Justin's B6 S4 Race Car Build Thread

[0000 V8]

***MORE PICS THROUGHOUT THREAD***

Hello AZ friends. My name is Justin aka 0000 V8. This has been a project in the making for a long time. I purchased my S4 back in 2009 with the intent of one day making it a track car. The S4 has always been my favorite car, and I realize there are cheaper and more "track suited" cars out there, but Im not into the cookie cutter cars. I wanted something I could really be proud of. I wanted a challenge. What better way to do that than make a luxury sport sedan into a full track bred beast.

The car will be raced in the WERC series.

2004 Audi S4

Engine/Power:
-JHM Tuned 4.2L V8
-Custom Catless Downpipes (2.5”)
-X-Pipe (2.5”)
-Custom Side Exit Full Race Exhaust System (2.5”)
-Summit Fuel Pump, High Performance (450lbs/hr,65psi,800hp)
-Canton Racing Accusump, 3q System
-Stratmosphere Intake with Heat Shielding
-JHM Intake Spacers with Heat Shielding
-JHM Heater By-pass
-Custom Fuel System with ATL Rear Cell 12gal Tank and Racing Fuel Pump
-Stock Tanks Gutted for Exhaust System Install
-Optima YellowTop, relocated to rear

Trans/Drivetrain:
-Quattro All-Wheel Drive with 6-spd Manual Transmission [upgrading to dogbox]
-Torsen 4:1 Center Differential Upgrade
-Stratmosphere Short Throw Shifter [upgrading to JHM]

Chassis/Suspension:
-Evil Genius Custom Built Full Roll Cage
-PSi Raceline Twin-Tube Coilovers with Ohlins TTX Dampers/Eibach ERS Springs 800/1800
-034Motorsport Solid Rear Sway Bar
-034Motorsport Sway Bar Adjustable End Links
-034Motorsport Fully Spherical Adjustable Upper Control Arm Kit (Race)
-Apikol Rear Differential Mount, Red
-Apikol Snub Mount w/bracket, Red
-034 Motor Mounts, Motorsport
-034 Density Line Transmission Mount

Brakes:
-STaSIS Alcon Mono4 355 BBK (F)
-Cobalt XR2 Track Pads (F)
-Slotted Rear Rotors
-Stainless Steel Brake Lines (F&R)

Wheels/Tires:
-Enkei 18x9 et35 5x112 PF01’s
-Federal 595 RS-R 255/35/18

Exterior:
-EuroGEAR Carbon Vented Hood w/AeroCatch Pins
-APR GTC-300 Carbon Wing
-APR Custom Carbon Splitter
-Custom 3" Brake Vents [awaiting fab]
-GT3 Carbon Side Mirrors (with curved glass)

Interior (Fully Gutted):
-Status Ring GT Blue Suede Carbon Racing Seat
-Sparco 383 Competition Suede Steering Wheel
-Sparco Quick Release Steering Hub
-Sparco Floor Plate
-Sparco Aluminum Pedals
-MOMO Shift Knob
-Custom Race Gauge/Switch Panel
-AEM Digital Gauges
-A/F Ratio, Fuel Pressure, Oil Pressure, Oil Temp, Water Temp, Trans Temp, Voltage
-ATL Fuel Gauge
-Auto Meter Pro-Shift Light

Safety Misc:
-6-pt Status Harnesses, Red
-Scroth Window Net
-Scroth Right Side Net
-Safecraft Fire Suppression System, 5lb Lever Release

- HANS 20-deg Neck Restraint (QuickClip with Gel)
- Sparco M-5 Driving Suit
- Sparco Slalom SL-3 Shoes
- Sparco Tide H-9 Gloves

[0000 V8]

[0000 V8]

Stock:





Gutted, cage install:








Fuel Cell:




Seat:



Nascar doors done:




Gauge Panel, with gauges just placed in for example:



Harness Mounts installed:



Battery located in rear with a solid mount:


One of the new mufflers for the side exit exhaust:


Suspension:

[nnnick]

Can't wait for pics. I've seen some of Evil Genuis' work via racing in 24 hours of LeMons, I bet the cage turned out killer!

What are you planning on racing this in? Time Trials?

[0000 V8]

Can't wait for pics. I've seen some of Evil Genuis' work via racing in 24 hours of LeMons, I bet the cage turned out killer!

What are you planning on racing this in? Time Trials?

Pics are up now, let me know if you cant view them.

Evil Genius has been pretty good so far. The guys are really nice, and the personalities youd expect for a shop that has their own TV, only not fake cool. They are legit nice guys and LIVE AND BLEED racing. Im lucky to have them so close to me.

Time trails on road courses, yes.

[QIKRNU]

What are you hiding under the cover in pic's 2 & 3?

[MBM6F]

Awesome project is awesome. Can't wait for more updates!

