003 seemed close enough.








10/22 - All machine work is complete and I'm picking up the parts tonight!









Check out my Photo Diary on Live Spaces

[A4DRIVR]

Engine Assembly:

10/23 - So I have been dealing with one major issue since the completion of the machine work. After assembly and clearance checking, I have determined that both my rod and main bearing clearances exceed the factory specification. I have started another thread on the topic if your interested CLICK HERE

I have decided to purchase new Calico coated bearings for only the rod bearings which alleviate the oil clearance issue... and many thanks go out to Bob Quindazzi (http://qedpower.com) for his help, sharing his knowledge/experience with high performance motor builds to help me determine the best solution.

Oh.. and I also decided to go with a set of custom ground camshafts supplied by Bob with an adjustable cam gear.

Added 12/23... for those who are curious(in progress)
Parts List:
Garrett GT3076r .82 A/R -
DEI turbo blanket and exhaust wrap kit -
Tial 38mm Wastegate (14lb spring) -
034 Oil/Coolant SS braid line kit -
SPA Logger T3 Manifold w/38mm EWG -
Supertech 83.0mm pistons (9.0:1)
SCAT 144/20 forged connecting rods
VW 2.0FSI forged stroker crank
OEM crank timing sprocket
OEM crank sprocket stretch bolt
OEM Main cap bolts
OEM Head bolts
Big Bore Gasket
QED custom intake and exhaust cam set -
CAT cams adjustable cam sprocket
OEM hydraulic lifters (20)
Supertech 20 Valve Spring Set w/Titanium Retainers -
Supertech Iconel Exhaust
Supertech Stainless/Nitride coated intake Valves
Siemens 630cc Injectors (4)
034 Motorsports downpipe for SPA mani -
Turbo Flange Hardware kit -
Bosch 044 Fuel Pump w/ 034 adapter ring to fit into OEM basket
034 Motorsports FMIC (large core) B5 kit
034 silcon 2" coupler
Extruded aluminum 45 degree tube (for FMIC hot side fabrication)
AWE Vent Gauge mount -
ECS Adjustable Fuel Pressure Regulator -
ECS Fuel Pressure Gauge -
034 SS coil cover (should have order the carbon one!)
OEM Headbolt Set (ordered 2 - one set was used for the torque plate only)
NewSouth Performance Intake Manifold Power Gasket -
Head Gasket Kit -
OEM timing belt -
OEM tensioner damper -
OEM thermostat with o-ring -
New alternator/power steering belt (shortened to bypass fan pulley)
Two (2) bottles of OEM G12 coolant -
OEM crankshaft seal and cam seals -
Metal impeller water pump-
OEM coolant flange (back of head)
OEM coolant flange (t-stat housing)
034 Motorsports catch can -
xxxx Green 1" breather filter -
2458 Green Inverted 4" Cone Filter -
Eurodyne Maestro7 Tuning Suite -
ClutchMasters Stage 4 Clutch and LWFW -
034 Street Density Motor & Transmission Mounts
Percision Bore/Hone block @ D&D's machine shop
Powder coating (Valve cover, intake mani, engine mounts, and acc. mounts)
Forge 004 BOV -


Things I would have done (plan to do) differently:
Large injectors and fuel rail
Big port head and intake manifold

[A4DRIVR]

Reserved - Turbo Install

[jrock]

Keep em comin!

[A4DRIVR]

Just put up some more pics... this time it's of the torque plate and the block being bore'd... SAWEET!

[Lou_B5]

Awesome!

Your build is pretty much identical to mine except for the injectors.

You should go for 830cc at least with that set up.

[biketsai]

I like the detail and the pics! Keep up the work.

[Altech75]

If you've got the time and money, then I'd look into some Swain Tech coatings for some of your parts. Link: Clicky clicky

Getting everything coated costs less than a grand. It's what I'll be doing and a couple other have done it as well.

[Gaberossi]

DO WERK SON

great to see another B5 build!!
starting my BT setup soon...keep em coming

[texasboy21]

Great build! I cannot wait to do mine!!

[Oceanside]

props to you sir

[JPJ2007]

To answer your question OP....
It's a magnetic Oil drain plug... what do I win? lol If your wanting to know whats stuck to it, I'd say piston rings?


Anyway, Looks great, Keep taking pics for us!

[jcb.]

nice, very similar to what I have going on
http://www.audi-sport.net/vb/showthread.php?t=58430

400 should be a cake walk for you on a 3076 2.0l. 15psi should do it!

the cylinders are meant to be bored with the torque plate in place, not just the hone IIRC.
any pics of the manifold and turbo set up?
I went Tapp 630cc file but am also undecide on intake plumbing and where I want the MAF

[A4DRIVR]

the cylinders are meant to be bored with the torque plate in place, not just the hone IIRC.

Since the last .005" of the bore will be taken out with the hone... it will be just fine. The cylinder walls will not deflect no where near that much once the torque plate is bolted down. Odds are, the 1.8 block is stout enough that using the torque plate at all is border line overkill. But since I plan on building the motor for longevity... I figured, it's a good insurance policy.

[A4DRIVR]

any pics of the manifold and turbo set up?

Soon... very soon! The parts have been ordered and paid for... just awaiting delivery.

I went Tapp 630cc file but am also undecide on intake plumbing and where I want the MAF

I'm thinking of going MAFless with Eurodyne software... but that's still up in the air.

[A4DRIVR]

To answer your question OP....
It's a magnetic Oil drain plug... what do I win? lol If your wanting to know whats stuck to it, I'd say piston rings?

Nice...

I sent pictures over to Joe @ Axis Motorsports and he said the same thing... piston rings. I'll check again tonight, but I swear the pistons and rings all look perfect!?!?!?

