Nynoahs Build thread

[nynoah]

Ok so I wanted to post a little bit about what I am up to. I have a 2001 Audi A4 1.8t Avant 5sp black on black. I have owned this car since 2002 and it just turned over 165K miles on it with a stock clutch . I never even chipped the car.

Anyways, I had an incident with the car a little while back where I hit a rock in the road. Its not uncommon out here in Colorado to come around a corner and find a rock slide in your path. Well that rock toasted my oil pan and ripped by AC compressor right off the block. When I say ripped, it ripped the mounting points right off the block. There is no way to fix that other than dropping a new block in. Best part is I was able to claim it on insurance and got a nice check. So rather than have a shop do the work to drop in a junkyard motor, I will do the work myself and drop in a fully built motor. Something that I can add way more HP to later if I so chose.

Well since I am building the car to keep running for a long time, I might as well mod it to make it better. I have managed to keep my car totally stock the whole time I owned it. During that time, I chose to mod my motorcycle to hell and back. Only thing original is the frame on that bike. Its a FZR400 with a YZF600r motor, GSXR750 forks, ducati front wheel, 17in TZ250 rear wheel, titanium exhaust and Japanese spec FZR400rr body work and rear swing arm. A total franken bike.



Anyways plans for the A4.

GTRS elim turbo setup with Franken Turbo manifold, 3in MAF, 630 injectors, Uni tune, KN filter, and heat shield. I also have an AEM wideband and boost gauge to monitor things. I have a FX300 240mm clutch kit with the fiber tough material rather than the normal FX300. I am also debating going to a comp turbo instead of the GTRS. I was thinking about being the first person to do a comp turbo eliminator. I know I know WHY? Just because. I also want to be able to drop in my stock cat to pass emissions which we have to do in Colorado. This depends if I can find a good deal on a spare elim housing. Know anyone with one?





I bought a spare AWM motor for the bottom end. I also purchased Morzechowski built AEB head to go on the block. I am going to sell both of my spare AWM heads after to recoup costs. Plans for the motor are all new seals, IE drop in rods, stock pistons, Calico main and rod bearings, fully balanced, pinned crankshaft pully, ARP hardware throughout.


A member who is local to me was parting out a 2001 S4 so I grabbed the interior and full braking system. I plan on putting steel braided brake lines to make it feel better. I addition, I am doing all the wheel bearings and installing a new set of suspension arms upfront at the same time.




Plans for later is to have a custom 3in exhaust made with Vibrant mufflers. I am also going to do an Ebay FMIC till Seerlah gets his custom core ready. Then I will switch out the Ebay core with that one.

I will add more in a little bit. Right now I am cleaning out the interior in preparation to get the seats welded in. God... the amount of crap that accumulates under the seats especially the rear base.

Enjoy
Noah

[nynoah]

This is how the car currently stands.


I ripped out the whole interior today.


I also washed the all the interior pieces with the hose and some dish soap.


Currently going to town on the carpet to get out all the crap in that.

[Seerlah]

You the original owner?

Also, what engine mods do you have planned? And I take it the eliminator is just the beginning? Best of luck, man. Snags are inevitable.

[nynoah]

I bought the car from the dealer when it had 6000 miles on it. I think it was used as a local Audi fleet or demo car. I bought it for a steal at the time. I had just sold my 1992 Corrado VR6 and walked into the dealership and told them it was that car or the WRX next door. It was the last week in Dec so rather than pay the year tax for inventory (from what I was told) they sold it real cheap. I paid 22K out the door in 2002. It came stock with the sport suspension, cold weather package, Bose, Xenon, home link. In addition to the fact that it was a black on black 1.8T manual Avant. It was the car I wanted the most and I got it. So I have had it since that time. I don't know of any other car I would want for a DD. It gets great mileage for an AWD car. So, I would guess I would call myself the original owner. I have done all the maintenance on it over the years too. Its been a great car and I don't mind keeping it for another 10 years. It does not even creak or make a noise inside.

Though part of me wants to build a TDi Synco Vanagon Westphalia. But those cost A LOT of money. Ever look at the resale value of those things. Jeez...

