The Build - A GT2871R build documentary

**MmmBoost** · 05-25-2010 11:05 PM

Well today was the day all the magic started. And since I was unable to post this in the projects/builds section......you guys are stuck with me putting this here.

I have been stock-piling pieces over the winter in anticipation for this day. After MUCH deliberation between keeping it simple and going with a cookie-cutter setup GTRS with Revo, I decided that if I'm going to spend this much money and effort.....why build a setup that will always keep me wondering "what if." Not to mention the fact that there isn't a single aftermarket high-flow OEM replacement that doesn't crack. I've ready about too many horror stories of installs and cracking etc. I didn't want to go that route.

So I guess now is the time where I lay out all of my info. Unless otherwise noted, parts will be from OEM AMB engine

Software: Eurodyne Maestro7 custom tuned by me
Injectors: Siemens 630cc Now using Injector Dynamics ID725
Fuel Pump: "005" from 034 Motorsport
MAF setup: Audi S4 4.2L MAF
Turbo: Garret T25 GT2871R w/.64AR. Internal wastegate, Ø2"outlet, and Ø3" inlet
FMIC: Racetec
DV: Forge 007
Oil lines: Braided stainless -4AN feed, -10AN return
Coolant lines: Braided stainless -6AN
Manifold: PSi Concepts T25 manifold
Testpipe/Downpipe: PSi Concepts Ø3"-Ø2.5" prototype testpipe (will be replaced with a production run unit), Milltek Ø2.5" Downpipe
Exhaust: Milltek catback
Intake: Ø3" aluminum inlet

Engine internals:
Integrated Engineering connecting rods with 19mm wrist pins
New rod bearings
New crank bearings
ARP head bolts
ARP main studs
ARP crankshaft bolt

Engine/trans:
034 Motorsports Street Density engine mount
034 Motorsports Street Density transmission mount
Clutchmaster FX300 w/240mm Billet steel flywheel

**MmmBoost** · 05-25-2010 11:12 PM

And now for the goods.....

**A4natomical** · 05-25-2010 11:15 PM

Awesome. Subscribed for a great setup that I would love to have.

**7speed** · 05-25-2010 11:26 PM

subscribed for more dope photos

**MmmBoost** · 05-25-2010 11:29 PM

Welcome aboard, kids!

**nein-reis** · 05-25-2010 11:57 PM

Nice! Looks like you have the energy to do a build AND take photos worth something? Awesome, thats more than I can say... mine were so snap-shotty after I was done working.

**Rejmow** · 05-26-2010 12:01 AM

Setup looks cool

Subbing because you have a dope camera !

**Jeff** · 05-26-2010 12:02 AM

Sexy pics!

Chris, you *may* want to consider going to a S4 MAF. From what I've found in the past, I managed to max out the VR6 MAF (which maxes out at 229g/s) on a race tune with just a GT28RS. Though you can scale the g/s readings on the tune, the MAF signal is way too close to 5vdc (your MAF reads 0-5vdc) at 4.2vdc. Though this will still work, having the MAF voltage at that high will cause it to burn out much sooner.

Just a thought. :)

**dougyfresh** · 05-26-2010 04:09 AM

I wish you the best with getting the MAF to work. Chris (bananas) is trying but with limited success. Probably in a couple of months CTapp will have the MAF scaling figured out [I hope] within Maestro.

Which S4 MAF Jeff? Different housing or housing and sensor?

**SleeperAvant** · 05-26-2010 05:05 AM

Finally you spilled the beans Chris! Take a picture of your old pistons when you've taken things apart.

**kneel** · 05-26-2010 08:44 AM

wow sick avant and a sick turbo build!

**Matt@EuropaParts** · 05-26-2010 08:53 AM

Only you could take a dirty job (turbo replacement) and make it look beautiful. Nice work!

**itsmatt33** · 05-26-2010 08:55 AM

this is the tits

**Sales@RAI** · 05-26-2010 08:58 AM

Originally Posted by Matt@EuropaParts

Only you could take a dirty job (turbo replacement) and make it look beautiful. Nice work!

I know right? I was like "Wow that's pretty... Wait, what? I hate spilling coolant!"

**AudiA4Turbo22** · 05-26-2010 09:14 AM

AWESOME! when will it be done?

**Dan[FN]6262** · 05-26-2010 09:26 AM

This is all wrong.

