Raacerx's (Max@034) 034 Tuned GT28R Elims to Single PT6262 Turbo

[Raacerx]

If anyone comes to the first page, laff...

Evolved to a built 2.8L motor, RS4 intake manifold, Hemi 80mm TB, and a lot more.

7/13/2011 Running on rough base tune, motor broken in, dyno tune soon on stock intake. Then move to big intake components.

12/3/2011 Things just haven't worked out exactly the way I hoped. I have a leaky wastegate actuator on the passenger side, requiring another motor pull.

So the decision was made to go single turbo. Turbo has arrived, project has begun.




















***************

So a lot of things have changed since I first posted this 4+ months ago... One disaster after another, but the light is finally at the end of the tunnel. I am going to keep my original post here, but offer the modified version as well.

Months after I started this latest Stage 3 project, I started working for 034Motorsport, which of course allowed me to deviate a little from my original plan. Needless to say, some modifications have been added, and some changes made. I am going to post up the new updated list of parts, although my goals remain pretty much the same (about 450whp).

I am finally near the final brinks of Stage 3, and thought I would start a little build thread if anyone is interested to see the progress of my car.

EDIT August 1st, 2010 - PARTS LIST

I bought this B5 S4 11 months ago, with blown turbos and needing some work, for under $5k with 115k miles. I will have taken it from bone stock to beyond full Stage 3 in under a year. I started with an ECU, and now I am here, with 3" downpipes, 4" exhaust, meth injection, Sparco seats, and more. The car is a 2001.5 Mbox with the factory sports package, I've put over 15k miles on it since I bought it and pulled the engine twice to replace the blown K03's with used K03's while I saved for K04's. I have replaced half of the vehicle in the time I have owned it, and it is finally nearing "completion" (is there ever such a thing with an S4?).

The goal of the car is that never-quite-attainable quest for a daily driver that can also destroy the track. It doesn't make financial or spacial sense right now for me to own 2 cars, and if I had a devoted track car, I would still have the same worries about getting it to the track and back. Despite living close to Laguna Seca, Thunderhill is my favorite track and its 5 hours away. I have always loved having a car that I drive everyday, but that destroys the track. Of course, this presents all kinds of problems and compromises in both departments, but that is part of the challenge. So far, the car drives wonderfully. There are S4 issues of course, but on the whole, I get 25-26mpg on the highway, its never left me stranded (even when the turbos blew I was able to drive the 30 miles home), and the car has kept a high level of comfort despite track mounts all around. Even with the 4" exhaust and Sparco seats and Tracksport suspension (before the Motorsports), I still made plenty of 4+ hour drives.


Here is a list of whats been installed so far (this is whats currently installed; lots of things have been preceded by other parts). Aside from these aftermarket parts, I have replaced every hose, gasket, etc in the engine, along with new oxygen sensors, new sensor this, new that, etc, etc.

- Stasis Ohlins Motorsports 700/800 suspension
- H-sport rear sway bar with CPP adjustable swaybar links
- Touareg 6 piston 330mm front BBK
- 034Motorsport B6/B7 S4 300mm rear BBK
- Carbotech XP10 custom front brake pads, XP8 rear pads and stainless lines all around
- Upper control arms and Tie Rod Ends
- 034Motorsport 3" downpipes, catless, and custom 4" exhaust
- K&N filter, darintake airbox, sidefire plugs
- 034Motorsport Track motor mounts, Track tranny mounts
- 034Motorsport poly snub mount
- 034Motorsport Billet Diff Crossmember and diff carrier mounts
- Apikol rear diff mount
- AWE DTS (finally got it to work with minimal vibration)
- 034Motorsport Power Steering cooler upgrade/relocation
- VAST meth injection kit
- VAST bi-pipes
- Samco diverter valves
- JHM SS shift knob
- Sparco Roadster seats / Recaro double sliders / Wedge Eng. brackets
- 17" Avus w/ Michelin PS2 for the street
- 17" Kosei T1S w/ Nitto NT01 R-compounds for the track

