Not really a B5 A4, but its a B5 A4 motor...

[zerb]

wasnt sure if i could post my project in here, but im going to try anyway. owned a 00 gti, dumped a bunch of loot to it last winter...built aeb head+034IIc+35r=useless in a few platform, at least for my taste. aside from the thing never hooking up when it was actually running right, avoiding the local cherry tops and trying to get an inspection in NYS (without the help of photoshop) were nearly impossible. sooooo....to fix all of said problems...i decided to build an audi, a 1990 90q20v audi to be exact.

plans.
awd block bored out to 83.5mm w/ 8.5:1 JE's
aeg crank
aeb head w/ cat 3652's
supertech incolnel exhaust valves, new guides
stock intake valves
CAT adjustable cam gear
SCAT rods
Clutchmasters fx700 twin disc
Stock 01A
4:1 center dif mod
audi v8q rear torsen swap(think lsd)
Bosch 044 fuel pumps (maybe 2)
96 lb/hr injectors
aeromotive adjustable fpr
homemade intake manifold
SPA exhaust manifold
gt35r sitting on it now, most likely will turn into a t3/t67 so i then have nothing bigger to buy that will fit on that SPA manifold
custom downpipe, custom three in exhaust w/borla muffler
034 Aluminum subframe bushings front and rear
034 motorsport spec mounts all around the car
034 Rear dif mount
034 IIc sem
Custom fabricated roll cage

thats the 'plan'....but im sure everyone knows how those go. just figured id share this in here cause i wasnt sure where else to put it for people to see it. enjoy the pics.

http://i39.photobucket.com/albums/e164/zerrb/DSC00025.jpg

chopping the acessory bracket for the drivers side mount bracket to bolt to the block...(sourced from a b6 passat)
http://i39.photobucket.com/albums/e164/zerrb/DSC00012.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00014.jpg

custom mount for drivers side motor mount
http://i39.photobucket.com/albums/e164/zerrb/DSC00231.jpg

passenger side just needed to be modified a bit, but it didnt take as much as the drivers side did to get it to fit.
http://i39.photobucket.com/albums/e164/zerrb/DSC00198.jpg


spa manifold goodness....
http://i39.photobucket.com/albums/e164/zerrb/DSC00232.jpg

and yes, i cut the floor to run a downpipe....
http://i39.photobucket.com/albums/e164/zerrb/DSC00292.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00291.jpg

intake mani
http://i39.photobucket.com/albums/e164/zerrb/DSC00301.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00302.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00306.jpg
(not 100 percent dont yet)

[AudiA4_20T]

wtf your not going to run the AAN beast?

[t1demont1]

Thats gonna be a fuckin cool project, but i thought the I-5 was more capable anyways

[zerb]

the aan beast has been more then proven in this platform. and i just figured that i was familiar with the 20v...and to the best of my knowledge i dont think anyone else has done this swap...which is one of my points in doing it.

[Kyle H]

wasnt sure if i could post my project in here, but im going to try anyway.
I approve.


http://i39.photobucket.com/albums/e164/zerrb/DSC00302.jpg
lol @ quaker oats.


badass build, can't wait to see the results. [up][up][wrench]

[t1demont1]

Im interested in how you think your homemade intakemani will flow better. That plenum would probably work for a transverse motor, but wheres the TB gonna go?

[zerb]

smack dab in the middle of the plenum. sorta like this....


http://i39.photobucket.com/albums/e164/zerrb/00A4_Engine.jpg

if it doesnt turn out the way i want it to, ill buy one of issams beautiful units, but at this point, money needs to go elsewhere (motor, suspension, clutch)...and id rather make it myself at the moment.

[t1demont1]

I can dig it

[zerb]

thats the idea at least...and with the b3 chasis, that cooland resivior is oriented a bit diffenently(i think, lol)...its been a while since its been in there so ill have to check that.

[317ssayzarc]

wtf your not going to run the AAN beast?

Nah Clint, he already has the uber built 20v in his MK4...

Johnny, welcome to the world of traction my friend [:D]

And just for the record guys, he's no noober [;)]

[mike-2ptzero]

Looks like a fun project Johnny.

[1fstavant]

LOVE IT ZERB-next year we will run dutchess--err let me correct that you will and ill trail behind

[t1demont1]

I wish i lived in New England, all the BATs are up there lol

[317ssayzarc]

Thats how we DO!!! haha

[f15046]

Nice project! I know man there are not very many BT/BAT Audi's down South. At least not around where I live.

[Siena]

This is a cool approach, quite liking the idea of a 1,8/2,0T I4.

*Subscribed*

[1fstavant]

new england ftmftw

[1fstavant]

we should really set up a bat dyno day some where in the middle

[zerb]

thanks for all the kind words. i forgot to include that the car will have a semi-shaved bay and im going to pull the fenders as much as i can without going crazy so i can get some wider rubber under there too.[drive]

[blkb6a4]

this is uber sick

subscribed!

[A4Rob]

Nice intake mani!

Mike, I have the same FPR :-)

[4Rings3Liters]

This is a sweet build. Keep the updates coming.

[zerb]

SPA mani is for sale for $350. im going to build a custom tubular for this venture.

[mike-2ptzero]

SPA mani is for sale for $350. im going to build a custom tubular for this venture.

If you end up needing a manifold I do have 2 Full-race manifolds here at my house.

[zerb]

took a new approach to the intake manifold, and im liking this idea more.

chopped the runners off the base plate...
http://i39.photobucket.com/albums/e164/zerrb/DSC00308.jpg

made a new base plate....
http://i39.photobucket.com/albums/e164/zerrb/DSC00310.jpg

chopped the bottom off of the d-plenum that i have...
http://i39.photobucket.com/albums/e164/zerrb/DSC00309.jpg

once the runners are welded onto the base plate, they will all get machined flat and then ill take a dremel and make then velocity stack-ish....

http://i39.photobucket.com/albums/e164/zerrb/DSC00311.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00312.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00313.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00314.jpg

and how the throttle body is going to work out too...

wouldve had it all done tonight, until my aluminum dremel bit shattered, lol.

http://i39.photobucket.com/albums/e164/zerrb/DSC00315.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00316.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00317.jpg

[317ssayzarc]

Well go to your nearest 24hr Walmart and get that ish done Johnny!

[zerb]

just fabbed up the exhaust manifold, enjoy.

http://i39.photobucket.com/albums/e164/zerrb/DSC00321.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00322.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00323.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00325.jpg

[silverman]

So sick!
great job man!

[317ssayzarc]

Looks good Johnny, but do yourself a favor and fab up a plate to seal off the passenger side front of the tranny opening... I didnt put mine in and ended up dropping a 3/8" drive rachet in there!!!

Where'd you get your SCH10?

[djwimbo]

Cool project. I had considered this myself. 5cyl are cool, but they're a bit out of their era now, and most of the cars are falling apart around them (at least around here). Why not update it with a 1.8T or even a 2.0T-FSI?

