Big Boost's VR6 BAT Build!

[diabolical1]

i must say, with all of the other gorgeous and top notch stuff you have going on with this build, i'm probably most impressed by this multifunctional custom bumper support piece. your friend (Jon, i think you said) has crazy skills! props to you both.

[diabolical1]

... i have 3 electric fans on mine. One big one and one small one pushing and another small one pulling, my car was still overheating in traffic, so i put a inline electric water pump to keep things moving in traffic..

just curious about a few things, but i suppose most of them are contigent on if you have an actual temperature gauge, so that's my first question: do you have one?

if so ...
(1) what kinds of temps did you see at moderate load/throttle before adding the electric pump?
(2) what kinds of temps did/do you see after adding it?
(3) do you run an oil cooler as well?
(4) just to clarify, are you running only an electric water pump or are you running it in tandem with the stock mechanical pump?

thanks.


oh and i'm glad to hear that you're out of the hospital. will you need rehab or no?

[Big Boost]

It's looking as if the build should be completed by next month. The next step will be to have it tuned. I can't wait.....

[NYCVR6]

just curious about a few things, but i suppose most of them are contigent on if you have an actual temperature gauge, so that's my first question: do you have one?

if so ...
(1) what kinds of temps did you see at moderate load/throttle before adding the electric pump?
(2) what kinds of temps did/do you see after adding it?
(3) do you run an oil cooler as well?
(4) just to clarify, are you running only an electric water pump or are you running it in tandem with the stock mechanical pump?

thanks.


oh and i'm glad to hear that you're out of the hospital. will you need rehab or no?

I only am working with the factory gauge, but in traffic it starts to overheat unless i give it gas and get the water pump spinning. So when im moving along the temps are fine. I havent ran it with the booster pump yet, but im running it in tandem with the stock pump. Yes i run an oil cooler. Thanks for the thoughts about getting out of the hopital, i have a fairly long road ahead, i have rehab and a lot of follow up doctor appointments.

[Haenszel20v]

I only am working with the factory gauge, but in traffic it starts to overheat unless i give it gas and get the water pump spinning. So when im moving along the temps are fine. I havent ran it with the booster pump yet, but im running it in tandem with the stock pump. Yes i run an oil cooler. Thanks for the thoughts about getting out of the hopital, i have a fairly long road ahead, i have rehab and a lot of follow up doctor appointments.

Are you on stock ecu? My stock gauge reads "190" all the way up until the autronic reads 240*....... NOT GOOD.

[NYCVR6]

Are you on stock ecu? My stock gauge reads "190" all the way up until the autronic reads 240*....... NOT GOOD.

I run ViPec V88, Ray Hall split from Autronic and started his own company. We've logged it and it's pretty accurate with the stock gauge, a little off but nothing like yours.

[Haenszel20v]

Nah I'm just sayin its crazy the span that the stock gauge stays.at 190 for.

[diabolical1]

thanks for the reply NYCVR6.

Haenszel20v,
yes, a 50 degree lag/dead time is pretty crazy. i'm sure it would probably vary from car to car, but it's still pretty unnerving.

[Big Boost]

UPDATE!!

The throttle cable and the acclerator pedal are done. The cable was made from two cables. Part of the
cable was from the unit 034 provided me along with a LOKAR unit I already had. Even the black factory triangle that fits
on the firewall was used. It fits like a OEM unit!

The water pump for the AWIC system is mounted and the hoses have been positioned. The water flow path runs in the
opposite direction of the air flow path. The water pump first sends the cooling medium from the heat exchanger to cool the
intake manifold through a channel underneath the plenum (approx 1 liter of volume). Next the medium flows to the AWIC.
After that, the compressor discharge pipe has been modified and now incorporates an intercooled plenum around it. It is
designed with an internal baffle that swirls the water around the neck 360 degrees and exits directly into the heat exchanger.
It is designed to reduce the inlet temperature before the AWIC and thus to further reduce the entire intake temps.

[Haenszel20v]

What's going on with the turbo outlet pipe? Why is the water routed through that?

[Big Boost]

There is over a half inch of clearance between the discharge plenum and the hood.

[laxman851]

So are you or your friend going to open a shop soon or something... goodness.

[skinnytirez]

i'd give them my business...just read all 5 pages of this; i want one!

Great job kids!

[Turbo Nerd]

Pure sex. What's left to do, doesn't look like much?

[colt45]

god damn this is an awesome build. cant wait to see the finished product.

[ECS Tuning-Audi]

Pure sex. What's left to do, doesn't look like much?

Looks like the plumbing from the AWIC to TB is all that is left in terms of hardware. Can't wait for an excuse to pop up to Chicago and visit this build and some other dub friends!

[Big Boost]

Pure sex. What's left to do, doesn't look like much?

The project is getting closer to being finished, but there are still some things left to do.
Here they are in no particular order except for the number 13. That happens 24/7!


1. Alternator bracket
2. New engine mounts
3. Thermostat housing
4. Catch can
5. Exhaust with cut out
6. Skid plate
7. Splitter
8. Longblock assembly
9. Wire the standalone
10. Finish the intercooler end tank
11. Install the fueling system
12. Tune for pump and race gas
13. Hide receipts from wife and enjoy life!!