- ATP GT2560 Eliminators
- 034Motorsport Stage 3 GT tune (~23psi, 90m MAF, EV14 injectors)
- 034Motorsport Bosch 044 dropin fuel pump
- VAST ported/ceramic coated exhaust manifolds
- 2.8L semi-built V6 heads with Supertech Inconel exhaust valves
- 034Motorsport Phenolic intake manifold spacers (RS4 transition)
- Ported intake manifold
- 034Motorsport X34 Carbon Fiber cold air intake
- JHM solid shifter linkage upgrade and Delrin stabilizer bushing upgrade
- VAST Stage 4 clutch and OEM flywheel (hate flywheel chatter)
- 034Motorsport Billet subframe bushings
- RS4 OEM oil cooler
- SAMCO hose kit


I am very excited for the 034Motorsport tune, as it is relatively new and I am also local to their shop, and it is important for me to be there for the tuning and have a dialog going on between me and the tuner. The initial goal is over 400whp @ 20psi on 91 octane. Very confident I can make this considering my Stage 2+ did 306whp on 91 octane. My eventual goal is 450whp with meth, 91 octane, aggressively tuned, with the 2.8L heads and a 3.2L VR6 throttle body. This would be one of the highest powered K04 cars on 91 octane around.

After this work next week, there are very few things I have planned. JHM shifter (only doing the solid shifter linkage now), 4:1 diff, and 2 piece rotors for the brakes, and eventually a transmission rebuild. As time goes by, and the car receives less and less daily driver responsibilities, I will be adding a cage and widebody. This car will never be sold; it will be driven till its too rough to go on the street, then it will be full track duty. Not the most ideal track car as far as lap times, but its all about fun.

Here are some pictures throughout my ownership, chronologically.

The day she came home. Passed SMOG that week, despite turbos almost gone


My first visit to 034Motorsport




Success! Mid May


Up and running


Emergency timing belt replacement (don't drop a socket into your timing belt area)


Yes, about 5 seconds from bending valves


Touareg BBK


Engine pull #2 (K03 blew @ 6800rpm 4th or 5th gear shift)


Yummy


Back on the road with free K03's from Hawaii (THANKS Will175!!!)


Destroying WRX




meth install


Custom 4" exhaust


034Motorsport rear BBK


Goodies


034Motorsport 3" downpipes






Sparco

[davidkae]

Very cool. Keep up the great work!

[exclusivett]

awesome. VAST does the tuning for 034 and JHM IIRC, right? Looking forward to gettign a vast tune myself.

[raaab2536]

damn that thing must haul ass

[Raacerx]

awesome. VAST does the tuning for 034 and JHM IIRC, right? Looking forward to gettign a vast tune myself.

It was my understanding that JHM used a modified VAST tune, but I really have absolutely no idea and that could just be a rumor. 034 does their own tune, far as I know. They only just released it. Not many cars have had it yet.

I am pretty excited. Funny thing is, I am actually perfectly happy with Stage 2+ power. The car is plenty fast, overly fast for my skills. However, Im sick of swapping turbos, and I figure, when in Rome...

[infinkc]

Great build Max, wish I documented mine.

[04/01-s4]

Im jealous to start my stgIII build, very nice rims....

STOCK 2.8 HEADS HAVE HOLLOW VALVES which is almost worse then sodium filled valves if your trying to run some serious go fast juice. spend like...350 on an entire set of solid exhaust valves. Now im not entirely sure if all the 2.8 guys will agree but just my 2 cents

How heavy were the stock s4 seats next to the sparco's ?

[S4jet]

Looks awesome keep it up

[HotSauce]

Im jealous to start my stgIII build, very nice rims....

STOCK 2.8 HEADS HAVE HOLLOW VALVES which is almost worse then sodium filled valves if your trying to run some serious go fast juice. spend like...350 on an entire set of solid exhaust valves. Now im not entirely sure if all the 2.8 guys will agree but just my 2 cents

How heavy were the stock s4 seats next to the sparco's ?

Stock S4 seats are almost exactly 60lbs/seat. Mine were power/heated for reference.

[Quattro_2.7tt]

Nice build. Im going stage 3 soon.

[alexverve]

where did u get the Tourag BBK? did u put it together or someone is selling whole kit?

[exclusivett]

It was my understanding that JHM used a modified VAST tune, but I really have absolutely no idea and that could just be a rumor. 034 does their own tune, far as I know. They only just released it. Not many cars have had it yet.
.

