Project Stormtrooper - 03 Avant 24V VR6T -> 2.7TT

**AudiA4_20T** · 06-27-2011 06:25 PM

Originally Posted by nefkntym

I can use B6/B7 S4 mounts to lower it, B7 RS4 mounts lower even more. These are working great so far for placement. He has RS4 mounts listed in the VR6 thread as well. Does your motor mount brackets have all the holes like the A4 ones do?

I am almost done with the fuel system, every time I think I am almost done. I end up having to make a change and have to get different fittings. I am ordering my last two fittings now.

No the S4 ones only have 1 hole in the center, and I think thats the problem. btw, I'm not entirely sure if I know how the Quattro tank works, but if you're not returning to the other side of the tank did you just half the size of your tank?

And you're using the stock A4 mounts? Wanna trade? lol

**nefkntym** · 06-27-2011 07:44 PM

Hmm, the B5 S4 brackets have multiple holes like the A4 ones do. I am using the stock brackets, I just got rid of the A4 mounts and got RS4 mounts.

I was wondering about that for the tank as well before I started all of this. The fuel has to get over there some how when you fill up and to the other side for pump. I need a picture from etka or something to see how it exactly works for fill up and siphoning from the other side.

**nefkntym** · 06-27-2011 10:53 PM

Originally Posted by AudiA4_20T

No the S4 ones only have 1 hole in the center, and I think thats the problem. btw, I'm not entirely sure if I know how the Quattro tank works, but if you're not returning to the other side of the tank did you just half the size of your tank?

And you're using the stock A4 mounts? Wanna trade? lol

I wasn't worried about the return. I found this awhile back, I am using the stock locations. Just massaged a bit.

**AudiA4_20T** · 06-28-2011 03:53 AM

Originally Posted by nefkntym

I wasn't worried about the return. I found this awhile back, I am using the stock locations. Just massaged a bit.

I'm pretty sure that "Fuel Return Line" is just a breather line.... This is how it works

Some B6s don't even have that line there, so that would rule out that it's a return line.

Did you throw your A4 mounts away?

**nefkntym** · 06-28-2011 08:36 PM

Finally finished the fuel system, I waited for almost a week for new fittings and decided in two minutes that I didn't want to use them at all. Oh well.

**AudiA4_20T** · 06-29-2011 06:16 AM

looks good

**nefkntym** · 06-29-2011 11:49 AM

MIG welding aluminum sucks, its time to study.

**AudiA4_20T** · 06-29-2011 11:51 AM

lol

**nefkntym** · 06-29-2011 05:35 PM

The best thing about doing a build yourself is getting new tools...

Old rig, meet new rig; new rig, meet old rig. Look at them get along.

Exhaust is suppose to get here on Friday and I need to order another weld cart.

**nefkntym** · 07-01-2011 08:18 AM

I finished the manual pedal assembly and removed the auto lockout cable from the lock cylinder last night. The car is full manual car now. I took a look at Biketsai's auto conversion thread before I started this. If you use the USP slave line, you can avoid having to remove the brake master cylinder all together because it replaces all the hard lines. It takes a couple of minutes to route as opposed to what could potentially be hours of work. I did not have to remove the pedal assembly either like Biketsai did. The manual swap is very very easy, the key to it is the flexible USP slave line.

I need to go pick up some parts from VW today and my exhaust is on the Fedex truck for delivery. I also need to grind down my tungsten rods and then I am set for TIG.

**AudiA4_20T** · 07-01-2011 08:19 AM

So the B6 was originally TIP? You said you're a student right? Where'd the money come from if you don't mind me asking? I'm a student and a TIG setup is so far out of range lol. I know you mentioned something about marines I guess you went after?

**nefkntym** · 07-01-2011 05:45 PM

Exhaust came in. Thanks Tim.

I will put a 3" Vband on the front and have a custom 3" down pipe feed into it.

Aluminum parts for the intake manifold are cleaned with acetone and rinsed. As soon as it is dry it will ready for welding.