**MmmBoost** · 05-26-2010 11:07 AM

So excited to finally have this project started! I've been wanting to do this for 5 years!

Steve I plan on taking photos of EVERYTHING :) That's how I roll..... So tonight I'm hoping to snap a few photos of some more goodies as well as possibly the manifold. I get off work at 5 tonight and hopefully should have a hoist by 6. The engine will be out tonight and hopefully I'll be able to start working on the rods and rings.

I would like to have the motor back together and ready to be fitted back in the car on Saturday......but who knows. I spend over 30 mins yesterday fucking with the lower coolant hose and heater core tubes. lol.

**dougyfresh** · 05-26-2010 11:22 AM

A little silicon grease on the o-rings within the coolant line connectors and they will go back on easy and come off next time even easier. Use on all o-rings.

Unbolt the a/c compressor from the engine and you can rotate the compressor and condensor to the passenger side, out of the way, with it all connected. No need to loose coolant.

Unbolt the power steering pump (bolts are though those three holes in the pulley) and place that on the driver side frame rail. No need to loose power steering fluid.

**bananas** · 05-26-2010 11:42 AM

Chris, glad to see the official unveiling :) We'll be in touch, I'm sure.

Originally Posted by dougyfresh

I wish you the best with getting the MAF to work. Chris (bananas) is trying but with limited success. Probably in a couple of months CTapp will have the MAF scaling figured out [I hope] within Maestro.

I've got it mostly figured out now. There might be issues with clipping beyond some value, but I haven't run across it yet with my turbo/sensor/housing. Super easy now, enter your MAF size, choose a starting point, and it gives you the scaling and offset values for Maestro: http://spreadsheets.google.com/ccc?k...ORGdnNXc&hl=en

Also, I agree with Jeff, go bigger than TT225 housing if you can. Check the "normalized data g/sec" tab in the spreadsheet linked above for voltage->g/s mappings.

**MmmBoost** · 05-26-2010 11:43 AM

Originally Posted by dougyfresh

A little silicon grease on the o-rings within the coolant line connectors and they will go back on easy and come off next time even easier. Use on all o-rings.

Unbolt the a/c compressor from the engine and you can rotate the compressor and condensor to the passenger side, out of the way, with it all connected. No need to loose coolant.

Unbolt the power steering pump (bolts are though those three holes in the pulley) and place that on the driver side frame rail. No need to loose power steering fluid.

The AC condenser is already unbolted and sitting on the passengers side.

The power steering pump, however, is still on the engine and the lines are drained. I needed to drain it anyway to get the cooler out from the rad support.

**MmmBoost** · 05-26-2010 11:46 AM

Originally Posted by bananas

Chris, glad to see the official unveiling :) We'll be in touch, I'm sure.

I've got it mostly figured out now. There might be issues with clipping beyond some value, but I haven't run across it yet with my turbo/sensor/housing. Super easy now, enter your MAF size, choose a starting point, and it gives you the scaling and offset values for Maestro: http://spreadsheets.google.com/ccc?k...ORGdnNXc&hl=en

Also, I agree with Jeff, go bigger than TT225 housing if you can. Check the "normalized data g/sec" tab in the spreadsheet linked above for voltage->g/s mappings.

We'll be in touch for sure. Haha. I'm going to need a few pointers from the people that have been messing with Maestro for a bit. All I've been able to do is open it up and look around so far. I haven't actually learned anything yet.

As for the MAF housing.... the VR6 MAF is going to have to do for now. I need my car back ASAP because I have shoots coming up. I'll figure out the MAF situation once I get things up and running with the parts I have. PS.... being able to swap MAF housings whenever I want is EXACTLY one of the reasons why I didn't go with Unitronic or Revo. I can make the changes myself. No BS with dealers or shipping ECU's.

**alexza4** · 05-26-2010 12:16 PM

Good luck with the build! Looks great so far

**dougyfresh** · 05-26-2010 12:41 PM

Originally Posted by MmmBoost

The AC condenser is already unbolted and sitting on the passengers side.

But its still connected to the a/c compressor. You are removing the motor right? Then remove the a/c compressor and move it all to the side.

**MmmBoost** · 05-26-2010 12:51 PM

Originally Posted by dougyfresh

But its still connected to the a/c compressor. You are removing the motor right? Then remove the a/c compressor and move it all to the side.