Cool. thanks... what tuner are you going with? Also, where did you find the best deal on the seat mounts and sliders? ive been looking around and cant find a good deal on that stuff anywhere.

[M.S4]

Cool. thanks... what tuner are you going with? Also, where did you find the best deal on the seat mounts and sliders? ive been looking around and cant find a good deal on that stuff anywhere.

034Motorsport... like in the title and the original post.

[RolledMySTi]

What intercoolers are you going with?

[damnthemansam]

034motorsport has just released their own tune, and a strong one at that. 390whp stg 3 for one example. plus being close to your tuner is huge so they can tweak for every last modification.

[drkenan]

Sounds awesome...you've done a great job with an inexpensive car.

[AudiSportB5S4]

awesome. VAST does the tuning for 034 and JHM IIRC, right? Looking forward to gettign a vast tune myself.

No sir, 034 does not get their tuning from VAST.. If you're looking for VAST tuning down in the Florida area, PM "BlackS4TT (Josh)"... He lives down there and has the flashing cable.

OP- Very nice build and looks like the car has progressed very nicely! Keep it up and enjoy stage 3 !

[Don Supreme]

Lofty power goals.

[BlkdoutA4]

Lofty power goals.

he's trying to finally beat me in a race...

[bakeravant]

I am pretty excited. Funny thing is, I am actually perfectly happy with Stage 2+ power. The car is plenty fast, overly fast for my skills. However, Im sick of swapping turbos, and I figure, when in Rome...

I think I'm in the same boat.. My stage 3 setup surely exceeds my driving skills, on the other hand, my k03 went out and I wasn't about to spend money to put in two more k03s and wait for them to fail again if I could afford not to. I'm kind of a gear head, so even though the s4 doesn't really need to be modded it happens anyways :) I hope to have a well sorted, custom tuned 3+ someday when finances permit! You're well on the way to being there. Oh, and the brake upgrade is sick!

[B_EEZY]

Lookin good, did the engine pulls on your own?

[csre9]

Looks like a solid build man! My car is at another forum members garage right now and were doing a vast tuned pjko4 setup.

As far as 034 software, I called them a few months back and they use Unitronic software.

Not to put any tuner/software down,I had uni for my ko3 set up and it ran strong, 10.2 afr's, but strong nontheless. I have a buddy with ko4/16's, actually my friend that has my car at his garage right now and he has Unitronic on a 60lb file, long story short, it runs like shit. My ko3 car would give his a run for his money it runs so bad. Breaks up under load, misses at idle, revs bounce at idle and the list goes on.

Hopefully you'll have better luck with the ev14's though, they are definitely better rounded injector.
Best of luck and keep us updated with the 034 tune!

[BlkdoutA4]

As far as 034 software, I called them a few months back and they use Unitronic software.

034 is now doing in-house custom dyno tuning for the B5 S4

[rouellettea4]

Looks like a solid build man! My car is at another forum members garage right now and were doing a vast tuned pjko4 setup.

As far as 034 software, I called them a few months back and they use Unitronic software.

Not to put any tuner/software down,I had uni for my ko3 set up and it ran strong, 10.2 afr's, but strong nontheless. I have a buddy with ko4/16's, actually my friend that has my car at his garage right now and he has Unitronic on a 60lb file, long story short, it runs like shit. My ko3 car would give his a run for his money it runs so bad. Breaks up under load, misses at idle, revs bounce at idle and the list goes on.

Hopefully you'll have better luck with the ev14's though, they are definitely better rounded injector.
Best of luck and keep us updated with the 034 tune!

I think Uni, IIRC, was releasing a platform for tuning that was available to dealers so that they could tune using it. Some kind of software suite I recall them advertising a little while ago. That being said, putting it in the hands of 034ms I'm sure they could make great tunes using it, even if the tools are being licensed by uni. Someone correct me if I'm wrong.

[BlkdoutA4]

I think Uni, IIRC, was releasing a platform for tuning that was available to dealers so that they could tune using it. Some kind of software suite I recall them advertising a little while ago. That being said, putting it in the hands of 034ms I'm sure they could make great tunes using it, even if the tools are being licensed by uni. Someone correct me if I'm wrong.

way to read my post right above yours

[USAFS4]

Thanks to you I will hopefully be riding your back bumper around Laguna. You are a standup guy for helping me with my car when yours was on the brink of Greatness. Best of Luck !!(not that you'll need it). And please don't forget us little people when you make it to the Big Show.

