Project Stormtrooper - 03 Avant 1.8T -> 2.8 24V VR6T -> 2.7TT -> 3.2 24V VR6T

[Gbomer]

love the new trim pieces.. what did the shifter come from ?

[nefkntym]

love the new trim pieces.. what did the shifter come from ?

It is from the B7 A4 DTM.

[nefkntym]

Not a huge update, but with a few hours on both Saturday and Sunday, I was able to wire in the S4 engine harness into the A4 body harness using female connectors from an Allroad body harness as a flying lead. Basically, I made a patch harness.

This is what I was able to strip out and eliminate yesterday from the existing A4 body/engine harness.



Tonight I want to finish wrapping and tidying the harness and then hook up the battery and see if I can connect to the ecu and start checking things out. If all goes well, then I can connect to EPL and flash my ecu. Once that is done, I need to modify the engine bay fuel lines for twin fuel rails, add oil and then I can try to start it.

Hopefully all goes well.

[JEENYUS]

startin' to come together nicely!

[lookaught]

Very cool build.

Are the Volvo rotors and Toureg calipers bolt on? If so that's pretty convenient.

Good luck finishing it all up.

[nefkntym]

Very cool build.

Are the Volvo rotors and Toureg calipers bolt on? If so that's pretty convenient.

Good luck finishing it all up.

They are bolt on. Thanks.

[Charlie240sxt]

Could you maybe post a link or something to the info that you found i thought it was Mercedes rotors you had to use and you had to grind to fit???

[nefkntym]

Could you maybe post a link or something to the info that you found i thought it was Mercedes rotors you had to use and you had to grind to fit???

Its in the DIY section.

http://www.audizine.com/forum/showth...ow-cost-BBK%29

[jaychen]

With a reference pic next to the coke can, you see just how big the 4 pots really are. The 6 pots must be monstrous.

[nefkntym]

From last night...





Neither of the gauges have been hooked up to their sensors since I removed the VR6. The gauges are completely disconnected until I hook the sensors back up. Making progress though...

[dougyfresh]

Awesome!

Keep it up.

[AudiA4_20T]

ballin! It must be those "wiring diagrams"

[nefkntym]

ballin! It must be those "wiring diagrams"

It was all the various wiring diagrams that helped. I forgot to ground out the white/black wire from J271. I don't have the Tip ecu to do it for me anymore . Damn, it is nice to be able to read and understand wiring diagrams and schematics. Fist bump to the Marine Corps for that.

[nefkntym]

ballin! It must be those "wiring diagrams"

Under your controller for brakes, under coding. Has there been any changes for brake type, Brembo is an option. I imagine that changes the bias.

[nefkntym]

It's been slow going lately, projects at work have been non-stop.

I finally starting working on the fuel system and the oil cooler setup. I am reusing the mocal 16 row unit I had from the VR6 and I am replacing the VR thermo sandwich with a 034 S4 friendly unit. Theirs comes with some barb fittings, I swapped those out for ano-tuffs.







I ordered some silcone S4 intercooler hoses and they finally showed up yesterday. I needed the top 2 hoses for the intercoolers. I mounted those up last night and then it was time for some test fitting. I have to add that, for the ER instructions, you have to do some clearancing and cutting to lock carrier/slam panel and mounts when installing on the S4. I was pleasantly surprised when I had to do nothing at all.











There are no issues that would keep me from bolting everything up, no show stoppers at all. I am glad that I stopped modding the bumper and stuff for the VR6 front mount when I did.

I have decide if I want to use the stock bumper rebar or use the ER B6 rebar that I bought for the VR front mount.



I am kind of leaning to the ER unit. I still need address the radiator fans. I have the option of keeping the stock B6 A4 stuff or using the Spal 16" 2630 CFM unit that is already mounted as a puller and using a Spal 12" 1630 CFM unit I have as pusher.



Love the clearance...