[nynoah]

So for the last few days I have been oiling the leather S4 seats. They are in pretty good shape for having 100K miles on them. But most owners never take care of leather the right way and they start to dry out and crack. This seat had a lot of wrinkle marks where the drive was getting in and out. If the seats are oiled regularly, that does not happen as much. So for the last week I have been oiling them with a light coating of Neatsfoot oil every night or so. I was introduced to Neatsfoot after a friend used it on his leather products. It does amazing things and brought his dried up leather back to supple life. Its an organic (not sure if it is all organic) leather made from mostly cow pieces and parts. I had to go to a horse supply store to pick it up. But they use it to keep saddles oiled. Saddles see a hard life and this stuff keeps em going. Warning, I have NO CLUE if it will alter the color of your lighter colored seats. I have black so I never cared. If you try this stuff, use it on a place where you can test it to see if it changes your seat color too much.


After doing that for the last week, I noticed that there was something under the driver seat that was starting to poke up. It felt sharp from the outside too. No good. So I took the seat apart. I think I might just remove it or use a dremel to get the sharp edge off. After that wrap the little bugger in some ductape to insulate that metal from the leather.


And I found this. A nice sharp barb. Sharp enough to cut my finger. I am surprised the leather did not get a hole yet. Goes to show that Audi uses good tough thick leather.


I also want to see if I can somehow repair some of the foam damage to the drivers side bolster. Still trying to figure out the best method. I am thinking that I am going to rip apart my old seat and hack some foam from that and pack it in there. Perhaps add some ductape or glue some cloth on the top portion to reinforce it some more.



Any suggestions?

[Nollywood]

Nice build!

[nynoah]

Thanks I am really looking forward to the change. So many things I need to do. Still deciding what I should and should not do. Much of that depends on money

[andyrew]

Nice bike!

[M-Hood]

I am also debating going to a comp turbo instead of the GTRS. I was thinking about being the first person to do a comp turbo eliminator. I know I know WHY? Just because. I also want to be able to drop in my stock cat to pass emissions which we have to do in Colorado. This depends if I can find a good deal on a spare elim housing. Know anyone with one?

Actually a Billet wheel turbo will help you since your at a high elevation, even more so if that billet wheel is ETT. So even if you went with the exact same size wheels as the GTRS you will see quicker spool while being able to make more power.

[nynoah]

Yeah I might do something like that in the future mike. I think I might step up a little bit though. We'll see...

Also thanks for the compliment on my bike. I put A LOT of work into that. I personally pioneered a lot of the fabrication involved. I use to run a small side business importing motorcycle parts in from Japan. The FZR400 community is one of the most mod happy bikers out there. That bike is built like a lego. So many parts can transfer over or be made to fit.

[nynoah]

Ok here is what I did today. Today I fixed the worn out seat bolster on the S4 seats. We all know that after a few years that the side bolsters, esp on the driver side, start to get worn out. The collapse and get mushy. What happens the 1000 times you got in and out of your seats that you slide your but over them. Over time you will start to see little bits and pieces of white foam that will fall under the seat. That is a tell tale sign that the foam is breaking down from that abuse. You can see from the earlier pictures that the cloth on the inside tore off. You can also see that the inside area is all cracked. What can not be seen is how much foam was just gone. So what I did was head down to my local custom upholstery guy and picked up some scraps from him. I also got him to give me a small amount of GOOD contact cement designed for upholstery use. This stuff is AMAZINGLY sticky. Sadly I found out the hard way because I got it on my fingers. Its like rubber super glue.

Here is the block that I picked from their trash pile.


Here it is cut down to the size I needed.


Here is what it looks like all glued together. I added some small nibs in little places to fill in the little holes. The seat feels almost the same as the non worn side. I over did it a little bit, but I think the leather will crush it down to just right.



For tomorrow, I am going to show you guys what Citric Acid Powder will do to rust. You are going to love this if you have never seen it before.

[nynoah]

Parts are rolling in. I just made an order for 2500 worth of engine and chassis parts. I also got this in the mail
Fully built motor with high flow head soon to go in. Anyone want to give me a AEB intake manifold? I am going to have to run my AWM until I get up more cash. sigh...