[rouellettea4]

way to read my post right above yours

sorry for taking your thunder...

post wasn't there when I started typing.

Edit: and it still didn't really answer the question as to whether they are using the unitronic suite to do the actual tuning or if they have their own setup for that, so... anyone?

[BlkdoutA4]

sorry for taking your thunder...

post wasn't there when I started typing.

haha no hard feelings, i'm just sayin...

[sparkyvw]

No sir, 034 does not get their tuning from VAST.. If you're looking for VAST tuning down in the Florida area, PM "BlackS4TT (Josh)"... He lives down there and has the flashing cable.

so do i!!


raacerx props to you for doing it your self. On DIRT with just some sheets on wood on the ground!

[ZMEY]

good job man, looks very good

[Sales@RAI]

Looks like a solid build man! My car is at another forum members garage right now and were doing a vast tuned pjko4 setup.

As far as 034 software, I called them a few months back and they use Unitronic software.

Not to put any tuner/software down,I had uni for my ko3 set up and it ran strong, 10.2 afr's, but strong nontheless. I have a buddy with ko4/16's, actually my friend that has my car at his garage right now and he has Unitronic on a 60lb file, long story short, it runs like shit. My ko3 car would give his a run for his money it runs so bad. Breaks up under load, misses at idle, revs bounce at idle and the list goes on.

Hopefully you'll have better luck with the ev14's though, they are definitely better rounded injector.
Best of luck and keep us updated with the 034 tune!

Sebastian, I keep telling you guys that you should have come up to get everything fixed man. I can promise that the Uni tunes are awesome, it seemed like it just needed to get dialed in

[washyourrhands]

good shit max!

[Raacerx]

Im jealous to start my stgIII build, very nice rims....

STOCK 2.8 HEADS HAVE HOLLOW VALVES which is almost worse then sodium filled valves if your trying to run some serious go fast juice. spend like...350 on an entire set of solid exhaust valves. Now im not entirely sure if all the 2.8 guys will agree but just my 2 cents

How heavy were the stock s4 seats next to the sparco's ?

I am not revving my engine past 7000rpm. Not really past 6800rpm unless I am doing FATS. K04 run out of breath up there anyways. I am not worried about it, and rather just do all the valves at once and do springs, retainers, lifters, etc. If I get paranoid, I can swap valves from the 2.7 heads. They are also the AHA heads, not ATQ.

where did u get the Tourag BBK? did u put it together or someone is selling whole kit?

put it together myself. no one is selling it as a kit. the calipers are quite hard to find these days.

Cool. thanks... what tuner are you going with? Also, where did you find the best deal on the seat mounts and sliders? ive been looking around and cant find a good deal on that stuff anywhere.

Wedge Engineering for the brackets. They are the popular choice. They run about $90 for the bracket, $50-$100 for the sliders depending on if you want double lock, etc. Not sure where to find them. I got my seats with the sliders and brackets all together, from a local forum member who sold his B5 S4. I got them for around $900 for everything.

What intercoolers are you going with?

I am not sure yet Rick... Can't quite justify dropping $1200+ on ER, and can't justify spending anything about $500 on anything but ER... So I think I will probably just go with a front mount. If I do, you can guarantee it will be painted black, and I will be minimizing trimming of the bumper as much as possible. I hate the look of the FMIC, and dont want the attention. Thats one of the reasons I love running stock rims. I blend in pretty good... except for the 4" exhaust of course. Not sure I can really afford ER's anyways. If I can't afford anything better or figure something else out, meth and FMIC will have to do. I have a core already, and actually have some make shift piping as well; just need a crapload of t-clamps or I will just invest in some better piping.

034motorsport has just released their own tune, and a strong one at that. 390whp stg 3 for one example. plus being close to your tuner is huge so they can tweak for every last modification.