Yes it's all still connected. You can see it off to the side in the 3rd last photo. I didn't want to have to have the AC recharged at the stealership.

**KFizz** · 05-26-2010 12:53 PM

Thanks chris. I often day dream of having the fastest B6 in Edmonton. That is unlikely to happen now. You destroyer of dreams!

**SleeperAvant** · 05-26-2010 01:51 PM

^lol. Just go with a slightly bigger turbo.

**teg2audi** · 05-26-2010 03:57 PM

Can't wait for new pictures and eventually the finished product!

**MmmBoost** · 05-26-2010 11:25 PM

Day 2: Complete

Well I certainly didn't make as much progress as I would have liked......but that's how things go. I work in an engineering department....... I know for a fact that NOTHING ever goes according to plan. haha.

I got hung up on the engine/transmission bolts for a lot longer than I had anticipated. They were SO tight. Every single one needed a love tap from a dead-blow hammer to crack it loose. I also had to fab up a couple of brackets for my engine stand because the neighbor I borrowed it from only had two. I certainly didn't feel comfortable supporting my entire engine on only 2 bolts.

So after struggling with the engine bolts the motor popped right out. I'm trying to removed the wiring harness in some sort of an order. The engine seems to have been leaking like crazy from the cam chain tensioner. There is also a pile of caked on oil from when my valve cover gasket was leaking before I changed my timing belt.

After inspecting the K03.....the bearing are definitely pooched. After removing the clutch......the clutch is also pooched. So at least I have SOME justification for my madness and empty wallet.

Enjoy the photos from today!

As promised.....some shots of parts from PSi

Prototype testpipe. Will be replaced with a pretty production unit.

The engine stand brackets I had to make.....

What a gong show of hoses and lines!

The obligatory K03 vs BT comparison shot.....

My fried clutch

**nein-reis** · 05-26-2010 11:48 PM

NICE!!!! Best build photos ever. When did you have time to work on the engine framing all these photos up? Very cool stuff Chris, excited to see where you are saturday.

**MmmBoost** · 05-26-2010 11:57 PM

Awww......shucks.....

It's hard to not shoot when something interesting catches my eye.

I don't think I'll be finished on Saturday like originally planned. At this rate I may have the engine back in by Sunday? Monday?

**A4natomical** · 05-27-2010 12:04 AM

Originally Posted by nein-reis

NICE!!!! Best build photos ever.

X2. I wish I had my DSLR during my build.

Since your turbo is internally gated, do you just use a block off plate on the exhaust manifold to close off the external wastegate port?

**SleeperAvant** · 05-27-2010 03:47 AM

Damn, Chris. You work fast especially when you're taking wedding photos of your turbos etc. Are you going to cap off the wastegate flange on your exhaust manifold? Your testpipe doesn't have a provision for a wastegate dump.

**Turbavanttro** · 05-27-2010 04:27 AM

^curious about that as well.

Your build is really looking good. I love the manifold choice. I'm going to guess you'll be done in 2 weeks. There must be a plethora of gaskets/hoses, etc. you can do right now while its all there in front of you, not to mention the engine bay detail opportunity you have~

Ands you can shoot more fantastic photos for us~

**Turbavanttro** · 05-27-2010 04:31 AM

Are you considering having your manifold/turbo/compressor coated? A car as pretty as yours seems to deserve as much....

**dougyfresh** · 05-27-2010 05:55 AM

Originally Posted by SleeperAvant

Damn, Chris. You work fast especially when you're taking wedding photos of your turbos etc. Are you going to cap off the wastegate flange on your exhaust manifold? Your testpipe doesn't have a provision for a wastegate dump.

His turbo is internally gated, he just doesn't have the actuator installed yet. Therefore, I presume, he'll bolt on a cover for the WG port on the manifold.

Originally Posted by nein-reis

NICE!!!! Best build photos ever. When did you have time to work on the engine framing all these photos up? Very cool stuff Chris, excited to see where you are saturday.

I second.

I REALLY like these photos for some reason:

SO cool.

The caption, angle, lighting, color contrast completes this image.

The contrast rules.

**EErie B6** · 05-27-2010 06:53 AM

wish i had your picture taking skillz...

**BEESIX** · 05-27-2010 07:17 AM

were almost in the same boat, awsome stuff man!, pics are amazing,

i was going to go with the psi concepts manifold but i was scared to try something new so i went with atp lol