What happened to the SPA manifold?

http://i39.photobucket.com/albums/e164/zerrb/DSC00232.jpg

http://i39.photobucket.com/albums/e164/zerrb/DSC00322.jpg

[zerb]

ive got the spa mani sitting on the floor in my garage, trying to sell it.

jake, i got all the sc10 through work, cause i can get everything @ napa, lol. vibrant performance is the manufacturer.

and the reason behind a custom tubular was because i think at the power levels that i am shooting for, a tubular would out perform a cast piece. plus, it looks cool as hell and i just wanted to take a stab at making my own manifold. [wrench]

[317ssayzarc]

How much did the whole thing cost you and where did you get your flanges? You may have to hook me up NAPA man!

[zerb]

flanges i got through work, the collector came pre-made too, just tacked together, but at least the hard part (making the thing) was already done. the head flange and all came from vibrant performance, which i think we unfortunately warped a bit while we were tacking all the runners up, but we'll fix that once all the runners are welded up. as far as a price, i get in touch with you tomorrow about it, i want to say it was somewhere in the 300 range though for the flanges/collector/butt weld pieces.

[1fstavant]

zerb u ass it is presurized and i got fuel everywhere lol o yea peoples gave me the wrong part number

[zerb]

i said it was pressurized, lol. but once the fuel is out of the lines thats there, thats all that'll come out. (as long as the cars off) and like i said man, a fuel pressure gauge in your bay aint gonna help you figure much out if youre dropping pressure at wot....gotta get some schit in the cabin.

edit one:
so if that fpr you gots dont fix the problem, and you want to get a fuel pressure gauge in there, get this...

http://www.42draftdesigns.com/categories/products/42hardware/fuelpressureadaptor.htm

then get in touch with me and ill get you an autometer setup. [up]

edit two:
better yet, now that i look at it, i can make that @ work with the fittings that we have. ill call you tomorrow once i see what i have.

[1fstavant]

lol life sucks balls big hairy ones....hopefully vw has the part i need tomarrow so i can check i mean it should be this considering when i opne the gas cap i dont hear any presure releasing, so im thinking i have a crapped out spring thats letting fuel return before necessary-idfk wanna help with that vr i got to put in my wagon need to stop driving this pos

[1fstavant]

nah i bought a 3bar fpr- o wait it was dented to shit and fucking a 4 bar haha there dumabsses there i swear

[Poopie]

nah i bought a 3bar fpr- o wait it was dented to shit and fucking a 4 bar haha there dumabsses there i swear

where did you order it? I though pretty much all places just modify a factory 4 bar FPR.

[1fstavant]

this place that is like a vw junkyard...tried cheaping out so now a trip to the dealers in order

[dougyfresh]

I wish i lived in New England, all the BATs are up there lol

haha [:D]

[zerb]

mocked up the dp this evening, yes...the floor is cut out for this reason, lol.

http://i39.photobucket.com/albums/e164/zerrb/DSC00334.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00335.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00336.jpg

cut this last 90 a biiiit to short, so that needs to get fixed and then another 90 will attach to that and go down the tunnel.
http://i39.photobucket.com/albums/e164/zerrb/DSC00337.jpg

[317ssayzarc]

Please tell me thats not mild Johnny... On the downpipe that is, I know the mani is 304

[zerb]

aluminized, sorry, lol. its not like its gonna rot out cause i wont be driving it in the cold months at all, and in the rain barely. so i went with aluminized from work

[317ssayzarc]

You suck...

[Poopie]

haha its not bad. part of my exhaust is aluminized

[317ssayzarc]

All 304 here... I declare non stainless plumbing non Audizine approved! [down]

[Poopie]

i approve all "home brew" and "git-r-done" style mods.

Take that!

[zerb]

jake, all the butt weld pipe cost me about $400. that was the head flange, t3 flange, pre-made collector, 12 inch straight piece, two tight radius 90's, five long radius 90's and five tight radius 45's.

[t1demont1]

wow im suprised you had to cut that much floor away. i thought the I5 was way longer than the I4, so i imagined youd have plenty of room.

[zerb]

was the floor cutting necessary, idk, maybe not. but with the tie rod setup in the b3 cars, its a bit tricky to get a downpipe in there(not that it hasnt been done because it has with very large turbos)...but unless you make the manifold so that the turbo sits a bit more towards the front of the car then mine does, and then you can snake a downpipe down under the axle and through the tunnel. so i just figured, to make it easier to put together and take apart, i did it the way i did it.

[317ssayzarc]

jake, all the butt weld pipe cost me about $400. that was the head flange, t3 flange, pre-made collector, 12 inch straight piece, two tight radius 90's, five long radius 90's and five tight radius 45's.

Very nice, I may be making my own manifold soon, this SPA in a bitch to A) put on/take off and B) build an oil return line for

[mike-2ptzero]

All 304 here... I declare non stainless plumbing non Audizine approved! [down]

Then you are going to hate my new exhaust when I get it done, 4" aluminum pipe after the down pipe. Its all about the weight. [>_<]

[zerb]

aluminum wouldve been just plain retarded cool, but im trying to save the pennies on the exhaust part, lol.

[zerb]

dropped the mani off to the welder this evening, should be done next week-ish. so i decided to take the motor apart and see what was up in the first place.

long story short, i built this thing last winter for my gti, power it made deemed it useless for fwd standards. i did not put locktite on the adjustable cam sprocket in the head (cat cams), it decided to wiggle loose one day, car sounded terrible so i shut it down, i replaced the piece that broke, and the car ran like ass, did a comp test, bad news, so i knew something was....fucked. anyways, this is what i found.

http://i39.photobucket.com/albums/e164/zerrb/DSC00338.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00340.jpg

theres one and three, two and four look just the same.

obviously bent some valves too, which would be easy to figure out once you saw the above pics.
http://i39.photobucket.com/albums/e164/zerrb/DSC00342.jpg

[Wizard-of-OD]

Those are stock John?

[zerb]

stock pistons, stock intakes, supertechs on the exhaust side....you sold em to me, so im assuming you meant the pistons.[>_<]

[zerb]

got the exhaust mani back today, yes...there is no external wg flange/tube on there yet. and yes....i am aware that i need one. looks pretty good if you ask me, will most likely be getting ceramic coated @ swain tech once the builds nears completion.

http://i39.photobucket.com/albums/e164/zerrb/DSC00364.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00366.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00367.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00368.jpg

[A4Rob]

wow that looks great. Nice work!

[bernB5]

might want to run it a bit before you coat it... just incase you find some weak points etc...

[zerb]

Thanks for the kinda words....and I'm not 100% sure that I'll be getting the manifold ceramic coated,it all depends on how finances go for the rest of the build....we'll see. I do plan on building some sort of tubo brace as well once I get the motor rebuilt and back n the car...

[zerb]

got the intake mani mostly done, just need to tap the throttle body adapter plate and that'll be going off to the welder this week. ill try and snap some pics of the baseplate welded to the runners as well before it all gets welded up, when i was there the other day it was done on the inside but he was waiting for the plenum to get there so he could weld that to the baseplate and then weld the outside of the runners to the baseplate. it looks freakin sweet, theres just no other words to describe it really...lol, pics...

http://i39.photobucket.com/albums/e164/zerrb/DSC00378.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00380.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00379.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00382.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00384.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00385.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00387.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00388.jpg

[1fstavant]

mani looks sweet zerb

[zerb]

Just got the intake mani back from welding, and i think it came out good. pretty much the exact way that i pictured it....aside from the fact that its not powder-coated yet. :-D

http://i39.photobucket.com/albums/e164/zerrb/DSC00391.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00394.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00395.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00397.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00398.jpg

[kovalevandrew]

That's simply awesome man! [up]

[michael66899]

Love it man, I definately plan on building my own exhaust and intake manifold this spring/summer, I'm in the vehicle research program at school and I have a lot of resources and programs that will aid in building the most efficient design. Last week we did some work with Burns exhaust working with variable length exhaust runners on our Formula car, (450 lbs, CBR600 motor). Can't wait to see some more pics man, I love watching people do all their own stuff. Good luck!