12" Spal Pusher fan



Getting closer, I still need to:

~ finalize the oil cooler and pusher fan setup

~ do the coil pack wiring

~ adjust shifter/ replace tranny linkage shifter rod

~ fill with fluids

~ Swap brakes, front and rear

~ do something with the exhaust

~ do sanity check and then check anything else

I sent my ecu to EPL yesterday, I don't anticipate getting back before mid next week, so I have time.

[AudiA4_20T]

CP wiring? You wiring in your own FSI cps?

[nefkntym]

CP wiring? You wiring in your own FSI cps?

Yes sir, I am wiring in FSI coil packs. Maybe one day, I will get the long denso stick coils and swap to my twin fire cdi ignition. I was using that with the VR6, that uses the short denso sticks though. That would be pretty badass, maybe I should do that instead. Nah.

[nefkntym]

Quick little update...

Finally got some carbon fiber goodness, I think they fit amazingly well.



Almost like it was meant to be...



I cut the lock carrier bracket intercooler pipe thing when I was doing the VR6, I didn't want the weight and there was no way to run a snub mount go I got rid of it. Now, I want to make sure that everything fits the way it is suppose to and I also need an attachment for the snub mount.





I finished welding both plates back on this evening.



Tomorrow, I will address the snub mount bracket for the carrier side and I will un-modify my main AC line to the compressor.

[Nebone]

Impressive! Same awaits my B7 Avant.

[nefkntym]

Impressive! Same awaits my B7 Avant.

Thanks, looking forward to seeing that. B7 Avant would be awesome. I still want to do a B7 front end on mine, maybe someday.

[nefkntym]

I checked out the shrouds last night. Either they need to be trimmed or the lower mounting point on the slam panel needs to be trimmed. Right now, I am not inclined to do either.



I think they could fit under the bumper though, however, my ecu gets back to me monday from EPL and it would be nice to try to start the car monday night. Gotta wrap things up, post haste. Jetzt, mach schnell...

Last night I also took a look at how the snub mount would work out.





This evening, with the help of this...



and a rod of filler and 1 brand new 034 snub mount setup, I have this now...









Tomorrow I will scrub it real good with a wire brush and shoot a couple coats of rustoleum on it. I need to cut the ends of the intercooler tube off as well.

[JEENYUS]

sick

[nefkntym]

sick

Thanks.

[AudiA4_20T]

good stuff man. Wish I had a fab setup

[Charlie240sxt]

Why did you use 308L on carbon steel is that all u had?? Also what welder is that

[The*Fall*Guy]

Subd:beer:

[AudiForeman]

SImply amazing, we need to cruise next weekend or something once your car is good to go.

[Greedo]

Please bring this to the next avant GTG. I'd love to see it, as would most of the others I'm sure.

http://www.audizine.com/forum/showth...hoto-Day/page5

[nefkntym]

All that I had, everything up to this point has been stainless or aluminum welding. Well, there was the passenger side engine mount in mild steel on the VR6 and I used my MIG for that. I could have used my MIG last night but I just chose to TIG it. It is a Miller Diversion 180 TIG welder.

[nefkntym]

good stuff man. Wish I had a fab setup

Thanks Clint.

Subd:beer:

Thanks, long week. I wish I had a beer right now.

SImply amazing, we need to cruise next weekend or something once your car is good to go.

Thanks buddy, I can't wait till this is good to go. It has too long already.

Please bring this to the next avant GTG. I'd love to see it, as would most of the others I'm sure.

http://www.audizine.com/forum/showth...hoto-Day/page5

I will see what I can do depending on how long this takes and when it is. Sounds like fun though.

[Charlie240sxt]

That's cool man 308l is ok to weld on carbon (not the best choice) in my CWI classes I've learned that it has about the same property's as 309L (witch is a carbon to stainless wire) Looks like a cool little welder I love blue(miller) no some much on red(Lincoln) or yellow(ESAB)

[nefkntym]

That's cool man 308l is ok to weld on carbon (not the best choice) in my CWI classes I've learned that it has about the same property's as 309L (witch is a carbon to stainless wire) Looks like a cool little welder I love blue(miller) no some much on red(Lincoln) or yellow(ESAB)

Yeah, not the best choice, but I knew it would work. I have a Forney MIG as well, that one is bright green.