[0000 V8]

What are you hiding under the cover in pic's 2 & 3?

That is actually the previous owners stuff. Thats the day I picked her up. :D

[jolio1994]

Subscribed, this is looking to be an awesome build

[bangoman]

Oh my. This will be fun.

[ilko]

Glad you kept the arm rest!

[0000 V8]

Glad you kept the arm rest!

Actually its gone lol

[65vetteC6]

Poor noggy, but cool project. I bet that thing feels like a whole new car with all that weight gone. Have you weighed it?

[0000 V8]

Poor noggy, but cool project. I bet that thing feels like a whole new car with all that weight gone. Have you weighed it?

Not yet, but I will towards the end of this build phase. It will also feel like a new car with $6000+ worth of suspension parts lol

[Slobo7x]

How'd you find an s4 without sunroof? Lol
Great job on gutting, could have installed recaros back :))

[NOGGYchris]

Love everything about this man! Subscribed for sure. I notice your tags are MD tags but your location says Cali?? Are you in MD if so what part?

[BUD-S4]

Good lord! That is awesome!!!!

Keep up the good work.

[JimmyBones]

0000 V8, all you need now is some boost.

How'd you find an s4 without sunroof? Lol
Great job on gutting, could have installed recaros back :))

It must have been an option to order a S4 and RS4 without a sunroof because I have seen a yellow RS4 without a sunroof too.

[0000 V8]

How'd you find an s4 without sunroof? Lol
Great job on gutting, could have installed recaros back :))

I got VERY luck, since I had my goals when I bought the car. The recaros are HEAVY. Front and rear seats are around 300#'s

[0000 V8]

Love everything about this man! Subscribed for sure. I notice your tags are MD tags but your location says Cali?? Are you in MD if so what part?

I bought the car from MD while I was living in VA. I moved to CA about a year ago.

[ilko]

Yep, stock seats are the first to go when putting a car on a diet. My vote is for Recaro Pole Positions. Are these Status seats up to the FIA 8855-1999 standard?

[ken5018]

WOW! Pretty cool what your setting out to do and definite props on being different! In for more updates as this seems like its going to be fun to watch!

[0000 V8]

Yep, stock seats are the first to go when putting a car on a diet. My vote is for Recaro Pole Positions. Are these Status seats up to the FIA 8855-1999 standard?

Status make 3 sizes of seats. Only their smallest size (the Ring, which is made for like a 5' 7" 140# person lol) is FIA rated, as most companies only get one certified because its expensive. The Ring GT seat is the same thing but an inch or so wider. The short answer is no, but in most clubs, even SCCA, if a FIA rated seat expires, it just needs a seat back brace added. Ill be installing one in a few weeks.

I looked into Sparco, Recaro, MOMO, etc seats but I really didnt want to give up my beautiful suede at the time. These seats are top notch.

[vdubjetta02]

My friend has a very similar build. It's a serious M3 race car, but he set it up so he has the option to install his passenger racing seat at any time.... are you going to consider having a passenger seat?

[0000 V8]

My friend has a very similar build. It's a serious M3 race car, but he set it up so he has the option to install his passenger racing seat at any time.... are you going to consider having a passenger seat?

I wasnt at first, but now I want one so I can give people rides on track days, and get good instructor rides, with becoming an instructor myself one day. I was looking at buying another Status seat, but if I can sell the one I have, I may get two new seats. I havent decided just yet.

[CHECKERED]

Chassis/Suspension:
-Evil Genius Custom Built Full Race Cage
Brakes:
-STaSIS Alcon Mono4 355 BBK (F)
-Cobalt XR2 Track Pads (F)
-Slotted Rear Rotors
-Cobalt XR3 Track Pads (R)
-Stainless Steel Brake Lines (F&R)

That race cage is complete overkill unless you are driving a fiberglass car at 200mph or doing rally racing with 600 foot clips there is no need for such a setup. But that’s just me,

Also, you will need far bigger brakes on the front, or atleast some serious twin 4” ducts for air cooling for each side.

[0000 V8]

That race cage is complete overkill unless you are driving a fiberglass car at 200mph or doing rally racing with 600 foot clips there is no need for such a setup. But that’s just me,

Also, you will need far bigger brakes on the front, or atleast some serious twin 4” ducts for air cooling for each side.

IMO its hard to justify any safety feature as being "overkill." I could have gone with roll bar or a 4 point cage, but I would never be comfortable driving it. These cars are not miatas that weight 1200#'s. In the event of a crash on the track, regardless of how fast, the last thing I want to be concerned with is if my safety systems are "good enough." This is the reason I STARTED the build with safety as phase one, spending as much as I can. Any racer will tell you the same thing.

As far as the brakes, this is just a start. I do want to do a duct, eventually.