[audiFUEGO]

nice mani!

[zerb]

havent posted much, but have been working on the car alot.

mocked up what i would like to do to add a sump to my fuel tank, so i dont need to buy a fuel cell.

http://i39.photobucket.com/albums/e164/zerrb/DSC00435.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00441.jpg

also started to spray some of the sections of the bay that im done shaving with some primer this afternoon. let it be known that i have never dabbled in ANY type of body work prior to shaving this bay....so if it looks terrible (which i dont think it does) go easy....

http://i39.photobucket.com/albums/e164/zerrb/DSC00464.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00466.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00467.jpg

other then that, nothing that ive got pictures of. i DID however get my powdercoating setup to work though, so im sure ill have pics of EVERYTHING that i spray before it goes back onto the car.

[A4Rob]

Looks great!

[Siena]

Looking good.

[zerb]

wow....i havent updated this in a while, well, ive been busy. blocks bored out and sitting in my garage, waiting on the crank to get here and then ill be ready to rock. got some other things done though in the meantime.

custom built coilovers...
http://i39.photobucket.com/albums/e164/zerrb/DSC00540.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00543.jpg

fuel cell in ze trunk...
http://i39.photobucket.com/albums/e164/zerrb/DSC00503.jpg

and the cage thats slowly going in...
http://i39.photobucket.com/albums/e164/zerrb/DSC00669.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00670.jpg

[317ssayzarc]

Slacker [:D]

[zerb]

seat brackets....
http://i39.photobucket.com/albums/e164/zerrb/DSC00696.jpg

view from the rear...
http://i39.photobucket.com/albums/e164/zerrb/DSC00702.jpg

that panel in the middle will house all the gauges and other electronic things. then i will be making another panel for the tach/speedo in front of me.

[zerb]

got the block back from the machine shop. so since im waiting on the head thats still there and the crank i figured ill mock everything else up and start to get cracking so once i get the head back i can hopefully put it all together prior to waterfest.


http://i39.photobucket.com/albums/e164/zerrb/DSC00704.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00705.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00706.jpg

[b5a4gt28]

gl with the build Johnny. I love that exhaust mani.

[speeding-g60]

I'm in da house!!!!

[mike-2ptzero]

I'm in da house!!!!

Aaron I am going to guess by your other post on the BW thread.[>_<]

[speeding-g60]

ya. and since Johnny and i are in good contact with these B5 A4 based motor builds (hee hee) i figured to let 'im know i am here as well....

screw VWPoortex....

and thanks for the hook on the FX-700, Mike. cant wait to run it :D

[zerb]

got some dash stuff 90 percent done, just missing the speedo and the satin black powdercoat.
http://i39.photobucket.com/albums/e164/zerrb/DSC00714.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00715.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00716.jpg

and also starter the fuel system a bit....
http://i39.photobucket.com/albums/e164/zerrb/DSC00724.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00727.jpg

[Wizard-of-OD]

I approve.

[solowb5]

Why no velocity stacks!?

[zerb]

in the intake mani?

idk, i asked myself the same question. i guess it would have been something nice to do, i just opted not to do it. i may be making a different style intake mani once the build is nearing completion though, it all depends on how i want to put everything together in there so we'll see.

[solowb5]

I mean you have all these top end parts and you are running a turbulance creators(ie. the welds at the top of each runner inside) in your manifold. Just junk it bc I'd say the oem one is going to out flow that thing. Sad to say, but there has been alot of R&D with these. You need a nicely built I/M to pull any gains over stock. That is how well they are designed.

[zerb]

i am going to have to disagree with that. but thats just my personal opinion. i have seen people just hack up stock intake manis and weld a tube onto them and there are gains. im not saying that you arent correc that i should have velocity stacks in there but at the end of the day..... what i have>stock.

[zerb]

gauges.
http://i39.photobucket.com/albums/e164/zerrb/DSC00731.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00732.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00733.jpg

cage.
http://i39.photobucket.com/albums/e164/zerrb/DSC00730.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00729.jpg

[pipe7284]

its been a while since i havent been on thos thread, ad there has been alot of improvement!!!!! props to you my friend.

[mike-2ptzero]

Specs on the tube used for the cage?

[zerb]

1 5/8 mild steel. dont make fun of the welds, lol...all im getting done is the tacking part.

[mike-2ptzero]

1 5/8 mild steel. dont make fun of the welds, lol...all im getting done is the tacking part.

You will be tig welding all of it right? NHRA is just really picky about the safety stuff.

[zerb]

i was not planning on having it TIG'd no. is that whats supposed to be used when welding a cage together? if so i wasnt aware of that. i know a-rons cage is all migged, so thats what i was planning on doing.

[mike-2ptzero]

i was not planning on having it TIG'd no. is that whats supposed to be used when welding a cage together? if so i wasnt aware of that. i know a-rons cage is all migged, so thats what i was planning on doing.

It might be ok if you dont ever plan on running in the 9's, but to get it cerified it has to be tig welded. You can always talk to Aaron about it.

[speeding-g60]

the weld process is determined by the material used for the cage. we (Johnny and i) both went ERW cuz we cheap. at least i am haha.

but NHRA spec says chromoly need TIG'd, and ERW can go either way. and DOM should be TIG'd as well, but it is not spec'd on the NHRA rules....

i did not TIG my cage, and the inspector i spoke to on the phone said the rules spec what process to use when building. he said i would be fine with how i did mine. Chromoly is way more spendy, and a so-so weldor (yes weldor is a word; it defines the PERSON doing the welding, whereas welder is the machine doing the welding) can ruin lots of $$$ real fast if its not done right.



4:11 ROLL CAGE
Mandatory in all cars running quicker than 10.99 seconds or faster
than 135 mph, or per Class Requirements. Cars with unaltered
firewall, floor, and body (from firewall rearward, wheeltubs
permitted) running between 10.00 and 10.99, roll bar permitted in
place of roll cage, or per Class Requirements.
All cage structures must be designed in an attempt to protect the
driver from any angle, 360 degrees. All 4130 chrome moly (CM)
tube welding must be done by approved TIG heliarc process; mild
steel (MS) tube welding must be approved MIG wire feed or TIG
heliarc process. Welding must be free of slag and porosity. Any
grinding of welds prohibited. Additionally, roll cage must be padded
anywhere the driver’s helmet may contact it while in the driving
position.

PS: i study that damned rule book like nothing else..... and i built mine to certify to 8.50.

[zerb]

wow. i was unaware that was the case. i dont plan on running in the nines anytime soon, but if it happens i would like to be prepared for it.

well i feel better reading that then. i know you sent me that entire book, but asking you is waaaayyyyy easier, lol.

