GabeRossi's Build Thread

[Gaberossi]

Hey there Audiziners, I am currently in the process Building my B5 A4. I am going with a Precision Turbo 5857 DBB, my power goal is 400FWHP+ and 500+HP when I build the head. Running an AEB 1.8 motor... Usp Motorsports is going to be supplying the parts, install, and software upgrade , Usp has never let me down!! What a great shop!.) I will be updating this as everything goes along. Thanks for looking!!

**UPDATED: 2-1-11**

Parts....

Engine:

AEB 1.8L
JE Pistons
Integrated Engineering Rods
ARP Head Stud Kit
Main Bearing Set
Rod Bearing Set
Thrust Bearing
Knock sensor
Head Gasket
Crankcase Gasket Set
RS4 Motor Mounts
034 Transmission mounts
034 Snub mount
Usp Motorsports custom catch can setup

Turbo/ECU:

Pag Parts Turbo kit/exhaust manifold V-banded
Precision 5857 Dual Ball Bearing Turbocharger .64 V-banded
Oil feed/return lines
Eurodyne Maestro

Forge DV
Tial MVS Wastegate
Precision 600hp core w/ custom Usp Motorsports Inter-cooler Piping
MAF/Harness
K&N cone filter

Fueling:830cc Injectors
044 fuel pump

Exhaust:
Custom Usp Motorsports 3in Down-Pipe/3in Down-Pipe back exhaust all V-band

Trans: OEM 5 speed with southbend stg 4 (4puck) clutch and LWFW
JHM shifter assembly, weighted shift knob and linkage with delrin bushings

Wheels: Team Dynamic Pro race 1.2 18x8.5
.................................................. .................................................. ............................................
I ordered Raxle's to help me stop breaking axles

[Polski]

im intrested in ur k04 setup, pm me what is included in the setup and some prices.
Thanks

[Gaberossi]

pm sent

[lowandslow4now]

Good stuff Gabe. Let me know if yo need any help with anything.

[nick71692]

Car looks good

[chris164935]

Pretty sure the AEB motor doesn't have balance shafts. Only VAG motor that I know of that has balance shafts are the 2.0t FSI motors. They might have been referring to the intermediate shaft? But that's not really any kind of problem... That I'm aware of anyway.

Best place I could think to find an 058 block would be VWVortex classifieds.

As for the clutch, I'd recommend doing the FX400 swap while your have the block out of the car (if you are planning on pulling the whole motor out); that will save you from having to drop the sub-frame to pull the transmission to swap out the clutch later. Clay at CTS Turbo has them for pretty cheap now.

In any case, good luck! Oh, and you will be kicking yourself wishing your car was Quattro when you are done with the build. Ask me how I know. Lol.

[Gaberossi]

As for the clutch, I'd recommend doing the FX400 swap while your have the block out of the car (if you are planning on pulling the whole motor out); that will save you from having to drop the sub-frame to pull the transmission to swap out the clutch later. Clay at CTS Turbo has them for pretty cheap now.

In any case, good luck! Oh, and you will be kicking yourself wishing your car was Quattro when you are done with the build. Ask me how I know. Lol.

Great info Thanks!! HAH i have been kicking my own ass for the past 3 years wishing it was!! I got the car from a family friend then had a whole lot of bs happen to the car and a ton of money went in it...this is going to be my weekend/show car when its done and i plan on getting an B5 S4 or BMW E30 M3

[Gaberossi]

Bump for update...and a quick pic of the engine bay with a K04 setup BEFORE its gets torn down!

[Seerlah]

Engine already built? Doesn't seem you held back on this build, minus head work. I would have gone a different route with the header, though. If I were going tubular, I would have contacted Jay Thorton. PM me if you want info.

[Gaberossi]

I just got all parts ordered and now im waiting for them to get here...Head Work will be done when i can get a spare AEB head and the money$$...but for now i dont plan on going WOT very often...i just want the car to have a nice setup for FIXX Fest

[Nate_R]

Car looks good. I've been thinkin of gettin my car to 400 bhp but haven't really researched it. I was wonderin how much it cost you to build your motor? And is there any huge advantage in going with a Precision 5857 turbo over a 30+r?