[BenSti]

IMO its hard to justify any safety feature as being "overkill." I could have gone with roll bar or a 4 point cage, but I would never be comfortable driving it. These cars are not miatas that weight 1200#'s. In the event of a crash on the track, regardless of how fast, the last thing I want to be concerned with is if my safety systems are "good enough." This is the reason I STARTED the build with safety as phase one, spending as much as I can. Any racer will tell you the same thing.

As far as the brakes, this is just a start. I do want to do a duct, eventually.

Exactly! Plus the cage does have performance benefits. It stiffens the whole car.

[B6JoeS4]

As I opened this thread, I thought is was just going to be a dumb new OP trying to make his S4 something that it's not, with the end result being the OP selling the car. But I am very pleased to find somene else besides 91gl that has the balls the gut the car and make it something it has the potnential to be with a lot of work.

PM 91gl over on Audirevolution. he gutted his red S4 and got it down to a crazy weight

Lexan rear window would be cool as fuck.

[0000 V8]

Thanks for the support guys. I want to try and answer every question anyone may have. I know there are other folks out there that want to start putting one foot in the water with something like this, and I hope to be able to push them over the edge to do something they were scared to do. I dont, however, recommend doing any of this on a DD lol.

[Renegade5]

I wanna see pics of your side exhaust.

[0000 V8]

I wanna see pics of your side exhaust.

The exhaust is all fabbed up and just tacked on. We just need to finish plumbing the ATL tank to do a test start to make sure its not too loud. Tracks always have a maximum allowable db, and if your car goes over that max, you cant drive on the track. *Laguna Seca is the most strict in NorCal.

Ill have pics of the exhaust in a few days. I was wanting to do a side skirt exit, but we ended up with turn downs before the rear wheels.

[CHECKERED]

IMO its hard to justify any safety feature as being "overkill." I could have gone with roll bar or a 4 point cage, but I would never be comfortable driving it. These cars are not miatas that weight 1200#'s. In the event of a crash on the track, regardless of how fast, the last thing I want to be concerned with is if my safety systems are "good enough." This is the reason I STARTED the build with safety as phase one, spending as much as I can. Any racer will tell you the same thing.

As far as the brakes, this is just a start. I do want to do a duct, eventually.

I understand the there is no such thing as ‘overkill’ on safety equipment but I have seen those type of cages for very specific requirements, 120mph rally racing, if the extra cost + extra weight is worth the safety feeling more power to you.
I’m glad the brakes will be upgraded later I can cook my 14.4” 8 pistons in just one downhill canyon run.

and I hope to be able to push them over the edge to do something they were scared to do. I dont, however, recommend doing any of this on a DD lol.

My daily beater looked like that, minus roll cage and fuel cell, I drove it daily for 2 years, but then again I’m a little crazy

[0000 V8]

I’m glad the brakes will be upgraded later I can cook my 14.4” 8 pistons in just one downhill canyon run.

What rotor design though? Slotted or drilled? What pads? What fluid?

I have slotted with track density pads and wont work 100% until HOT, and 600 fluid. SS lines of course, as well.

[CHECKERED]

What rotor design though? Slotted or drilled? What pads? What fluid?

oem RS4 drilled, with oem pads, SS lines and Motul RBF 600 fluid.

[Axel-]

oem RS4 drilled, with oem pads, SS lines and Motul RBF 600 fluid.

The pads seem like your weak point there.

[CHECKERED]

The pads seem like your weak point there.

The S4 is not my track car so I don’t really care, once the pads need replacements I’ll get something better, but seeing how I only put 3-4K miles a year that will take a while

[Axel-]

The S4 is not my track car so I don’t really care, once the pads need replacements I’ll get something better, but seeing how I only put 3-4K miles a year that will take a while

I was specifically referring to your downhill canyon run.
As for pads, I went with Carbotech Bobcats and I'm very pleased with them. I did skim the "too hot" range once during a 20 minute spirited forest drive with lots of twisties but those drives are quite rare. For normal driving I find them to be extremely linear with just the right amount of initial bite.

I have XP12 pads for the track but I haven't tried them yet. Car wasn't ready this season and now it's winter.

[beemercer]

Nice stuff OP. Planning any power adders to go with the engine build?

[mttam510]

I’m glad the brakes will be upgraded later I can cook my 14.4” 8 pistons in just one downhill canyon run.

OE rotors have a LOT of mass and will retain a lot more heat than the Alcon disc. Brake ducts are a must, but dual 4" is certainly overkill the OP's needs.....but maybe not Bristol. a Good 3" directed to the throat of the rotor should be sufficient....the only issue is the bumper ducts.....it's pretty limited up there, was a bitch on the WCTC A4's. Also, a true rally cage is not even close to the majority of most circuit car cages.

I noticed that someone posted about rear windscreen in Lexan. Sheilds has a pattern for front and rear polycarbonate, that's what we used on the STaSIS cars. Good luck with this build. You bought the right dampers!