[speeding-g60]

i know you sent me that entire book, but asking you is waaaayyyyy easier, lol.

ASS..... [:D]

just kidding. i help when i can, especially if it is something i know like that.

[djwimbo]

I like how you're leaving the fake wood grain in.

Gotta keep is classy for the race track.

[zerb]

ya you like that?

you should wait and see til the wood grain shift knob goes in there.

[mike-2ptzero]

the weld process is determined by the material used for the cage. we (Johnny and i) both went ERW cuz we cheap. at least i am haha.

but NHRA spec says chromoly need TIG'd, and ERW can go either way. and DOM should be TIG'd as well, but it is not spec'd on the NHRA rules....

i did not TIG my cage, and the inspector i spoke to on the phone said the rules spec what process to use when building. he said i would be fine with how i did mine. Chromoly is way more spendy, and a so-so weldor (yes weldor is a word; it defines the PERSON doing the welding, whereas welder is the machine doing the welding) can ruin lots of $$$ real fast if its not done right.




PS: i study that damned rule book like nothing else..... and i built mine to certify to 8.50.

I also went DOM and mine is fully Tig'd.

[1fstavant]

wow zerb coming along real nice, cant wait for that thing to rip up the streets...unfortunately i will have nothing but a bike to watch with all the turbo goodies i sold off the gti to pay back some bills

[zerb]

rs2 bumper mounted, and the b4 hood is on there now too.

http://i39.photobucket.com/albums/e164/zerrb/DSC00746.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00747.jpg

[zerb]

got some stuff done, not going to make waterfest, but i will be shooting for fall SNG, we'll see.
dash and such
http://i39.photobucket.com/albums/e164/zerrb/DSC00753.jpg

intercooler piping mocked up.
http://i39.photobucket.com/albums/e164/zerrb/DSC00752.jpg

downpipe mocked up.
http://i39.photobucket.com/albums/e164/zerrb/DSC00761.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00762.jpg

solid shift linkage...will be used in conjunction with JHM shifter, for completely solid shifting.
http://i39.photobucket.com/albums/e164/zerrb/DSC00759.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00757.jpg

intercooler mounting.
http://i39.photobucket.com/albums/e164/zerrb/DSC00770.jpg

rad mounting, custom hoses, all AN fittings, custom t-stat housing.
http://i39.photobucket.com/albums/e164/zerrb/DSC00775.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00777.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00779.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00772.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00773.jpg

[Wizard-of-OD]

i see ABF

[B5A4Kevin]

really great progress. cant wait to see the finished product.

[mike-2ptzero]

Hey Johnny, are you going to be running a steering pump? I would love to lose mine but the water pump runs off the steering pump which means I would need to find a pulley to run the water pump right off the crank pulley.

[speeding-g60]

Mike, for 058 block setup you ditch the PS, run a VR6 water pump pulley, and like a 38.5" belt, 5 rib. this is what i did on the rabbit.

http://i86.photobucket.com/albums/k81/gtipix/rabbit%20habit/waterpumpbelt1.jpg

http://i86.photobucket.com/albums/k81/gtipix/rabbit%20habit/waterpumpbelt2.jpg

[mike-2ptzero]

Mike, for 058 block setup you ditch the PS, run a VR6 water pump pulley, and like a 38.5" belt, 5 rib. this is what i did on the rabbit.

http://i86.photobucket.com/albums/k81/gtipix/rabbit%20habit/waterpumpbelt1.jpg

http://i86.photobucket.com/albums/k81/gtipix/rabbit%20habit/waterpumpbelt2.jpg

Pefect and I already run a electric fan.

Do you know where I can pick up that VR6 pulley?

[speeding-g60]

its just a factory pulley, any MK3 VR6... or Issam sells an aluminum one that i run right now.

your belt length may be a lil tiny bit different, notice that was with an UR aluminum pulley, not factory balancer.

[zerb]

i am running power steering, the rack i have has female threads in it, 14x1.5 oringed, so i just got adapters from work to go from that to say -6an male, then i will just make hoses to go from there to the pump and ill be set. ill also have a ps fluid res that has the an fittings welded onto it, so all the hoses will be -6. idk what im going to do about the banjo side of the lines, the pump side. but if worse comes to worse i can always chop them out and get -an fittings welded onto them.

[mike-2ptzero]

its just a factory pulley, any MK3 VR6... or Issam sells an aluminum one that i run right now.

your belt length may be a lil tiny bit different, notice that was with an UR aluminum pulley, not factory balancer.

Cool, I will just have to look around for a MK4 VR6 pulley or hit up 034. Thanks.

[speeding-g60]

Mike, YGPM

[zerb]

heres my plan as of this morning. i attempted to make the ABF alternator fit, but i didnt really want to cause there wasnt a whole lot of adjustability there, and if the thing were to ever shit the bed, they arent easily found.

so i made a plate to move the tensioner down a bit, and now i just have to fab something up to get the bottom bolt of the alternator to bolt to....something. i have a few ideas in my head, ive just gotta go get some more materials to see if itll work. i would rather NOT weld to the mount bracket, but if that ends up happening that way then oh well. i want to try and get something that would be removable if need be.

this was the initial plate, but i found it to be too thin so i just used this as a template for whats bolted on there now.
http://i39.photobucket.com/albums/e164/zerrb/DSC00787.jpg

http://i39.photobucket.com/albums/e164/zerrb/DSC00788.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00789.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00790.jpg

[Wizard-of-OD]

Cool, I will just have to look around for a MK4 VR6 pulley or hit up 034. Thanks.
And then what will you do about your power steering...

[zerb]

gauges, battery, ecu mount, wire tuck. still chipping away....shooting for fall show and go.

http://i39.photobucket.com/albums/e164/zerrb/DSC00798.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00802.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00805.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00808.jpg

[mike-2ptzero]

Johnny are you going to end up putting that battery in a sealed box?

[zerb]

hellllllll ya mike. its just a pain in the ass to do that now. so thats near the bottom of the 'to do' list.

[1fstavant]

keeps lookin better and better

[zerb]

so put the engine bay pretty much together today. looking pretty good me thinks. going to hopefully make a catch can this week, and thats all that i still need to make make. maybe ill even get my fuel rail back from being machined and then i can run the fuel lines up in the bay before i pull the motor out, we'll see.

still need to make an upper mount for the rad.
http://i39.photobucket.com/albums/e164/zerrb/DSC00850.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00851.jpg

oil cooler line fittings.
http://i39.photobucket.com/albums/e164/zerrb/DSC00854.jpg

rad hoses.
http://i39.photobucket.com/albums/e164/zerrb/DSC00855.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00856.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00857.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00859.jpg

[zerb]

got my breather setup pretty done. just need to send the thing off to get welded all up and then find another point to mount it to as well cause its a bit flimsy with just those two tabs holding it on the rain tray there.

this was my first experience with ss braided twist on hose ends, i mainly just deal with the stuff you cut to length put in a large press at work and crimp it on, and i will have to say.....that twist ends suck major.

anyway, making a relay panel hopefully this evening. then perhaps running the harness in the bay to get that all set to go. few minor things like making ss brake line and mounting my blow off valve and wastegate still need to be done. and then once i get my fuel rail back i can get that all situated.

http://i39.photobucket.com/albums/e164/zerrb/DSC00869.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00870.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00871.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00872.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00873.jpg

[jsquillz22]

looks good man, are you planning on painting it red again?