[Gaberossi]

PM'd^^Nate_R

I think the pte5857 flows more than the 30r

[Papa Stone]

It does, but is also has a slower spool. If you are researching the block, you should really look into going 2.0L. It will help with spool and more HP.

[Gaberossi]

I know that the 2.0L is the way to go for spool... i feel that a 1.8 or 1.9L will be more reliable...i dont mind the lag anyway.

[Seerlah]

Expand the power band and the lag shouldn't really be a big concern. These cars love to drive in the higher RPMs.

[Gaberossi]

I totally plan on it in the near future Seerlah... when i can afford it i am definitely building the head..i should take a pic of the invoice ..it really jumps in price when u add a head job lol i would not have a dime left if i build the head now.

BTW Seerlah how is your hunt for BT parts coming along??

[A4Rob]

Cool project you have there. Moved to projects and builds.

[Gaberossi]

thanks Rob!

[Kyle H]

1.8L with a 5857? I'm curious to see how this will turn out... Can't really take advantage of that turbo without bigger displacement or a built head. I'd go smaller so you can actually have some more usable power.


otherwise, cool build. I love those team dynamic wheels.

[Gaberossi]

thanks dude i love these wheels...once the head is built i think it will be just fine, i want this together by fixx fest this year so i can have some fun runs down the track.

[Oceanside]

i want this together by fixx fest this year so i can have some fun runs down the track.

I officially challenge you to a duel of the FL FWD BATS! :)

[lowandslow4now]

I am going to try to get in on this too. Hopefully I can get a better clutch.

[Gaberossi]

I officially challenge you to a duel of the FL FWD BATS! :)

I accept hahaha!! FWD BAT's FTW!

[Gaberossi]

I am going to try to get in on this too. Hopefully I can get a better clutch.

yea man get that clutch so you dnt have to worry about any slippage

[lowandslow4now]

I know I have been lucky so far but if I want to put it on the track and run it hard I will definetely need a new clutch.

[Gaberossi]

oh definitley dude...that monster of a setup you have needs to be unleashed

[Dan[FN]6262]

PM'd^^Nate_R

I think the pte5857 flows more than the 30r

the 5857 flows almost as much as a 35R

35R flows 65lbs/min
5857 flows 60.5lbs/min
30R flows 50lbs/min

a 5857 will make more power on a lower boost than a 35R. example: 35R @ 20psi will make less power than 5857 @ 20psi. This is only true up to a certain pressure, but I can't remember what it is. This is because 5857 has Extended Tip Technology

Also, you'll want a better clutch than a FX400 if you're running this turbo. I would recommend the FX850 Super Single. I have one, and I love it. and its only slightly more expensive than a FX400

1.8L with a 5857? I'm curious to see how this will turn out... Can't really take advantage of that turbo without bigger displacement or a built head. I'd go smaller so you can actually have some more usable power.

I'm running a 5857 on 1.8L with stock pistons and built small port head. there is more than enough usable power.


OP, you'll love it.

You can see my build if you click on the link in my sig

[chris164935]

When is FIXXfest this year? Late October, right? I wish I could get in on some of this action. Although, my car won't be FWD.

As for spool, I didn't have any problems running a 35r on my 1.9L. Boost came on around ~4500 RPMs and that was with a shit tune.

EDIT: PTE series turbos are ball-bearing AND extended tip?

[lowandslow4now]

I believe fixxfest is the weekend before thaksgiving November20.
http://www.fixxfest.com/

[Dan[FN]6262]

When is FIXXfest this year? Late October, right? I wish I could get in on some of this action. Although, my car won't be FWD.

As for spool, I didn't have any problems running a 35r on my 1.9L. Boost came on around ~4500 RPMs and that was with a shit tune.

EDIT: PTE series turbos are ball-bearing AND extended tip?

Yeah, Precision Turbos come in ball bearing and extended tip (as long as they're the new billet wheels). I have a Journal bearing 5857 and I have 18psi by 4.5~ 4.8k rpms on my Revo 550 tune running 0* timing.


*I wanna see your build finished. lol.

[chris164935]

Yeah, Precision Turbos come in ball bearing and extended tip (as long as they're the new billet wheels). I have a Journal bearing 5857 and I have 18psi by 4.5~ 4.8k rpms on my Revo 550 tune running 0* timing.