Exactly! Being able to have an open and local dialog with the tuner is very important to me. I also have experience with 034, I run a lot of their products, and I like guys. They do a lot of B5 work, and they took a long time to release this tune, so I have confidence it will end up with the power I want. And like you said damnthemansam, I want to be able to have the tune tweaked for mods such as the 3.2L throttle body I will be adding in the near future. I don't want something like that done remotely, and 034 is 45 minutes away from me.

he's trying to finally beat me in a race...

Hahahahah! You know... it was never my original intention, but lately I have realized that I might have a few extra goodies on BlkdoutA4, so yes! Yes now I am trying to beat Brian. He put down good numbers, and is a good goal to beat, despite it never being my original intention to "one up" him. Muhahaha!

Thanks to you I will hopefully be riding your back bumper around Laguna. You are a standup guy for helping me with my car when yours was on the brink of Greatness. Best of Luck !!(not that you'll need it). And please don't forget us little people when you make it to the Big Show.

Thanks jason! I cannot wait to get you, Brian, Kanyon, and more of us out on the track. It would be phenomenal to have a big B5 turn out somewhere. We'll get your car good enough to give us all a run for our money. VAST tune with meth... your going to be hauling.

Lookin good, did the engine pulls on your own?

yep... just finished my 7th pull this last week. Doing my 8th next week (my own). Have to admit... I did a suspension swap today and it was incredibly refreshing compared to pulling engines. I've pulled 3 in the last month and a half, and about to do my 4th in a 2 month span. Satisfying, but not terribly fun.

so do i!!


raacerx props to you for doing it your self. On DIRT with just some sheets on wood on the ground!

haha thanks. luckily i've upgraded to a large patio and a garage, but the dirt was fun. I think thats what I get the most comments on. just got to work with what ya got. I am one of the cheapest guys ever, so sometimes I deal with less then ideal situations or settings.



Appreciate the kind and encouraging words gents... The day is getting near... I am giddy. Feel like a little kid.

Oh, and I will be running 255/35R18. Need to find me some 8.5 or 9" wide rims, ET30 offset

[Raacerx]

Oh, forgot to mention. With the 034 tune, and everything I've got listed here, my total investment (after selling off parts I have replaced, and including the multiple sets of tires, etc), I have spent about $15k-$16k. That includes the cost of the car, registration, everything.

This is encouraging, since the going rate for a good running Stage 3 is about $15k. So, not that I would ever sell the car, but I could make back my entire monetary investment.

[RolledMySTi]

Also, do the 4:1 diff now. It is freaking awesome, especially if you go to the track. Trust me, you will be pissed off if you wait once you realize how awesome it is.

[veggiemonster]

Looks like a solid build man! My car is at another forum members garage right now and were doing a vast tuned pjko4 setup.

As far as 034 software, I called them a few months back and they use Unitronic software.

Not to put any tuner/software down,I had uni for my ko3 set up and it ran strong, 10.2 afr's, but strong nontheless. I have a buddy with ko4/16's, actually my friend that has my car at his garage right now and he has Unitronic on a 60lb file, long story short, it runs like shit. My ko3 car would give his a run for his money it runs so bad. Breaks up under load, misses at idle, revs bounce at idle and the list goes on.

Hopefully you'll have better luck with the ev14's though, they are definitely better rounded injector.
Best of luck and keep us updated with the 034 tune!

1. that thing needs a 3 bar soooo bad. i bet the tune is decent with a 3 bar, maybe not the most powerful, but def not a 9.0 afr or w/e he's been getting.

2. how far along are you? i need your car done to get my car done ;)

[kbS42001]

NICE, Best of luck man, it looks solid. Makes me sad that i didnt do more research and build a cheap s4 that needs help rather than trying to find a low mi pristine car.( which didnt happen either, lol)
and kudo's x2 for DIY in tha dirt

[exclusivett]

Wedge Engineering for the brackets. They are the popular choice. They run about $90 for the bracket, $50-$100 for the sliders depending on if you want double lock, etc. Not sure where to find them. I got my seats with the sliders and brackets all together, from a local forum member who sold his B5 S4. I got them for around $900 for everything.

Thanks!

[NOTORIOUS VR]

I can promise that the Uni tunes are awesome

LOL

[awd2ks4]

So 034 is going to set u up with a custom file and tweak it on their dyno?