[zerb]

been doing a bit lately, cars ready for the cage to get all welded in and then its getting a full respray...which will not be the stock tornado red. got some wiring pics, custom fuel rail stuff, some circuit breaker stuffs, some custom front tie rod pics, some rear suspension pics on the ground, etc...

edit, yes i know i need to make brackets to mount the fuel rail to the manifold. and yes, the battery will be in a box at the end of all of this.

http://i39.photobucket.com/albums/e164/zerrb/DSC00930.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00932.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00933.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00919.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00913.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00911.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00914.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00917.jpg\
http://i39.photobucket.com/albums/e164/zerrb/DSC00918.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00894.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00898.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00899.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00889.jpg

[Jake39454]

Yea Jonny! I'll see you at sng brotha!

[NYEuroTuner]

Great Build.



Subscribed. [up]

[pja0750]

Looks fun man, you gotta post up some videos I wanna hear this thing run [:)]

[zerb]

so, ive been alive, just havent done too much with the car. got the fuel rail made, and got the cage all welded in and painted up, and the engine harness all finished... next is off to my pal to get a full respray, then its assembly time, after i powdercoat about 100 things.

http://i39.photobucket.com/albums/e164/zerrb/DSC00952.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00954.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00955.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00957.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00959.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00960.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00963.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00961.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00964.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC00965.jpg

[Jc61990]

looks like a good build [up]

cant wait to see the end result

[dwi_gti]

hope the welds on that cage pass tech, does the 1.8t block bolt up to the stock 90 trans with out a adapter plate? does that trans take the same clutch a b5 a4 would?

[zerb]

those welds will pass tech just fine.

and the stock 90 trans is just an 01a, so it bolts up just fine. uses an audi a4 1.8t starter and uses same clutch.

[zerb]

car is almost ready for paint, gotta do a bit more sanding first. started motor pre-assembly last weekend (gapping rings making sure rods and pistons all weighed the same). hoping to get paint in the next few weeks, and have the motor all assembled by then. after that, its assembly time, oh and i gotta make tranny mounts to get the 01e from my buds b5s4 parts car in my car.

pics of car, powdercoated stuff, vbanded stuff, other stuff

oh, and i got a new turbo 6765 .82 a/r [:D]
http://i39.photobucket.com/albums/e164/zerrb/DSC01090.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01091.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01053.jpg

intake mani/fuel rail
http://i39.photobucket.com/albums/e164/zerrb/DSC01079.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01080.jpg

new stainless allen socket head bolts for everything the eye can see, cause SS + satin black = a good time
http://i39.photobucket.com/albums/e164/zerrb/DSC01081.jpg

front end pretty much ready to rock for paint
http://i39.photobucket.com/albums/e164/zerrb/DSC01082.jpg

bay spray bombed
http://i39.photobucket.com/albums/e164/zerrb/DSC01072.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01073.jpg

coolant overflow, power steering rez, 044 bracket setup
http://i39.photobucket.com/albums/e164/zerrb/DSC01076.jpg

decided to run a side exit instead of dealing with the rear exit bs, and didnt want a pipe just dangling neither so...
http://i39.photobucket.com/albums/e164/zerrb/DSC01031.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01025.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01029.jpg

it has been clearanced more since then around the pipe, but i assume you'sll get the jist

side exit pipe
http://i39.photobucket.com/albums/e164/zerrb/DSC01059.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01061.jpg

vbanded 70mm bbk throttle body (which has since been powdercoated to match the rest of the bay)
http://i39.photobucket.com/albums/e164/zerrb/DSC01065.jpg

[A4Rob]

Wow your really going all out! nice update

[O2VW1.8T]

Damn dude that is looking GOOD.. 6765 is a monster, thats what i want for my VR... Should make some nasty power.

[BenjaminR]

Looking slick! I like your style.

[zerb]

car is almost ready for paint on ze outside. fuel system setup was finished up the other day.....

http://i39.photobucket.com/albums/e164/zerrb/DSC01108.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01109.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01110.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01111.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01112.jpg

high volume low pressure, 8 psi, pump pulls from the bottom of the cell and feeds the surge tank. i did a bunch of calculations to get the size i wanted...and i now forget the capacity of the thing. two 044's pull from the bottom of it. fuel rail return empties back into the top of the surge tank, and there is also an overflow from the top of the surge tank into the top of the fuel cell. -8 ss line in the entire system, everywhere.

[zerb]

fuel system all done up. matte black vinyl wrapped the car. cage is all finished, had to do the door bars and drivers seat back mount. re did the bumper/intercooler/rad mount up front. now i can pop the bumper off in about 10 seconds by undoing some dzus fittings and then the intercooler, rad, etc is all right there for me. the initial setup sucked balls cause the bumper was actually molded into the rad/ic mount (stupid idea looking back) ALSO a stupid idea, was the intake manifold, it sure looked cool powdercoated, but it was going to suck nuts for flow. so thats been re-done too. bit of the rmr d plenum, custom formed velocity stacks, shortened runner length about 2 inches. waiting on that, and then waiting on a custom Cometic head gasket to show up and the motor will be in the car. mounted the five speed 01e in the car, and also re-did the motor mounts...ended up going solid to the frame since i made the motor mounts that way. also made a nice custom solid shift linkage upgrade for the 01e trans. looked at the JHM piece for a while, poked around in some books at work, showed my welding buddy, and had it done in a week.

vinyl
http://i39.photobucket.com/albums/e164/zerrb/DSC01149.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01151.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0210.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0212.jpg

finished fuel lines...
http://i39.photobucket.com/albums/e164/zerrb/IMG_0286.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0287.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0288.jpg

custom solid 01e shift linkage...
http://i39.photobucket.com/albums/e164/zerrb/73a84b89.jpg
http://i39.photobucket.com/albums/e164/zerrb/474c0929.jpg
http://i39.photobucket.com/albums/e164/zerrb/1a29a98f.jpg
http://i39.photobucket.com/albums/e164/zerrb/7ca98db7.jpg
http://i39.photobucket.com/albums/e164/zerrb/798efd71.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0354.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0355.jpg


dzus fitting bumper, new ic/rad mount...
http://i39.photobucket.com/albums/e164/zerrb/36d0dbf7.jpg
http://i39.photobucket.com/albums/e164/zerrb/32c5e791.jpg
http://i39.photobucket.com/albums/e164/zerrb/f26e35e2.jpg
http://i39.photobucket.com/albums/e164/zerrb/7f2e76c8.jpg
http://i39.photobucket.com/albums/e164/zerrb/ef193858.jpg


new intake manifold...
http://i39.photobucket.com/albums/e164/zerrb/06bcf7ae.jpg
http://i39.photobucket.com/albums/e164/zerrb/c3a900f2.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01156.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01162.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01164.jpg

[Lowdaily]

I like the Exhaust mani looks nicely welded, i also liked the first intake mani now a second one its just truely awesome good work wish mine looked like that. Awesome build vids on youtube when done i won't beable to see it rolling otherwise!