**PNB7** · 07-01-2011 06:07 PM

FYI on the fueling. There is a suction from the drivers side to the passenger side. I had to do the reverse and push over to the drivers side because the return is in the fuel neck so I wasnt getting equal distribution return to my 044 pumps. You should be fine the way you are. I really didn't want to run my pump/pumps up front for various different reasons but hopefully it works out for you. There really isn't much of a choice on our cars. Looks good so far. You are definately struggling with the same stuff I did for sure. I would just say cut the hood latch out. Hood pins are the way to go anyway. Up to you though. If you need anything I've been through hell and back on my VR6. I'm finally starting to make everything cosmetically perfect then im turning up the boost on 2000cc injectors w/ E85 :) should be lots of fun.

**Elliott** · 07-01-2011 06:14 PM

Looking good dude. Let me know if you need any help on the welding... I'm right up the road.

**nefkntym** · 07-01-2011 06:45 PM

Originally Posted by PNB7

FYI on the fueling. There is a suction from the drivers side to the passenger side. I had to do the reverse and push over to the drivers side because the return is in the fuel neck so I wasnt getting equal distribution return to my 044 pumps. You should be fine the way you are. I really didn't want to run my pump/pumps up front for various different reasons but hopefully it works out for you. There really isn't much of a choice on our cars. Looks good so far. You are definately struggling with the same stuff I did for sure. I would just say cut the hood latch out. Hood pins are the way to go anyway. Up to you though. If you need anything I've been through hell and back on my VR6. I'm finally starting to make everything cosmetically perfect then im turning up the boost on 2000cc injectors w/ E85 :) should be lots of fun.

Yeah the fuel return is a source of consternation for sure. I was thinking about lowering the tank bit in the front and putting a Y adapter in and dumping the fuel into both sides. Time will tell if it is needed.

How did you run the throttle cable? I think the B5 guys already have the provision for the throttle cable. Lucky them.

We will see about what is required for the latch shortly.

**nefkntym** · 07-08-2011 08:01 PM

...and so it begins.

**AudiA4_20T** · 07-09-2011 09:11 AM

easy! lol. Did you get everything you needed for the A4 wiring? I finally figured this thing out 100% on the bentley diagrams. Got every pin on the S4 figured out

**nefkntym** · 07-13-2011 03:30 PM

Originally Posted by AudiA4_20T

easy! lol. Did you get everything you needed for the A4 wiring? I finally figured this thing out 100% on the bentley diagrams. Got every pin on the S4 figured out

I know right? I am making some progress, I am still waiting for Bentley DVD to show up in the mail. Hopefully soon.

**AudiA4_20T** · 07-15-2011 06:41 AM

Originally Posted by nefkntym

I know right? I am making some progress, I am still waiting for Bentley DVD to show up in the mail. Hopefully soon.

I could have e-mailed you all the pdfs, but that makes it easier

**nefkntym** · 07-15-2011 07:29 AM

Please do. I just got off the phone with ECS, the DVD isn't even in the mail yet. They said it should go out today.

**AudiA4_20T** · 07-24-2011 07:56 AM

Hey can you do me a favor? I need pics of the B6 1.8T front clip from the engine side of it. Specifically around the bracket that the snub mount goes into

**nefkntym** · 07-24-2011 10:31 AM

Originally Posted by AudiA4_20T

Hey can you do me a favor? I need pics of the B6 1.8T front clip from the engine side of it. Specifically around the bracket that the snub mount goes into

Here you go. I think this is what you want. You can have it you want it.

**AudiA4_20T** · 07-24-2011 11:26 AM

No no I just need pictures of that area. Like a shot from far back so I can see where that mount is placed

**nefkntym** · 07-24-2011 07:34 PM

A little update...

Pulled the motor and tranny out of the car. I wanted to clean the engine bay again "Clint Style", put some 034 density line B6 and B5 tranny mounts to make sure there is as little driveline movement as possible and beat the shit out of the subframe where the starter is for good measure.

