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  1. #1
    Senior Member Three Rings
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    Jun 24 2010
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    Canada

    Project Papa Smurf Version 2.0 - Better, Bigger, Badder

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    Hopefully this will find its way to the S4 Projects and Builds Section....mods
    *maybe someone can get rid of the 90 day stuff as well


    Maybe a quick introduction, new to the Audi community after coming over from the VW scene.
    My previous project was a 1997 GTi VR6 Drivers Edition in Jazz Blue. Owned the car for 7 years and did an extensive amount of work to it (along with an extensive build thread ) that turned it from a completely stock car to a 400+hp VR-Turbo beast that was passing almost everything but gas stations.
    http://forums.vwvortex.com/showthread.php?3571869


    Wustefest before I sold the original smurf




    After doing the 6500km drive from Canada to Vegas and back...following a b5 S4 a friend of mine owned, I made the decision I wanted a new toy/project that was a little more grown up. It had gotten a little embaressing picking up coworkers in a car with racing seats and an open dump exhaust, and the GTi was just no longer practical. I swore to myself however that I culdn't go back to a slower car, so something would have to be done.
    I had been looking at a b6 s4 avant for the longest time, the v8 sounded pretty cool and the wagon practicality just fit the bill. When i found out I could get the 2.7TT in a b5 the search was on. I never thought I would find a nogaro wagon...i loved the blue...as you can tell from my previous car, but I never thought I'd find one as they are a little like the great white buffalo.

    With some help from a buddy who works for a dealership, and a lot of looking online in the US for cars, i found an original owner b5 s4 nogaro avant. Did the cross border shopping thing and had the thing imported within a month of arriving home from Wustefest.
    Car has 140k on it, and is in almost mint condition. There is a little work that needs to be done on the front and rear bumpers, and the back hatch due to the original owner having a kayak on the roof a lot and opening the hatch into it.

    Other than that though the engine pulls hard, with no issues. The interior is flawless and overall im very happy to use it as a foundation for what I want to do.

    What do I want to do? Well thats easy. I want a 450awhp wagon that maintains all of the creature comforts and luxuries that I have come to love with the Audi.
    As with my first build, this isn't a weight saving, cost saving project. it's about doing it right the first time so I dont have to live with the headaches down the road.


    Introducing Smurf Version 2.0

    This is from the night after I got the car back to Canada....notice the crubbed stock wheels and the 4x4 status.



    Apparently I supported Obama in 2008.....though I dont think he would be his clean air policy would be a fan of my plans for the car



    And the interior...in brand new condition




    With the car I got a 3" thick folder complete with every receipt and piece of paper that had to do with the car, including original brochures and sales receipt.
    Not very many people that buy cars that are 9 years old get that with a car. Its nice to know that the previous owner was as meticulous as I am with cars.




    So the plans.....

    Tial 605's
    034 3" DP's
    AWE Twin1 Exhaust
    19" BBS LMs
    KW V1 Coilovers
    Hotchkiss Front and Rear Sway Bars
    Stern Motor Mounts
    034 Snub Mount
    034 Tranny Mount
    JHM Transmission Brace
    Bosch EV14 60lb injectors
    Eurodyne Maestro 7 Tuning Suite
    Upgrade the MAF
    ER intercoolers
    VAST bi-pipes
    Cayenne Brembo 6 piston brakes
    AEM meth injection kit
    SouthBend Stage 3 ENDURANCE clutch (dont know if this will be enough?)
    Bosch 044 drop in fuel pump
    Upgraded metal slave cylinder w/ braided clutch line

    While the engine is out I'm also planning on:
    Upgrading Water pump
    Timing Belt
    CV joints/axles
    Crank Seal
    Cam Seals
    Shifter linkage


    The good news....
    The coilvers are already in, the downpipes I brought back with me when i got the car, and the turbos have already been ordered and should be arriving in a few weeks.
    Now its just matter of collecting the rest of the pieces, so that I have every single thing I need before I tear the car apart, bag and tag everything, and go about turning this "fanny pack" into something that scares the living $hit out of me.


    Stay tuned for more.
    Last edited by RONDAL; 09-05-2010 at 01:28 PM.