[zerb]

manifold pretty much complete. i think it came out amazing. my friend took the time when he welded the pieces all together to polish the inside of the weld so everything in the manifold is nice and smooth. same with the outside on the top, it almost looks like its completely one piece.

http://i39.photobucket.com/albums/e164/zerrb/c39bf608.jpg
http://i39.photobucket.com/albums/e164/zerrb/2a46e9c3.jpg
http://i39.photobucket.com/albums/e164/zerrb/08a3480b.jpg

and the bbk 75mm throttle body with half of the Vibrant vanjen clamp welded to it.
http://i39.photobucket.com/albums/e164/zerrb/b290b20c.jpg

[Lowdaily]

Make me one please thats awesome!!!!

[zerb]

so. FINALLY got all the pieces together for my motor assembly this evening. the breakdown list is at the beginning of the thread but here is is regardless.

83.5mm JE pistons 8.5:1ish comp
SCAT connecting rods
Calico coated main bearings
Calico coated +.001 rod bearings
Cat hydraulic cams. 3652 intake custom ground exhaust
AEG cast crank
ARP main studs
ARP head bolts
AEB head (stock port)
Integrated Engineering manual tensioner roller
16v style manual timing belt tensioner
Gates Blue timing belt
Custom Cometic 84mm bore .051 headgasket
Other random little odd things....onto the pics

tack welded oil pump gear bolt
http://i39.photobucket.com/albums/e164/zerrb/cf013aea.jpg

tack welded crank trigger bolts
http://i39.photobucket.com/albums/e164/zerrb/2593c782.jpg

TDC stopper.
http://i39.photobucket.com/albums/e164/zerrb/6892e856.jpg

TDC wheel setup
http://i39.photobucket.com/albums/e164/zerrb/84d15272.jpg

Custom Pinned Crank Timing Gear
http://i39.photobucket.com/albums/e164/zerrb/2a9b8327.jpg

Cometic 84mm headgasket
http://i39.photobucket.com/albums/e164/zerrb/23dcaf1a.jpg

ARP SS exhaust manifold studs
http://i39.photobucket.com/albums/e164/zerrb/3c1d4451.jpg

Pretty much buttoned up, missing the manual tensioner and timing belt. oh, and the oil pan.
http://i39.photobucket.com/albums/e164/zerrb/e1cd0469.jpg

hopefully will get that finished this weekend, and may have a motor in my car this coming week. have to finish making a few things hopefully first while the motor sits, downpipe and ic piping. then once it goes in i can bolt everything together, finish some wiring, and hope for the best.

[zerb]

Ok, so ive been doing alot of everything....i tend to jump all around at this part in time of the project.

friend of mine made 662whp on his t3 6765 .82a/r (pretty much balls on exact setup as mine) on a quick dyno tune, which is impressive, but i was personally hoping for more. he decided to go to a t4 housing, .91 to be exact. after he got it on, i saw some vids, he told me the spool was still ridiculous for a 67mm turbo, so i hopped on the t4 bandwagon. and thus where i sit as of now.

brake booster is in, rough brake line running just to make sure i have enough line here. made a little bracket for the aftermarket adjustable proportioning valve for the rear brakes.
http://i39.photobucket.com/albums/e164/zerrb/DSC01173.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01174.jpg

had a pipe thread fitting welded to the booster for the vac line that feeds it. ALLLLLLLL vac/boost lines are push to connect tubing, 18 wheeler air brake tubing to be exact. pain in the nutters to get all the fittings correct, especially that 1/16th NPT on the aeromotive fpr, but in the end its worth it to have no, hopefully, boost/vac leaks. and an easy assemble/disassemble setup
http://i39.photobucket.com/albums/e164/zerrb/DSC01172.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01176.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01175.jpg

saw a thread on here the other day about dash material and flocking. hadnt a freaking clue as to what it was, but it sure looked sweet. made some calls the next day at work to one of our distributors and had the stuff in a few days to flock the dashboard. not the toughest thing in the world at all to be honest, messy though. didnt come out perfect perfect, but for a first time attempt im satisfied, it sure feels cool.
http://i39.photobucket.com/albums/e164/zerrb/DSC01171.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01170.jpg
http://i39.photobucket.com/albums/e164/zerrb/6304a87f.jpg
http://i39.photobucket.com/albums/e164/zerrb/dc819776.jpg

figured out my manual serp belt tensioner setup and got the parts today, thanks to mcmaster carr. should work out pretty well, just gotta get some belts in the size range that i need tomorrow and ill make sure that all works out nicely. didnt use the stock mounting hole for the alternator, drilled a hole about 1/2 inch behind it and then ground down the opposite side where the bolt comes out to get a nut in there, needed to do that to get the room for the tensioner setup to be far enough back that i could tension it out once a belt got on there. needed a spacer bushing so i ended up finding a nice assortment of door hinge pin bushings this afternoon at work and one happened to work out pretty much perfectly.
http://i39.photobucket.com/albums/e164/zerrb/DSC01182.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01184.jpg

last but not least, the new tubular manifold with a t4 flange, which will have the t4 .81 6765 on it and a turbosmart 50mm pro gate attached to it (somehow)
http://i39.photobucket.com/albums/e164/zerrb/DSC01180.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01179.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01178.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01177.jpg

[zerb]

mocked up the downpipe yesterday and handed my buddy the turbo housing so i could get the vband welded to it so that i could finalize the downpipe this evening. just got a text with this in it....
http://i39.photobucket.com/albums/e164/zerrb/6707bfa3.jpg

so hopefully tonight ill be able to finish up the downpipe and fender hole and then figure out how im going to mount that thing to the body. WANTED to dump the external wastegate into the downpipe but im not too sure that will happen with the space i have, i dont want it to look hookey NOR do i want to have a 90 degree elbow dumping into the donwpipe cause im sure that wouldnt be good for exhaust flow.

http://i39.photobucket.com/albums/e164/zerrb/f2d995c5.jpg
http://i39.photobucket.com/albums/e164/zerrb/fac265f8.jpg
http://i39.photobucket.com/albums/e164/zerrb/45eb25c0.jpg
http://i39.photobucket.com/albums/e164/zerrb/51720d2d.jpg
http://i39.photobucket.com/albums/e164/zerrb/ba2f211c.jpg

[Derv]

dude... thats fucking sick.

[ThatA4T]

crazy build we need more progress! where have u gone?

[ZimbutheMonkey]

Yeah, that's about one of the most bad ass builds I've ever seen. Mad fabrication skills and thinking outside the box, regardless of where the OP went, it's still a sick build.

