Return of the Lead Sled: B7 S4 Turbo Episode: TWO
Built Motor Consist of:
- Supertech Valvetrain (HD Springs, Titanium retainers, +1mm Stainless/Inconel Valves)
- Wossner 9.5:1 Pistons (coated skirts of course)
- Pauter 154/20mm X-Beam Rods
- Misc seals, gaskets, timing stuff etc...
- as of Dec2019, it has Schrick Cams
Rest of build consist of:
- Borg Warner S300SXE-69mm T4 .91a/r
- Twin TurboSmart Comp40 wastegates
- Turbo Smart Big Bubba DV
- 4in/102mm MRP Manufacturing MAF housing
- Bell Air/Water Intercooler (made by me) with Merc Racing B8 S4 heat exchanger
- Custom Direct Port Water/Meth Setup (30cc nozzles)
- Custom intake flapper (thin acrylic sheet coated in black silicon to aid in sealing)
- Cortex Electronic Boost Controller (also controls the WM via PWM)
- Bosch MS 980cc injectors
- AEM 340LPH pump
- KenneBell 17.5v Boost-a-Pump (voltage booster for fuel pump)
- Custom Return fuel system using mk4 jetta fuel filter and an additional B6/B7 S4 fuel feed line (roughly -6AN size)
- Euro B7 S4 fuel rail (has 4bar FPR)
This was a long build (7months)!
I blew the original engine Nov 13, 2016 around 11pm. Car was assumed to have been making round abouts 500whp at 12psi and 14* timing. I had just bought a bigger turbo a few days prior too!
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I had bought a spare short block and heads about a year prior in preparation for this event!
In December i decided i'm gonna do the whole shebang and do pistons (4~6wk lead time for custom orders). Originally i was going to do RS4 rods and stock pistons.
Mid-December i dropped the heads off to have the new guides installed and valve seats cut for the larger valves. The machinist (only one in Savannah) kept leading me on this whole time saying he's working on it and needs this tool to cut or the valves seats were TOO HARD to cut. Blah blah blah... It was now late February and the pistons were on the way! The headwork was quoted to only take two weeks mind you. I even took time to send the manifolds off for ceramic coating.
So, once i knew the pistons were on the way i really started to grill the machinist...it was only when i borrowed a friend's car and showed up did he FINALLY tell me he couldn't complete the job. 3 MONTHS LATER I was extremely patient but INFURIATED
. So he charged me nothing and basically i had new guides installed and heads cleaned for free. I then proceeded to drive 2hours north to Charleston, SC and dropped my heads there to a well known machinist company (Simon's). The had the job done in two weeks. IMG_20170410_222815.jpg
During this time is when i decided to put the bottom end together and found out the RS4 rods were skinnier in width on the big end and would not work. It was all my fault i never took the time to measure them.
Shit happens. I immediately start the hunt for forged rods. Pauter was the way to go. Lead time would again be 4~6weeks. Once they arrived, first week of May, things went together nicely!
pistons installed.jpgIMG_20170514_092222.jpgIMG_20170514_134144.jpg
It was a long couple of weeks. With UPS f'ing me over on overnight shipping and some coolant leaks. I also could only work during shop hours for the most part. They did open just for me a couple times.
Furthermore, i worked backwards to check and double check different things like rod bolt torque with moly lube.
One thing about this engine is EVERYTHING takes time.
It all came together in the end and Thursday night i fired it up for the first time!
She had a dead battery (original from 2005) and a maf wire mix up so it wasn't perfect but she fired up
After sorting those issues, i chased down a coolant leak behind the head and fixed that, then went to break her in on her first 12miles.
Come to find out during this time i left the cam sensor unplugged from the coolant leak fix LOL.
I proceeded to change the oil (regular 10w30), plugged the sensor in and she ran like a dream
She made it out on the town later and i made sure to do plenty of solid pulls without going overboard on 4psi.
I am BEYOND relieved that all this came together and worked out in my favor. It wasn't cheap. It wasn't easy. It wasn't EXACTLY fun. I can PROUDLY SAY i built this all myself. BOY did i miss her!
Thank you all for those who supported even with the harsh criticism at times. Here's to a fun year ahead!
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Originally Posted by Kambesama
B6 Nogaro 
B8 Nogaro Avant 
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