  2. #2
    Veteran Member Four Rings S4 Big Head's Avatar
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    Dec 09 2009
    AZ Member #
    51870
    My Garage
    2000 Audi S4
    Location
    Tri-State area

    So sick... cannot wait to see how this turns out
    B8.5 Monsoon Grey Allroad - Airlift 3H / BC Forged Wheels
    Anthracite B5 S4 6MT //J-Fonz Tuned - SOLD
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  3. #3
    Veteran Member Four Rings CELison's Avatar
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    Feb 23 2010
    AZ Member #
    55053
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    Emmaus Pa

    Tial noggy avant. awsome build
    B5 S4- K24s, built bottom end, E85 - Gone
    B9 S4- EPL/AWE
    996TT X50 - Marski 700hp

  4. #4
    Veteran Member Four Rings
    Join Date
    Dec 06 2007
    AZ Member #
    23142
    Location
    Calgary, AB, Canada

    I had no idea...

  5. #5
    Veteran Member Four Rings witwer4444's Avatar
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    Dec 13 2008
    AZ Member #
    36320
    Location
    Palm Beach FL

    Awesome
    Current:
    2005 Black W211 E55 AMG

    Sold:
    2002 Stering Grey E39 M5
    2001 Nogaro Blue S4

  6. #6
    Established Member Two Rings stew44's Avatar
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    Dec 27 2008
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    36789
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    BC

    Beauty. Welcome to the dark side.

  7. #7
    Veteran Member Three Rings audikidS4's Avatar
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    Sep 03 2008
    AZ Member #
    32680
    My Garage
    2001.5 S4 Avant 6spd - Sil/Blk, 1995 S6 Avant - Blk/Ercu
    Location
    Wareham, MA 02571

    Extremely nice color combo - love the interior - this car will build-out very nice indeed! Congrats...
    The original audikid! Coined as ebay username spring 1999.

    **MTM ECU, Piggies, ASP Tru-Duel, Stratmo ss kit, Stern sm, AWE DTS, Voltgland GT2, Neuspeed 19mm RSB, full Samco kit, drilled and slotted rotors, PODI/S-W boost gauge, Sportec pedals, 30% Huper optik, CCMod, stubby antenna, VMR 708s 18X8.5 32mm**

  8. #8
    Senior Member Three Rings
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    Jun 24 2010
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    Canada

    i guess i should start with some questions;

    1. anywhere else i can buy ER intercoolers other than JHM?
    2. any maintainance stuff i should be doing while the engine is out that i haven't already listed?
    3. what kind of boost levels am i looking at if i want to be making 450awhp on the tials?
    4. i wasn't planning on doing rods, pistons, etc. as i didn't want to get too deep into the motor. otherwise i would have gone GT28's and been done with it (and my bank account). is not doing rods going to be an issue with that kind of power?

    thanks

  9. #9
    Veteran Member Four Rings gearhead1186's Avatar
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    Mar 17 2009
    AZ Member #
    40016
    My Garage
    02 S4, 02 M3
    Location
    Queens, NY

    TiALs

  10. #10
    Senior Member Three Rings
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    Jun 24 2010
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    Canada

    haha gearhead. your build thread was one which i was (am still) following quite religiously to see how things went with the Tials. I was slightly disappointed when you didn't end up going with them in the end, but the new ones are sick

  11. #11
    Veteran Member Four Rings gearhead1186's Avatar
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    Mar 17 2009
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    40016
    My Garage
    02 S4, 02 M3
    Location
    Queens, NY

    Quote Originally Posted by RONDAL View Post
    haha gearhead. your build thread was one which i was (am still) following quite religiously to see how things went with the Tials. I was slightly disappointed when you didn't end up going with them in the end, but the new ones are sick
    thanks. still got TiALS.. just 770s. below are two build threads that used 605s.

    As4driver's EPL Built TiaL 605

    Flyingfish EPL Tial 605

    Flyingfish actually has my rebuilt 605s on his car up in Colorado and I believe As4driver has the first built 605 car.

  12. #12
    Veteran Member Four Rings gearhead1186's Avatar
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    Mar 17 2009
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    40016
    My Garage
    02 S4, 02 M3
    Location
    Queens, NY

    Quote Originally Posted by RONDAL View Post
    i guess i should start with some questions;

    1. anywhere else i can buy ER intercoolers other than JHM?
    2. any maintainance stuff i should be doing while the engine is out that i haven't already listed?
    3. what kind of boost levels am i looking at if i want to be making 450awhp on the tials?
    4. i wasn't planning on doing rods, pistons, etc. as i didn't want to get too deep into the motor. otherwise i would have gone GT28's and been done with it (and my bank account). is not doing rods going to be an issue with that kind of power?

    thanks
    you can get ERs straight from Evolution Racewerks. You will probably see 25-26 lbs of boost with a stock block. 605s were meant to be bolted to a stock block and 450+ is being pushed through stock blocks all the time.