[nemick]

Looking good. I have to say though, I sure hope whoever built the engine did a better job on the internals than on the cam cover breathers, or whatever those things are that are scabbed on there. I'm looking forward to seeing this whole project come together. Looks like boat loads of fun.

[nynoah]

That cover was put on there for transport reasons. No way I am using it. lol I have to replace 3 bent valves in the head to get that head good. Which I will have the shop check it over at the same time. The bottom end is being assembled by 3zero3 Motorsports. I am sure I am capable of doing it. But I would rather pay someone who does it all the time. Mental insurance reasons. But I am staying with stock displacement because I like my MPG (average 30+) and building the bottom end to take what ever I want to throw at it in the future. I don't think I will ever go past 450 WHP but I like to over build rather than find the weakest link.

I have been trying for weeks to source some 6 piston Touareg calipers to no avail. But those might go on instead of the S4 fronts if I do find them for a good deal.

[nemick]

That cover was put on there for transport reasons. No way I am using it. lol I have to replace 3 bent valves in the head to get that head good. Which I will have the shop check it over at the same time. The bottom end is being assembled by 3zero3 Motorsports. I am sure I am capable of doing it. But I would rather pay someone who does it all the time. Mental insurance reasons. But I am staying with stock displacement because I like my MPG (average 30+) and building the bottom end to take what ever I want to throw at it in the future. I don't think I will ever go past 450 WHP but I like to over build rather than find the weakest link.

I have been trying for weeks to source some 6 piston Touareg calipers to no avail. But those might go on instead of the S4 fronts if I do find them for a good deal.

Thank God for that, lol. I know what you mean about mental insurance. I try to do whatever I can, but I know when I'm out of my depth. I would follow the same path as you, quite honestly. Good thinking.

[nynoah]

Yeah stock block, stock HP I can do it. Building for double stock HP... well. I would rather not miss something simple and pay two times.

[morzechowski]

That valve cover is fine, just a little ugly. The -10 breather bungs are welded on but must of eventually got a small crack and they leaked on me a little bit so I through some right stuff around them and solved the problem.

Glad the box survived! looks like it got beat up a little bit lol.

[Seerlah]

Not sure if these calipers interest you or not.

http://www.audizine.com/classifieds/...ware-kit&cat=8

It looks like the seller had these possibly on a B5 S4, so possibly a plug and play setup.

[nynoah]

Yeah those are what I am looking to put on. But that kit is WAY over priced. I can build one with new parts for less than he is asking for used pads and rotors.

[thenj3]

i really want those brakes.

[nynoah]

Some parts started to come in. Engine headed to the machine shop tomorrow. I am having 3zero3 put my bottom end together for me. http://www.3zero3motorsports.com/ Scot the owner is a great guy and I always enjoy any chance I get to catch up with him.

[nynoah]

Well today was a productive day. I pulled all the front suspension components. That was a bitch. I had to drop the subframe to get those stupid rear trailing arm bolts to slide out. I also disconected the drive shaft, removed the front CVs too. I removed most all the bolts so I can pull the engine and the transmission as one unit. I think it will be far easier to pull that as a unit rather than fight to get those stupid bolts out from the bell housing. I painted my S4 brakes red. Welded the plates in place for the S4 seats. Yesterday I pressed in new wheel bearings for the S4 uprights too. I also pounded out some dents in the chassis from highsiding on some rocks while on driving on rocky trailhead roads. Colorado is great that way. Still got a big one to pound out later. Its like 6 inchs long. :/ Hopefully in the next few days I will get the motor out. I am going to drail the tranny fluid in the next day or two. Soooo much to do.

I basically called it a day when both of my forearms went into muscle spasm. Mainly from trying to get all those stubborn suspension bolts and the damn driveshaft allen head ones. Sigh... I am beat.

[Seerlah]

Update?