[Sales@RAI]

Hey man great build! A few things

1. If you're set on 400whp, the 630ccs at 4 bar should do it, but I would have gone a bit bigger
2. Why not go for an AEB head? You have everything apart, and it's going to get you to your power goals easier
3. If you're interested in Unitronic (they have some great ME.7 big turbo files), or any of the OEM parts for the engine build, shoot me a PM.

[pac1085]

yea...those definitely look like rings!

[A4DRIVR]

1. If you're set on 400whp, the 630ccs at 4 bar should do it, but I would have gone a bit bigger

I realize I jumped the gun when I purchased these... My original build plan was a GT2871R (eliminator) with just A freshened block and some stronger rods. The goal then was 300 whp... so these were perfect. Now things have changed a little...

2. Why not go for an AEB head? You have everything apart, and it's going to get you to your power goals easier

I thought about the AEB head... and this may be an option in the future, but I think the AWM will provide improved port velocity resulting in stronger low end torque, which is something I am trying to preserve since this will be my DD!

3. If you're interested in Unitronic (they have some great ME.7 big turbo files)

I'll keep that in mind... but with this being a setup that will be a constant "work-in-progress", I really like the idea of having the adjustability at my finger tips. I want to be able to setup different tunes for different seasons... different needs, etc. etc.

[A4DRIVR]

Well... I have a brand new Walbro in-line pump and four brand new 630 Dekka injectors for sale!

I hate buying parts twice! But... I've decided that I should probably just start with larger 870cc injectors and since I'm a neat freak, I've decided to change from the in-line pump to a more cosmetically pleasing in-tank pump.

I'll be posting up these parts in the classified in the next day or two.

[A4DRIVR]

Well... my valvetrain components just were delivered!!! WOO HOO!!!

[fenderstrat1184]

i mean, nice.

[Kyle H]

I spy CAD drawings.

[Lou_B5]

sexy!

[A4DRIVR]

Good eye!

I spy CAD drawings.

[Kyle H]

Good eye!

Engineering student.


What do you design?

[A4DRIVR]

not a student .... just an engineer!

ps... surfing and typing from a phone sucks.

[Stumanbmx]

I spy CAD drawings.

Glad I'm not the only one.

I see you're an engineering student as well. What kind? I'm mechanical.

[Kyle H]

Haha, no, I am an engineering student. What do you engineer?
edit-
that was to A4DRIVR



I'm doing mechanical too. It seems like a lot of engineer-minded people are drawn to Audizine....

[flashovermac]

Haha, no, I am an engineering student. What do you engineer?
edit-
that was to A4DRIVR



I'm doing mechanical too. It seems like a lot of engineer-minded people are drawn to Audizine....

[flynnr]

i am in engineering (student status as well) too! plastics engineering though...

junior year currently


your build looks so nice! what is estimated total cost?

[A4DRIVR]

I'm a Mechanical Engineer.. but I have my Associates in Manufacturing Engineering. I've been out of school for about 8 years.

I started in injection molded plastic design... Worked for a supplier creating A-surface interior parts for a major Japanese auto-maker. I have since moved to a new job, something closer to home, and now design manufacturing/product assembly equipment for a local company most people have heard of before...

[killa]

I'm a Mechanical Engineer.. but I have my Associates in Manufacturing Engineering. I've been out of school for about 8 years.

I started in injection molded plastic design... Worked for a supplier creating A-surface interior parts for a major Japanese auto-maker. I have since move to a new job, something closer to home, and design manufacturing/proiduct assembly equipment for a local company most people have heard of before...

Funny you say that, do you know John Bozzelli or Kip Doyle? John is an injection mold guru and runs his own seminars.

Just curious as I know people in the industry.

[A4DRIVR]

Names don't ring a bell...

[A4DRIVR]

So... I stopped by the machine shop tonight. Block work is complete... However, two things were brought to my attention which caused me a little concern.

First... My oil clearances were as follows: 0.0028" for the crank to rod bearings; and 0.0029" for the crank to main journal bearings. The reason these dimensiones were so concerning is because the oil clearance on my 150,000 mile bearings were 0.0026... 0.0002" tighter than brand new bearings. In addition, the Bentley give a tolerance for the 06a oil clearances as: rod bearing shells 0.0004~0.0020"... and main bearing shells 0.0008~0.0016". WHich are obviously smaller than what I have measured.

Second... I originally bought my bearings for the 06a block. Before the stroker build. However, I noticed that the new (stroker) rods have locking tang notches, but my rod bearings do not. Is this going to be ok?

Let me know your thoughts...

[Lou_B5]

So... I stopped by the machine shop tonight. Block work is complete... However, two things were brought to my attention which caused me a little concern.

First... My oil clearances were as follows: 0.0028" for the crank to rod bearings; and 0.0029" for the crank to main journal bearings. The reason these dimensiones were so concerning is because the oil clearance on my 150,000 mile bearings were 0.0026... 0.0002" tighter than brand new bearings. In addition, the Bentley give a tolerance for the 06a oil clearances as: rod bearing shells 0.0004~0.0020"... and main bearing shells 0.0008~0.0016". WHich are obviously smaller than what I have measured.

Second... I originally bought my bearings for the 06a block. Before the stroker build. However, I noticed that the new (stroker) rods have locking tang notches, but my rod bearings do not. Is this going to be ok?

Let me know your thoughts...

Get the AWD rod bearings with the locking tangs.

[A4DRIVR]

Get the AWD rod bearings with the locking tangs.

That was what I was thinking...

[lotusgardener]

How much did all those nice valvetrain parts cost? Did you go oversized on either?

[A4DRIVR]

How much did all those nice valvetrain parts cost? Did you go oversized on either?

They weren't cheap! Call Joe @ Axis Motorsports... He'll set you up! Everything is stock in size, just a lot stronger.