New density line mounts, B6 mounted and driver side B5 S4 up top. Stock B6 tranny mount with holes to the left.

B5 S4 tranny bracket

The results of a good beating with a 5 pound hammer.

The starter cleared before but I am more happy with this.

For Clint...

AFourQ said in his thread that he used 3.0L snub mount goodies for his swap.

**AudiA4_20T** · 07-25-2011 06:01 AM

Hmmm. Yea It's gonna be a bitch to find a 3L slam panel though.

**Haenszel20v** · 07-25-2011 10:11 AM

lol, I did the same thing for my starter.

**nefkntym** · 08-07-2011 08:49 PM

Almost finished with the intake manifold, was getting pretty close today and I burned a couple of holes through a runner. SOB, took a while to get those closed up, now I have to sand grind/file down the excess aluminum. This intake is the bane of my existence. I am hoping to have the intake manifold finished in the next few days.

In between the cursing and cooling, I pulled off the valve cover and cut off the stock fitting and welded on a aluminum -8 fitting and put in another -8 bulkhead fitting for catch can hook ups. I also painted the cover. That was the most productive part of today.

The rear portion of the exhaust is on and I started putting the interior back together again. I need to order some Vbands and some stainless pipe for the down pipe. I took a few weeks off from the car because my kids came out to visit me. They left on Friday and I have a couple weeks before school starts up again. I am looking forward to investing more time into the car.

I want to get my Avant back on the road.

**AudiA4_20T** · 08-08-2011 09:29 AM

great stuff

**AudiHere04** · 08-08-2011 09:47 AM

This is a total beast. I am very scared at the power behind this car, its gonna be absolutely ridiculous!!! Excellent build for the records.

**themadscientist** · 08-09-2011 11:37 PM

Was this originally a direct injection engine?

**Haenszel20v** · 08-10-2011 07:52 AM

Originally Posted by themadscientist

Was this originally a direct injection engine?

No sir. Regular ass 24v vr6.

**nefkntym** · 08-11-2011 07:30 AM

A little update from last night...

T1 ID1000s

Installed

Fuel rail back on and throttle cable installed

Intake manifold test fit, I have a slight clearance problem with the pivot on the top alternator mount. A little grinding goodness will fix all that.

**AudiA4_20T** · 08-11-2011 08:13 AM

looks so clean

**nefkntym** · 08-11-2011 08:29 AM

Originally Posted by AudiA4_20T

looks so clean

Thanks buddy, it is so dirty. I need to clean it up after I weld the end plates and the TB flange on. Then I want to take it to machine shop and have the flanges checked/decked for straightness. Clean again and the paint it.

**Audi Skate Snow** · 08-11-2011 11:12 PM

Lovin it man! sucks I am not around in Denver to see it done soon!

**nefkntym** · 08-19-2011 03:30 PM

A little update...

working on the coil pack harness.

Final fitment for slam panel radiator support and measuring for all the IC, exhaust and coolant pipes last night.

Ordered all the goodness to finish this off this morning and picked it this afternoon. I also got my Argon tank filled and picked up some more 308 stainless filler. Lets get it on...

More to follow.

After these messages...

**nefkntym** · 08-20-2011 07:36 PM

Last night I took off the old oil cooler sandwich from the old block, cleaned it up a bit and put it on with the mocal external cooler sandwich.

After I was done, I did a quick mock up of the fmic and the mocal oil cooler. The general idea right?

This morning when I started back up again, I went to work on the IC. I was going to weld custom brackets. I had some extra angle brackets, so I used them instead of reinventing the wheel. They are strong enough to hold up my garage opener...

Next up was mounting the oil cooler, I was stumped. There is really no good way to mount it. So, now I went custom. I cut up some scraps of aluminum and well...

Clears the hood just fine.

I also cut the first few pieces to make my down pipe, but I am also finishing the intake manny. I can't started welding up the down pipe because I would to change the Tungsten from Pure to Thoriated for welding stainless. I should be finished with the manny and starting on the down pipe tomorrow afternoon.