My first Audi - 2001.5 S4 with Custom Single Turbo setup...

**britishturbo** · 09-26-2012 12:18 PM

So I recently picked up my first Audi... a 2001.5 S4 6 speed.
Got it from a friend of mine, he had it parked in his junk yard... it had dropped a valve which put a hole through a piston.

So I towed the car home (Always had a love for B5 S4's)

Then I pulled the engine:

Another friend had a complete running 2.7 from an A6 so I got that from him.

So then came the decision... put the stock engine in and be content with 250HP for a while and then tear it apart when I want more power... Or do it right from the start?

So I did it right from the start.... Over the last month or two I've been building my own custom single turbo setup.
Mocking up the single turbo up pipes (used 2.8 manifolds and 034 Motorsports flanges)

Late night victory - engine installed. And yes I'm doing this outside under my car port... The garage is full with my Eclipse racecar I'm building...

Turbo installed - yes I cut the 2nd firewall slightly for many reasons, but It's going to get boxed back in nicely :)

I'll post more pics and details soon when it's all complete, but here's the first start up of the car :D

Now I need to install my fuel system... :-D

Goal is a 400 to 500 WHP daily driver at first to replace my 350HP daily driver AWD Talon.
I'll build a new motor over the winter with all forged internals, CNC ported heads (I'll port them myself), Billet Intake manifold (again I'll make this myself ;-)) and much much more...

P.S. I'm sure this belongs int he builds and projects sub forum but I don't have enough posts to put it there yet...

**britishturbo** · 09-26-2012 12:19 PM

I have to fly out to Arizona this weekend to help some people setup and tune some Megasquirt's, once I'm back I will hopefully have the car moving under it's own power next week. :-)

**034Motorsport** · 09-26-2012 12:22 PM

From stock to big single turbo! Love it!

Looks like you got your work cut out with the fueling system, but looks like you are doing it right.

What turbo did you go with?

**s4930** · 09-26-2012 12:22 PM

Wow way to break the ice lol.... Interested in seeing the out come for sure!

**britishturbo** · 09-26-2012 12:28 PM

Hey Max, thanks I was quite inspired by the 034 STK as you can see... I just couldn't wait to get started lol.
The fuel system shown is the planned final fuel system, but at first I'm just going to run with a bigger pump and injectors until I get my new fuel rails made. Then I'll go with the full system.

The turbo is a custom build based on a Borg Warner S256 w. 0.63 A/R hot side.
Turbo will support about 550 WHP. Should be good to start ;-)
I actually already had it from my Eclipse I'm building...
Here's the state of the Eclipse:

Originally Posted by Max@034

From stock to big single turbo! Love it!

Looks like you got your work cut out with the fueling system, but looks like you are doing it right.

What turbo did you go with?

**britishturbo** · 09-26-2012 12:29 PM

I'm never happy with stock power... I'll be sure to keep everyone updated :-)

Originally Posted by s4930

Wow way to break the ice lol.... Interested in seeing the out come for sure!

**coolgraymemo** · 09-26-2012 12:32 PM

These forums need new members like yourself.

**kbS42001** · 09-26-2012 12:37 PM

very nice...cant wait to see more

**Monty23** · 09-26-2012 12:37 PM

BEST FIRST POST EVER! Glad to see another close by single setup. We will have to meet up when I finish my build!

What clutch are you running?

**hendrj5689** · 09-26-2012 12:41 PM

Looks awesome! Can't wait to see how everything finishes up!

**britishturbo** · 09-26-2012 12:41 PM

Thanks man! I appreciate that.
I've been reading AZ for a cpl months now doing research and the like.
OF all the forums for Audi's I think I like it the most!

Originally Posted by coolgraymemo

These forums need new members like yourself.

**britishturbo** · 09-26-2012 12:45 PM

Fidanza Flywheel and Clutchmaster FX-400 6 Puck clutch

And sure man I always love to meet new people :-)

Originally Posted by Monty23

BEST FIRST POST EVER! Glad to see another close by single setup. We will have to meet up when I finish my build!

What clutch are you running?

**britishturbo** · 09-26-2012 12:49 PM

Btw I must say I feel the B5 s$ platform is very underrated to this day.
I think the problem is not many people push the engine to it's limits in every aspect.
Many people bolt on bigger turbos, but most people seem to not do enough work when it comes to the intake system or the fuel system.

I plan on seeing how far I can push things... I already have port designs ready to CNC and I'm working on my Intake manifold design too...
It doesn't hurt that I build 5 Axis CNC machines for a living ;-)

**AudiNFS** · 09-26-2012 12:51 PM

I wanna come by too! I rode in edge motors single turbo S4 and that thing was a monster.

**britishturbo** · 09-26-2012 12:51 PM

Intercooler setup:

Air to Water... because I can :-P
I like the idea of 3 feet of intercooler system lol.
Ignore the mess and dirt... things are still very much work in progress...

**britishturbo** · 09-26-2012 12:53 PM

CNC port I did myself for my 420A Eclipse project

**britishturbo** · 09-26-2012 12:54 PM

Originally Posted by AudiNFS

I wanna come by too! I rode in edge motors single turbo S4 and that thing was a monster.

Give me a month or so to get it all done and running well :-)

**bgzs4** · 09-26-2012 12:57 PM

I feel like a poser reading this thread. Good stuff.