Damn, I'll bet those aren't cheap! I'd love to run one though, if they make a 72mm flavor.

*I wanna see your build finished. lol.

Me too! Lol.

[Dan[FN]6262]

Damn, I'll bet those aren't cheap! I'd love to run one though, if they make a 72mm flavor.

mine was 900 bucks brand new email Clay@CTS Turbo.

and yeah, Precision makes some pretty decent sized turbos. check them out.

[Gaberossi]

I'm running a 5857 on 1.8L with stock pistons and built small port head. there is more than enough usable power.


OP, you'll love it.

You can see my build if you click on the link in my sig

Sweet man thats awesome....i will definitely upgrade to the fx850 when this one goes

[Seerlah]

BTW Seerlah how is your hunt for BT parts coming along??

Didn't even notice this question. Parts are coming along gradually. I don't plan on installing till next spring, so that leaves me plenty of time to get the rest of my parts. But for now, I want to complete my drivetrain and susppension mods. Just ordered Hothckis sways to complete my suspension (I have other goodies already) and now need motor/tranny mounts to complete my drivetrain (I have other goodies installed, and def want to get the 034 billet rear diff carrier in the future for safety reasons). As for turbo build parts, I have these:

-Catch can
-ATP fuel rail (need to get adapter to use stock like fpr)
-630cc injectors
-PSi Concept t3 manifold
-PSi Concept oil/coolant line package
-Forge 004 BOV
-Injen/Amsoil 3" filter with Hydro Shield
-Turbo-XS BC-HPBC (hoping the bleed valve will reduce torque spikes and help my engine out)
-Precision PW39 Wastegate
-034 Bosch 044 fuel pump (needed to buy replacement pre-filter due to damaged in shipping, and that bad boy ran me $70 for a f*cking little screen filter. bought used, so could not complain to anybody. nor did I want to give the seller a burden, as he is a regular on here and let me pay off in installments)

Then picked up some other goodies, such as 034 powder coated vavle cover and coil cover. I just need the turbo, clutch, intercooler (Mike Hood is trying to have an intercooler made to fit behind our stock bumper, so I am waiting on that. 530hp garrett core), PSi Concept tp/dp (will have a full custom 3" one made to my 2.75" Milltek, but will need this to get me to the shop), Innovate LC-1 (already have gauge for it), SAI block off plate, and miscalaneous parts (clamps, couplers, hoses, gaskets, etc). Going to try and scoop most of this up during the Christmas sales. Plan on running with the Garrett GT2860RS T3 flanged and .63 A/R (stock block). I have Eurodyne software currently, so my tune will cost me $250 (purchased CTapp originally for my stock turbo flash for this very purpose).

And you need to update this thread

[Gaberossi]

I will update this thread as the parts get to the shop...Then I can document everything.

I want that valve cover! I think there is going to be a ton of cutting to my bumper to fit this Precision 600hp core =/

[Sales@RAI]

the 5857 flows almost as much as a 35R

35R flows 65lbs/min
5857 flows 60.5lbs/min
30R flows 50lbs/min

a 5857 will make more power on a lower boost than a 35R. example: 35R @ 20psi will make less power than 5857 @ 20psi. This is only true up to a certain pressure, but I can't remember what it is. This is because 5857 has Extended Tip Technology

Also, you'll want a better clutch than a FX400 if you're running this turbo. I would recommend the FX850 Super Single. I have one, and I love it. and its only slightly more expensive than a FX400



I'm running a 5857 on 1.8L with stock pistons and built small port head. there is more than enough usable power.


OP, you'll love it.

You can see my build if you click on the link in my sig

Dan, while this is cool in theory, I don't know how much the whole extended tip thing does

[Gaberossi]

Got my car on the lift at school today after getting it towed to take out my broken CV shaft on the drivers side...the dealership didn't have one in stock so I had Usp find me one...EDIT: Just Ordered a Raxle

[fr3nz33]

I'm building a very similar setup, that should be done in the next week hopefully. PTE 5857 ftw. Subscribed

[Gaberossi]

Are you documenting your build??

[Lowdaily]

Nice Build.!