[zerb]

still around, almost time to fire it up actually....

so, i got my exhaust manifold back so i decided to put in some work today. everything fit back up perfectly so far, the turbo flange got pretty warped when it was welded so i have to get that machined hopefully within the next few days here at the local machine shop. after that gets back i just have to re do the wastegate dump on the one side and i should be all done after that as far as welding/fabrication goes. hopefully once the flange gets machined it doesnt throw the downpipe orientation outta whack too much, or else ill have to doinga bit of cutting and re-welding there too. enough talk, onto the pics...

first off, i re did the outter heim on the tie rods because when the car was off the ground they would interfere with the strut arm itself.
http://i39.photobucket.com/albums/e164/zerrb/DSC01249.jpg

hole in the inner fender for the intercooler pipe, both pipes are one piece with Vibrant VAN-Jen clamps on all connections, more pics on those below.
http://i39.photobucket.com/albums/e164/zerrb/DSC01246.jpg

Vibrant Van-Jen clamps, kinda like a vband, kinda like a wiggins i guess from the pictures that ive seen of them, kinda like pretty fucking cool and surprisingly easy to work with.
you first weld the two ends to whatever it is youre connecting...
http://i39.photobucket.com/albums/e164/zerrb/DSC01239.jpg

then this sleeve goes over both ends
http://i39.photobucket.com/albums/e164/zerrb/DSC01240.jpg

the clamp goes over the sleeve
http://i39.photobucket.com/albums/e164/zerrb/DSC01241.jpg

you latch that bastid down and....VIOLA!!
http://i39.photobucket.com/albums/e164/zerrb/DSC01242.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01243.jpg

they will allow for 12 degrees of misalignment, but all the connections i have are straight balls on with maybe 2 degrees max of misalignment, hopefully they keep everything together

my new Turbosmart race port blow off valve
http://i39.photobucket.com/albums/e164/zerrb/DSC01223.jpg

close up of the power steering hose setup
http://i39.photobucket.com/albums/e164/zerrb/DSC01219.jpg

Accessory bracket setup with the manual tensioned alternator
http://i39.photobucket.com/albums/e164/zerrb/DSC01217.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01218.jpg

the exhaust manifold
http://i39.photobucket.com/albums/e164/zerrb/DSC01224.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01225.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01226.jpg

the 'downpipe', if you can even call it that.
http://i39.photobucket.com/albums/e164/zerrb/DSC01228.jpg

and onto my FAVORITE part of the engine bay that a few of my good friends despise, but i adore.

neon pink.

http://i39.photobucket.com/albums/e164/zerrb/DSC01230.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01232.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01233.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01234.jpg
http://i39.photobucket.com/albums/e164/zerrb/DSC01237.jpg

[zdriver]

so badass, I wanna hear this thing fire up

[Ldiaz12]

Can I buy your car?

[zerb]

Can I buy your car?

maybe once im done with it, lol

[[email protected].]

LOVE IT.

[ThatA4T]

yes! your back keep us posted

[Dan[FN]6262]

I love this build.

[Doctor]

5857;6198059']I love this build.

Who doesnt. :)

[zerb]

Hey thanks! That's nice to hear. Hopefully it'll be running soon, which will make me for one love it even more.

[ZimbutheMonkey]

Absolutely BADASS!!! Fire that bitch up.

[BenjaminR]

http://i39.photobucket.com/albums/e164/zerrb/DSC01232.jpg

Hot pink brings the awesomeness!

[the_pirate]

Oh wow….I want your skillzzzzz. Sick build dude.

[ECS Tuning-Audi]

I wish there was a like button so I could click it every day!

Great job!

Keep up the good work!!

Pete

[AudiA4_20T]

Yes

[zerb]

car fired up the other evening, i have an awful iphone video that a friend took and thats all. this is the second fire up.

http://www.youtube.com/watch?v=HNi0UxGyPzo

the idle was still high cause we set the idle screw on the throttle body so the motor sat at 2k rpm for the initial break in and i didnt have to hold the throttle.

[Snow]

Unbelievable.. What a monster. Interested in numbers so keep us updated

[zerb]

car moves now....

http://www.youtube.com/watch?v=R7GzPMd6mNA

[coolgraymemo]

soo dope!

[A4Rob]

I am amazed at how well you have built this car. I got your PM, I will respond later tonight.

Rob

[zerb]

Thanks man!

http://i39.photobucket.com/albums/e164/zerrb/fcd2a9a4.jpg

[ThatA4T]

we need more videos!

[zerb]

http://www.youtube.com/watch?v=y1RYT7WV1-M

[ThatA4T]

yes!

[diabolical1]

great build and i like the fact that you went old school with the chassis choice! usually, i call bullshit on the whole "i-built-it-to-be-unique"-thing, but i must admit that in this particular case ... i'm a believer! also, the fact that you did som much of the work yourself gets you extra, extra thumbs up and respect from me (but really, who am i? [:)]). pat yourself of on the back for a job very well done!

any metrics on it yet?

[zerb]

no dyno as of yet. its moving along pretty good for a street tune, 28 psi at the moment, and really not so much timing up top at all (especially with how low the comp is on the motor). hoping to hit the rollers sometime soon (and stop at the hp i set my personal goal at because i only need to much to run the times that im shooting for and dont need a dyno queen number) and then off to the track, but you break things there and for right now im just trying to enjoy it and drive it.

on that note.....350Z TT, 18g's, built motor, trans work, fueling,etc. made somewhere over 600 @ the wheels on the dyno on 93 octane according to the owner. my car was all over the road first pull...it was only the second or third time i actually went balls deep with 28psi. second run i was a little more expecting of what was going to happen, and how fast the damn rev limiter comes up, lol.


http://www.youtube.com/watch?v=u02GGSs1zLY&lc=tnQKuEOSAcGY8AO-FEj19o__rgtXhLG7wsM_a6o4LlA&feature=inbox

[Dan[FN]6262]

seen this over on Vortex [up]

car really hauls ass.

[speeding-g60]

ummm, so why hasnt the XXX AWHP video been popped up here??? hmmmm?

[Dan[FN]6262]

ummm, so why hasnt the XXX AWHP video been popped up here??? hmmmm?

I was wondering exactly that.....



I'm also curious as to why no numbers have been posted.... [:(]

[034Motorsport]

I'll take an update!

[speeding-g60]

numbers been posted on Kotex Dan. 648 AWHP. 38 psi. 8200 rpm.

[Dan[FN]6262]

numbers been posted on Kotex Dan. 648 AWHP. 38 psi. 8200 rpm.

Sorry, I rarely go venture in there.

Good numbers though!

[speeding-g60]

5857;6845029']Sorry, I rarely go venture in there.

Good numbers though!

are you not DanA4 over there? whoever that was posted this:


in for results :thumbup::thumbup::thumbup:

cuz the results were there three times or so on that page??? [confused] [confused] [confused]


http://www.youtube.com/watch?v=ubrmlgnC7sE

[Dan[FN]6262]

lmao yes that is me. and I obviously need to work on my skimming skills.

[viceprp]

Dan woke me out of bed to share this with.. his exact words "there is a 20v stuffed into a 90.. mmm I'm touching myself"..,kidding but seriously.. he did. Very sick build and look forward to some unsafe boost levels!

[zerb]

there is nothing unsafe about 40+ psi, hahaha.

we made 648awhp and 508tq last hit. if we had more time we would have pumped 40+ psi into it.


baseline pull with a street tune was 28psi and we made in the neighborhood of 440ish whp and 380ft lbs. we made the above numbers just cranking 10 more psi into it and making sure the fuel was there.

[Dan[FN]6262]

1.8T nevah loses!!!

[M-Hood]

Johnny will you be posting up a dyno plot? I would love to see how your power band compares to my GT35r since both are making about the same hp/tq at the wheels pushing right around the same boost.

[zerb]

Kevin has the files, at least I think I pulled the right ones off the dyno computer the other day for him. He's just at the Pitts race this weekend so hopefully I'll have a graph tomorrow or Tuesday. I have the printout from the last pull on paper, but no scanner.