**britishturbo** · 09-26-2012 12:57 PM

Billet Aluminum Intake Plenums I made for a certain Lamborghini project at work recently... Took me 80 Hrs to make these bad boys!
Hopefully my S4 intake will be as sexy ;-)

**AudiNFS** · 09-26-2012 12:59 PM

Wow, that is some impressive stuff IMO. I can't wait to see how your build turns out!

**britishturbo** · 09-26-2012 01:07 PM

Turbo Up Pipe - I even welded in bungs for the factory EGT probes.
I figure they are a great feature, so why get rid of them!

**Monty23** · 09-26-2012 01:14 PM

What is the thought behind putting a flex pipe on only one side of the up pipe? I would assume you would want a flex pipe on both sides....

**s4930** · 09-26-2012 01:16 PM

Noob question but what goes in that small opening on the up pipe?

**britishturbo** · 09-26-2012 01:16 PM

Originally Posted by Monty23

What is the thought behind putting a flex pipe on only one side of the up pipe? I would assume you would want a flex pipe on both sides....

Same reason for 034 only using one, all you are really doing is dealing with the expansion of the engine. When the engine heats up the banks will actually grow and move the exhaust manifolds ever so slightly further apart. If you didn't have a flex section the up pipe would crack.
This should take care of that problem.

**britishturbo** · 09-26-2012 01:18 PM

Originally Posted by s4930

Noob question but what goes in that small opening on the up pipe?

That is the flange for the Tial wastegate.
You can see it installed here:

**Monty23** · 09-26-2012 01:18 PM

Originally Posted by s4930

Noob question but what goes in that small opening on the up pipe?

Wastegate.

Same reason for 034 only using one, all you are really doing is dealing with the expansion of the engine. When the engine heats up the banks will actually grow and move the exhaust manifolds ever so slightly further apart. If you didn't have a flex section the up pipe would crack.
This should take care of that problem.

thanks

**britishturbo** · 09-26-2012 01:22 PM

Another future plan / experiment I have planned is testing a Megasquirt vs Motronic ecu.
I'm a big Megasquirt guy, I've built and installed many many units through the years.
I'm going to make a harness adapter that will let me unplug the factory ecu and plug in a Megasquirt.
Only other changes needed will be the Throttle Body and removal of MAF sensor.

But that's down the road...

**s4930** · 09-26-2012 01:23 PM

Originally Posted by britishturbo

That is the flange for the Tial wastegate.
You can see it installed here:

Thanks! your work looks super legit, I'd love a custom mani from you no homo

**britishturbo** · 09-26-2012 01:26 PM

Originally Posted by s4930

Thanks! your work looks super legit, I'd love a custom mani from you no homo

lol thanks. I don't know about offering manifolds for people yet though, with 034 introducing their STK I think that would be the best solution for most people... But I never say never ;-)

**caliskate12** · 09-26-2012 01:38 PM

DROOL

**Monty23** · 09-26-2012 01:39 PM

Originally Posted by britishturbo

lol thanks. I don't know about offering manifolds for people yet though, with 034 introducing their STK I think that would be the best solution for most people... But I never say never ;-)

He is most likely talking about an intake manifold. And fyi, don't talk about selling anything unless your an advertiser or its in the classifieds or you may get in trouble.

**s4930** · 09-26-2012 01:45 PM

Yea I meant intake mani... And we must also beware of AZ secret police ....

**britishturbo** · 09-26-2012 01:45 PM

Ah yes didn't think about the intake... And I have zero plans of making and selling anything at this point... Purely personal parts ;-)
But thanks for the heads up!

Originally Posted by Monty23

He is most likely talking about an intake manifold. And fyi, don't talk about selling anything unless your an advertiser or its in the classifieds or you may get in trouble.

**haggard69er** · 09-26-2012 01:45 PM

Originally Posted by britishturbo

Intercooler setup:

Air to Water... because I can :-P
I like the idea of 3 feet of intercooler system lol.
Ignore the mess and dirt... things are still very much work in progress...

Exact same setup I'm using in my build! consistent iats and minimal pressure loss! Good luck with your build sir!

**britishturbo** · 09-26-2012 01:46 PM

Originally Posted by haggard69er

Exact same setup I'm using in my build! consistent iats and minimal pressure loss! Good luck with your build sir!

Sweet and thanks!!! You have any pics? Curious to see how your setup is!

**britishturbo** · 09-26-2012 01:47 PM

Originally Posted by s4930

Yea I meant intake mani... And we must also beware of AZ secret police ....

Haha beware the Gestapo? lol ;-)

**Don Supreme** · 09-26-2012 01:47 PM

Originally Posted by britishturbo

Ah yes didn't think about the intake... And I have zero plans of making and selling anything at this point... Purely personal parts ;-)
But thanks for the heads up!

Can you tell us more about your line of work? It seems like you have a pretty solid skill set fabbing parts manually and using a CNC.

**britishturbo** · 09-26-2012 01:51 PM

Originally Posted by Don Supreme

Can you tell us more about your line of work? It seems like you have a pretty solid skill set fabbing parts manually and using a CNC.

Sure... My official job title is "Systems Engineer" I work at a company that makes CNC machines and controls... This company actually: http://www.centroidperformanceracing.com/ / http://centroidcnc.com
So I have access to many nice toys at work... just never have much free time to take advantage of it all.

**haggard69er** · 09-26-2012 01:55 PM

Originally Posted by britishturbo

Sweet and thanks!!! You have any pics? Curious to see how your setup is!

I will take a few next time I'm at the garage. I have all the pieces to the puzzle, just finishing up the engine. Waiting till summer to put it together. I don't like cold lol.