  13. #13
    Senior Member Three Rings
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    Jun 24 2010
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    i like the sound of that. yea i've followed those other 2 build threads as well. sucks i cant get in there to comment. *cough* mods *cough*.
    im hoping the 605's are good for the 450-480 i'd like to see at the wheels with meth and 94.

  14. #14
    Senior Member Two Rings stllboostin's Avatar
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    Oct 06 2006
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    12373
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    NY

    subscribed...looking to do the same with my avant...hopefully you get some good numbers..(rods = insurance my 0.02 cents)
    avantpwr

  15. #15
    Veteran Member Four Rings NishadJoshi's Avatar
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    Apr 22 2010
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    57982
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    Playa del Rey, Ca

    I'm growing to like wagons more and more everytime I see 'em.
    derp.

  16. #16
    Senior Member Three Rings MLFHNTR's Avatar
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    May 29 2010
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    59663
    My Garage
    '04 Allroad, '02 GTI
    Location
    Daytona Beach

    wow, like wow that thing is immaculate. minus the bumper stickers... i mean
    2 Hooker Limit...

    Embry-Riddle European Car Club President

  17. #17
    Senior Member Three Rings
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    Jun 24 2010
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    the bumper stickers are gone. was the first duty of business. but not before some fun photoshoot stuff with the obama sticker still on.

    What MAF are most people running for the RS6/Tial/GT setups? the 85mm mitsu?

  18. #18
    Veteran Member Four Rings Dutchsider's Avatar
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    Aug 19 2010
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    NEPA

    Welcome fellow MKIII convert

  19. #19
    Junior Member Two Rings
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    Aug 07 2009
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    Westchester NY

    nice. I had a similar story to yours, and I'm glad I waited for the blue/blue wagon. Yours is going to be sweet when it's done.

  20. #20
    Veteran Member Three Rings jesters22's Avatar
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    Oct 14 2009
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    49212
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    new jersey

    i wish my nogaro was an avant, i coulda got one if my insurance check came 2 weeks prior...
    PARTING OUT A SILVER 2001.5 S4 PM ME FOR PARTS

    http://forums.vwvortex.com/showthrea...2#post83363922

  21. #21
    Veteran Member Four Rings GramCracker's Avatar
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    Mar 11 2007
    AZ Member #
    16317
    My Garage
    1990 R32 GT-R
    Location
    Somewhere in CT

    wow, awesome car man! avants FTMFW

  22. #22
    Veteran Member Four Rings Turbo1A4's Avatar
    Join Date
    Aug 04 2008
    AZ Member #
    31600
    My Garage
    2002 s4 nogaro
    Location
    Jax

    very sick build!
    i cant wait to see the final product
    211,000 miles
    ||Borla||forge dv||35%||awe||k&n||autobahn hoses||awe smic||ssac||walbro 255||

  23. #23
    Veteran Member Three Rings
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    Sep 16 2005
    AZ Member #
    7979
    Location
    Asheville, NC

    Fuck me! I want an Avant sssooooo bad!
    2000 S4 - SSP tuned Stage 3

    CrtchRktRcr: You could turn it into a unicorn with a gigantic pink dildo and i'd still love a b5s4.

  24. #24
    Veteran Member Four Rings RolledMySTi's Avatar
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    Jul 06 2007
    AZ Member #
    19342
    My Garage
    2001 S4 Sedan Laser Red
    Location
    San Jose, CA

    Welcome. Sounds like a sweet build!
    01 Laser Red S4 Stage 3 | Vast Fueling | Clutchnet 6 Puck Disk with RS4 PP | APR Downpipes | Aluminum Flywheel | Neuspeed Exhaust | SRM Side Mounts | ECS Pulley Kit | RS4 Airbox | UUC Short Shifter | ST Coilovers| Samcos | AWE DTS Bar | JHM Center Diff | 034 Track Motor Mounts + Street Trans Mounts | Apikol blue rear diff mount and bushings | Areomotive Fuel Pump | ECS 2.0T Coil Conversion | Hooked on Meth

  25. #25
    Veteran Member Four Rings jibberjive's Avatar
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    Jan 11 2007
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    14790
    My Garage
    01.5' S4, 04' A4 USP, 04' CRF450r
    Location
    Salt Lake City, Utah

    Nice man. Will be sick, GL!
    ** GT2860R-7 S4 Build Log--

    LOOKING FOR:
    --Late 2.7t Block "BF"
    --Your Broken/Sheared OEM Axles--

  26. #26
    Senior Member Three Rings
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    Jun 24 2010
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    Canada

    where is the best place for STERN mounts?