[nynoah]

WAITING WAITING WAITING.... on parts. I ordered a set of 1mm over pistons and had them coated on both the side skirts and the tops. That order was put in back the week before Thanksgiving. The shop that was working on the engine for me dragged their feet, then the machine shop dragged their feet. Then I finally got a call saying that my piston jugs were too far gone to use stock. Which then triggered having to buy pistons. Its only 200 to coat them and I think every piston at a min needs the side skirt coated. They come coated like that from the factory. Then since it's being done, might as well do the tops.

I have installed the brakes front and rear with steel lines and bled it down.

I have the S4 seats welded in and bolted down. I also oiled the hell out of the seats and they are nice and soft. I might still dye them to get them totally black again. I have to find some leather stain.

I just got a hold of a guy who might paint both my front and rear bumpers for 200. Gravel, which we put down instead of salt, does hell to the bumpers out here in Colorado. But we don't have rust issues. Heck my bolts look nearly new on the underside.

I also just ordered an 034 high flow cat with a 3rd bung welded in place for the wideband. But I wish I had not because I really want that exhaust that just popped up. Anyone want to buy it off me? I will cut you a deal.

[Seerlah]

If you want to pass Denver emissions, stick with the 034 HFC.

[nynoah]

If you look in the for sale section, there is a full 034 3in exhaust for sale. It comes with a downpipe with a HFC welded in place and it is set for a stock placement. Just like my eliminator. I swear, why don't these things come up before I spend the money on other stuff? Like I said if anyone with an elim or a Franken turbo wants a High Flow Cat, I will sell mine for a good deal. I ordered it with the install kit and a 3rd bung already welded in place. Its way better than a test pipe. No bad smell to gross out the little lady or those behind you. Don't be that guy who runs a testpipe. Buy my HFC and save the planet while increasing HP.

[Seerlah]

Meh, not a big Magnaflow fan. But whatever floats your boat. FWIW, picked up my Resonated Milltek for $500 shipped years ago. Deals are out there. What you also can do is pick up a B5 S4 3" single (used aftermarket of course), cut it off at the y-junction, and fabricate piping from there back to the 034 HFC. Bam, cheap 3" custom exhaust. haha. But really!

[nynoah]

Hey keep a lookout for me. Only reason for wanting the 034 system that was for sale was because its a good deal. I most likely am going to weld up a custom one with Vibrant mufflers. I might even run double resonated plus a dual out muffler. Costs a little more. But I want silent as possible. Stealth = good

[Seerlah]

That is the reason I am not a fan of Magnaflow. After I heard the resonated Milltek, I did not want any other exhaust. Hawked classified sections and ebay for 7 months and jumped on the first deal I found. And when I do or if I upgrade to a full 3", I'm going with the B5 S4 resonated 3" single Milltek with the same procedure I posted above.

Edit: And there you go...http://www.audizine.com/classifieds/...catback&cat=23

[nynoah]

Sadly that exhaust is welded solid and I live in Colorado so shipping is just going to be a pain. I think once all those factors are added up, it will be more expensive than a custom setup from a local speed shop.

[Seerlah]

Only the inserts are welded. I would offer him $550 shipped. If he says no, then that is that. It's the Christmas season, and he may just take it.

[nynoah]

I would not go for it unless it was 400 shipped. It will cost me over 100 for a custom down pipe to be spliced in. It will cost me 350 for 1 muffler and 1 resonator from Vibrant and 350 to have a custom system made. So new custom system for around 6 or 7 hundred. 550 plust 100 makes it not worth the hassle.

[Seerlah]

My setup cost me around $750 all said and done, so understandable.

[NewDays]

Nice build so far, 3zero3 does really good work and Scott's a great guy(my dads known him for years so I have to), but where were you driving when you ran over the rock if you remember?

[iLovPieNCake]

This is going to be an amazing build, good luck.

[nynoah]

How do I get this thread moved to the build section?

[Seerlah]

You need to request it. My build thread is still in this section because I have yet to ask for it to be moved. I will once I am completely happy with my vehicle. Till then, it stays .

[nynoah]

Today was a good day....

[Mal]

awesome update! i will be following this

[donkeysaudi]

I am loving this build i want this to go well and see a Gnarly beast at the end. keep it