[DevilS4]

Making serious progress. I must have missed it somewhere but what trans are you using? B5 or B6 O1E? I like the idea of using the b5 mounting if it will work with my swap for ground clearance issues (The b6/b7 trans mount is the lowest hanging point on the car). Cant wait to finish up my b7 swap. This is exactly the route I wanted to go but I'm holding off on the tials until I get mine running and work out any kinks.

[nefkntym]

Making serious progress. I must have missed it somewhere but what trans are you using? B5 or B6 O1E? I like the idea of using the b5 mounting if it will work with my swap for ground clearance issues (The b6/b7 trans mount is the lowest hanging point on the car). Cant wait to finish up my b7 swap. This is exactly the route I wanted to go but I'm holding off on the tials until I get mine running and work out any kinks.

I am using the B6 01E. I was planning on holding off on the Tials as well, but I decided why not. The B5 mounting made it bolt in like stock without any issues. I was using the wishbone mount with the VR6, so I have used both. The B5 way is way nicer, I would used both B5 and B6 mount if the downpipes cleared, but they didn't.

[nefkntym]

The last time I posted I needed to finish tweaking the passenger IC piping. The aluminum tube that came with the ER kit was just a tad too long with this placement of the unit.






I don't have a bead roller and I was too lazy to make a tool so just welded a bead around the pipe.

One of the next things that I needed to do was address the main AC compressor line.





Unfortunately, the hose broke mid way inside the crimp right as I started tacking the pieces together. A couple of days later I went and talked to a local hydro and bearing shop and they can make replace the hose portion on the metal line.

Once again, I decided I did not like the placement of the fuel pump. The problem has always been that I didn't have the extra hose when I had the motivation or I was too lazy to get motivated to order more hose. The other day when I was at the hyrdo shop, I picked up some more AQP hose and went from there and picked up a big piece of thin metal plate from the local hardware store.













I am going to move the line to the top of the hanger and put some extra heat sleeve I have on for good measure.

Speaking of heat sleeve...





In keeping with the heat protection theme, I wanted to do something to protect the wiring and try to get less hot air into the intake. With the big piece of metal plate for the fuel pump, I had some left over.

This is after I wire brushed it real good. I painted the inside and outside of it with 2000* flame proof paint for extra protection.







Notice the ICM delete , I have also wired in the coilpack plugs as well.

[JEENYUS]

lookin' real good! are you worried about the fuel pump's exposure with it located at the bottom of your car?

[nefkntym]

lookin' real good! are you worried about the fuel pump's exposure with it located at the bottom of your car?

Not really, it is covered by the plate and the stock plastic cover. When I pulled the evap crap, all it had was a coat of dust on from over the past 9-10 years. I think I should be good.

Suggestions?

[JEENYUS]

the only reason i mention anything is because you live in CO. the snow and rocks and stuff on the roads are similar to what we have here in UT.

I have no suggestions... you're doing a good job man!

[nefkntym]

the only reason i mention anything is because you live in CO. the snow and rocks and stuff on the roads are similar to what we have here in UT.

I have no suggestions... you're doing a good job man!

You bring up a good point, I have the stock rubber fillers on there. I think I will get some injection foam to go around the perimeter to make sure no winter stuff gets in. Thanks.

[JEENYUS]

You bring up a good point, I have the stock rubber fillers on there. I think I will get some injection foam to go around the perimeter to make sure no winter stuff gets in. Thanks.

you can do that or you can find some way to just cover the whole thing completely. just like you did, but larger to cover up any gap. hell, i feel like you could just do a large rectangle, paint it black and call it a day.