Looks like the plumbing from the AWIC to TB is all that is left in terms of hardware. Can't wait for an excuse to pop up to Chicago and visit this build and some other dub friends!

When it's close to being ready, I'll hit you up and arrange a time we all can get together. Some of the Milwaukee crew said they would roll down with me.

[A4 TSCHUSS]

Thing is insane, I just pray it gets a good tune after all this work.

[Turbo Nerd]

Not sure I'd you mentioned it but which standalone are you going with 034's? That's not to bad of a list to be done, btw love number 13 haha goodluck man looking good.

[Big Boost]

Not sure I'd you mentioned it but which standalone are you going with 034's? That's not to bad of a list to be done, btw love number 13 haha goodluck man looking good.

I have 034's Stage IIc standalone with the plug and play harness.

Thing is insane, I just pray it gets a good tune after all this work.

I'm in the process of looking for an excellent tuner right now. And yes, that receipt will be hidden too......

[Big Boost]

Here is a quick shot of the shortblock. It is a 2.9L with JE 9:1 polished pistons and Eurospec rods. Honestly, I suspect that 034,
Eurospec and Integrated Engineering rods are all the same. I might be wrong, but after weighing IE and Eurospec units
I found that they weigh EXACTLY the same. The good thing is that all 12 rods were dead on the same weight. Visibly
they look the same too. I've seen these rods support well over 1000chp so I feel confident but at the same time I probably just
jinxed myself.

On another note I decided to upgrade to 288 TT cams. I need a little more, OK a lot more RPM than the 268's will provide. The head
is getting resurfaced and the longblock should be assembled this weekend. I'm going to use the mock up VR6 already in the car
as a spare to build over the winter. I intend to build that engine with a little higher compression, internal coatings and a few other
tricks. It's inevitable that something is going to give sooner or later so I might as well be prepared.

[sean1.8t]

It's inevitable that something is going to give sooner or later so I might as well be prepared.

SMART!

[Haenszel20v]

Be careful with the 288's, especially if you've decked the head and/or block, they're already ultra close.

[Mcstiff]

Update?!?

[Big Boost]

Right now, three separate things are being fabbed. The thermostat housing/coolant system, alternator bracket and new engine mounts. I'll update as soon as all three are complete!

[Big Boost]

Here are some new pix showing the beginning fabrication of the machined upper alternator bracket and the aluminum plate that
will function as the lower alternator bracket, power steering bracket AND driver's side engine mount. The driver's side should be
completed by Sunday or Monday at the latest.

[Haenszel20v]

All this stuff is super neat, but now it really seems like you're just trying to find things to make. The OEM bracket worked just fine???

[Big Boost]

Not really. Remember, the alternator had to be relocated due to the size of the intake manifold. At this point, many things have been made because of function, it just happens that the form looks cool. I can't apologize about that. Besides, this is a build thread....LOL.

[Big Boost]

Update! The driver's side engine mount/alternator and power steering bracket is complete!

This was the previous starting point for the combo alternator bracket, power steering bracket and the driver's side engine mount.





Next, is the actual engine mount welded to the plate. Notice the upper alternator bracket.









This is the lower alternator bracket that was just welded onto the main assembly.












A pass through hole was drilled and chamfered to reach the inner bolt connecting the bracket to the block.









All stainless bolts were used on the mount plate and power steering pump front and rear. The alternator
stainless bolts still need to be sourced.








This is the base for the passenger side mount. Fab work should begin in the next couple of days.

[Big Boost]

The Fuelab components were ordered on Friday. After the passenger side engine mount is complete, the focus
will switch solely on the cooling system until that's complete. The alternator and power steering pump will be rebuilt or replaced
with new units.

The exhaust fab will begin after the engine mounts are finished.

This is the elbow for the 4" downpipe.

[Sigma 3]

Looks Really good.

[O2VW1.8T]

wow amazing build, wish i had skills with a tig welder.

[GURUMAN]

I'm stoked with all that alu, really impressed !

[Big Boost]

Update! The driver and passenger side engine mounts are now complete!!













Here's the underboob shot!

[AudiSportB5S4]

Holy crap..

I was about to type, what were your intentions with the car, then I read your very first post... HA, that's funny.. Gotta love Prince's advice... Surprised he didn't get you into a Mustang!

[Big Boost]

Actually, believe it or not, this is will be a daily driven street car. Next year my goal is to put AC back into the car! It's really more fun to have a car that you can drive 9 months out of the year.

[nefkntym]

So much win!!! This build thread is Awesome!!!

[sean1.8t]

the awesomeness of the work is simply awesome!!

[Big Boost]

Update! The 1/4" thick aluminum skid plate is finished. This part will protect the oil pan against the very thing
that was the cause of this project, a pothole! I don't know the origination of the oilpan, and I waited over three weeks
for this one, so anything that can protect it is a great benefit. Anything that can be done to reduce downtime is also a plus!

[nizmosx]

HAWT