  27. #27
    Veteran Member Four Rings GramCracker's Avatar
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    Mar 11 2007
    AZ Member #
    16317
    My Garage
    1990 R32 GT-R
    Location
    Somewhere in CT

    Quote Originally Posted by RONDAL View Post
    where is the best place for STERN mounts?
    VAST, they have great pricing and are quick to ship Thats where I ordered mine from.

  28. #28
    Veteran Member Four Rings gearhead1186's Avatar
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    Mar 17 2009
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    My Garage
    02 S4, 02 M3
    Location
    Queens, NY

    Quote Originally Posted by RONDAL View Post
    where is the best place for STERN mounts?
    got mine from PureMS

  29. #29
    Veteran Member Four Rings
    Join Date
    Dec 06 2007
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    23142
    Location
    Calgary, AB, Canada

    Quote Originally Posted by RONDAL View Post
    where is the best place for STERN mounts?
    Drop me an email and I'll help you out.

  30. #30
    Senior Member Three Rings
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    Jun 24 2010
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    Canada

    does anyone ceramic coat their hotside housings to keep heat down and away from the transmission tunnel (your right calf and knee)?

  31. #31
    Senior Member Three Rings
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    has anyone run tial 605's on race gas yet?
    looking for some power results.

  32. #32
    Senior Member Three Rings
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    It's been waaaaay too long since an update....and it still hasn't been moved to the build section.

    What can brown do for you? A heck of a lot.












    The twins have arrived.

    Waiting on some other parts to arrive hopefully later this week.

  33. #33
    Veteran Member Three Rings NogaroAvant's Avatar
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    Nov 23 2004
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    My Garage
    02 911 Turbo, 89 964, 01.5 B5 S4 Avants, 98 GTI VR6s, 86 GTI VR6
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    Looking good man. I still have my MK3 VR and love my Nogaro Avant. Welcome to the club.
    David Esposito
    BUTZI GEAR LLC - Performance, Tuning, Styling & Fine Detailing
    Milford, CT | Instagram: @butzigear | FB: butzigear
    02 Porsche 996TT 3.8L • 01.5 Nogaro S4 Avant • 01.5 Santorin S4 Avant
    01 D2 S8 • 98 GTI VR6 • 86 Porsche Carrera 3.2 • 86 GTI VR6

  34. #34
    Veteran Member Four Rings Turbo1A4's Avatar
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    Aug 04 2008
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    31600
    My Garage
    2002 s4 nogaro
    Location
    Jax

    its like heaven
    211,000 miles
    ||Borla||forge dv||35%||awe||k&n||autobahn hoses||awe smic||ssac||walbro 255||

  35. #35
    Veteran Member Four Rings gearhead1186's Avatar
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    Mar 17 2009
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    02 S4, 02 M3
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    Queens, NY

    looking good. billet is sexy.

  36. #36
    Senior Member Three Rings
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    thanks mike.
    im sure i'll be bugging you a fair bit in the coming days haha.

  37. #37
    Veteran Member Four Rings
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    Oct 13 2010
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    colorado

    wow cant wait to see the tearing apart begin for this build

  38. #38
    Established Member Two Rings cjernigan's Avatar
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    Jul 20 2010
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    Auburn, AL

    You should do your auxillary water pump while you have it all apart. Many people run the 034 MAF housing or whosever you like with the hitachi sensor. No reason to use the RS4 Bosch unit that fails often. What Southbend clutch did you get?

  39. #39
    Veteran Member Four Rings gearhead1186's Avatar
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    Mar 17 2009
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    02 S4, 02 M3
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    Queens, NY

    Quote Originally Posted by cjernigan View Post
    You should do your auxillary water pump while you have it all apart. Many people run the 034 MAF housing or whosever you like with the hitachi sensor. No reason to use the RS4 Bosch unit that fails often. What Southbend clutch did you get?
    agreed on the pump. one of many "while you are in there" parts. EPL supplies an 85mm CNC MAF housing with their fueling kit.

    EDIT: my mistake. i thought he was on EPL fueling. multiple 605 builds going on now.
    Last edited by gearhead1186; 11-23-2010 at 10:57 PM.

  40. #40
    Senior Member Three Rings
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    Jun 24 2010
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    aux pump, timing belts, DV's, acc belts, new clutch fans, etc. are all part of a box that should be arriving on Friday.

    Then im just waiting on intercoolers, bipipes, injectors, MAF housing, fuel pump and a few odds and ends

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