The power peaks at 7300ish then it drops off a few hp til we let out of it, 8200ish. I wish I weighed the car prior to getting on the dyno, because the weight you tell the program obviously is used to load the rollers accordingly, and I know we shot high for the weight. Because I would rather have a lower number, then something that just didn't make sense.

[M-Hood]

Kevin has the files, at least I think I pulled the right ones off the dyno computer the other day for him. He's just at the Pitts race this weekend so hopefully I'll have a graph tomorrow or Tuesday. I have the printout from the last pull on paper, but no scanner.

The power peaks at 7300ish then it drops off a few hp til we let out of it, 8200ish. I wish I weighed the car prior to getting on the dyno, because the weight you tell the program obviously is used to load the rollers accordingly, and I know we shot high for the weight. Because I would rather have a lower number, then something that just didn't make sense.

Well you can always just take a picture of it and email it to me directly.

[zerb]

car made fall show and go a few weeks ago. got 4 passes in, learned that i can't launch an add car to save my life, but had fun for my first 4 passes ever down the track. best et was 11.1, best mph was 136.8. street tires, falken rt615's. hoping to get to the track one more time before the years out and see if i can't get into the 10s on street tires. then spring time, hello hoosiers.


http://www.youtube.com/watch?v=pWyHd6peh5g

[M-Hood]

You should be able to get into the 10's on those tires, those are better then the all season Falken tires that were on the Eurocode S4 when I ran 10.8 with it. It will just take some practice to get used to launching the car.

[zerb]

I think I can do it too, staged boost would be cool too...boost vs wheel speed, I just haven't set it up yet. Thats on the list of things to do over winter.

[ThatA4T]

very nice!

[zerb]

very nice!

Thanks! We are gonna try for 10s this Sunday hopefully.

[Don Supreme]

Thanks! We are gonna try for 10s this Sunday hopefully.

Good luck man..

[zerb]

Its looking like we are going to have to wait til next year. Fucking SNOW is coming tomorrow allday here, and this was lebanons last test and tune of the season. Oh well.

[speeding-g60]

put it on snows and BOOST THAT SHIT!!!!!!

[zerb]

some revisions for winter have started.

got the manifold pretty complete today, at least the runners are done. just need to figure out how i want to run the intercooler piping and then i can see where i want to put the waste gate and either dump it or reroute it. came out pretty much balls on as i wanted it to. need to just put a few bungs here and there for the get probes and the back pressure sensor and then the waste gate tube and it will be complete. oh, need to get some thread inserts in the bottom two holes of the turbo flange as well because of the angle i ground the collector down at there just isn't a possible way to get a nut/bolt in there, jet nut even isn't going to cut it.

http://i39.photobucket.com/albums/e164/zerrb/5cf366cd.jpg
http://i39.photobucket.com/albums/e164/zerrb/779b6ac1.jpg
http://i39.photobucket.com/albums/e164/zerrb/41ec4e47.jpg
http://i39.photobucket.com/albums/e164/zerrb/03905249.jpg
http://i39.photobucket.com/albums/e164/zerrb/ef734b46.jpg
http://i39.photobucket.com/albums/e164/zerrb/2b467c5c.jpg


now the question is to either run the down pipe over or under the steering arm. it will fit either way with room to spare, but I'm still just not sure HOW i want to run it. i like it under the arm for looks but i don't really want a tight 90 right out of the turbo.

http://i39.photobucket.com/albums/e164/zerrb/d806fad1.jpg
http://i39.photobucket.com/albums/e164/zerrb/d68010cf.jpg
http://i39.photobucket.com/albums/e164/zerrb/b4443807.jpg

[speeding-g60]

you'll finish this one, and start a new one before next season. then scramble to finish #4 in time for opening day at the track. i just know it.

[zerb]

NO WAY! i can honestly say this time around i like the way this one came out very much so and i think it will be the last one i make for this chassis.

...but you know me.

[M-Hood]

you'll finish this one, and start a new one before next season. then scramble to finish #4 in time for opening day at the track. i just know it.

He likes making manifolds like you like building new motors. [;)]

You 2 need to head to vegas with your cars so we can do some racing this weekend in 50 deg temps with full sunshine. [drive]

[speeding-g60]

awwww snap. he went there!

neither of our cars run right now. but you let me know, i will watch it on 1320go.... just tell me your number!

[M-Hood]

awwww snap. he went there!

neither of our cars run right now. but you let me know, i will watch it on 1320go.... just tell me your number!

I still have my number on the car from the IFO event at Fontana, will have to see if they let me use that again.

#2932

[Doctor]

Lucky guys you over there . . . with tracks to enjoy your cars . . .

[zerb]

i dont need no track to drive my car!

[M-Hood]

i dont need no track to drive my car!

No he is just saying we are lucky to have actual race tracks to race our cars, he lives in Greece. His daily driver A4 1.8t has a 6262 on it.

[nunya]

Uh oh, its a precision turbo.... queue Dan[FN]5857 for his "input". :-)

Nice work Zerb.

--dillon

[zerb]

whats wrong with PTE turbos?

[M-Hood]

A good amount of A4 1.8t owners have had their Journal Bearing PTE's fail.

[Doctor]

No he is just saying we are lucky to have actual race tracks to race our cars, he lives in Greece. His daily driver A4 1.8t has a 6262 on it.

Yeah, I thought it was clear what I meant. I need to improve my english more, LoL


A good amount of A4 1.8t owners have had their Journal Bearing PTE's fail.

There might be another connection of PTEs to B7 chassis hahhaha [wrench][drool][:p]

[zerb]

put the old wheels on and dropped the rear of the car on the ground just to see what was what, i THINK i can get the wheel/tire combo i am looking to get under there now, but we will see. according to all of the wheel/tire calcs i use online it will be close. I'm going to get a tire hopefully from my buddy who works at the local tire shop sometime this week and then we will get that mounted on the one rim i have and see how it looks.

i tried to space the wheel/tire combo i have now out from the hub to get it to sit about where the wider setup will, but the studs are too short.

http://i39.photobucket.com/albums/e164/zerrb/835f3962.jpg
http://i39.photobucket.com/albums/e164/zerrb/b22212be.jpg
http://i39.photobucket.com/albums/e164/zerrb/876a5a01.jpg
http://i39.photobucket.com/albums/e164/zerrb/2d7d316f.jpg

[zerb]

Well. Got the test fit tire today. And all is well. They fit in the rear under tr fender and they fit in the front without rubbing on the steering shit. I = stoked.
http://i39.photobucket.com/albums/e164/zerrb/07cbd4d0.jpg
http://i39.photobucket.com/albums/e164/zerrb/ac9c0088.jpg
http://i39.photobucket.com/albums/e164/zerrb/e082ce9f.jpg
http://i39.photobucket.com/albums/e164/zerrb/359c7ff5.jpg
http://i39.photobucket.com/albums/e164/zerrb/44f35131.jpg
http://i39.photobucket.com/albums/e164/zerrb/c3fbc025.jpg
http://i39.photobucket.com/albums/e164/zerrb/c468c505.jpg

[zerb]

so, 4 inch pipes weren't really meant to go under these chassis, even with the custom tunnel to go directly over the passenger side transmission mount its still a mother****** to keep things tight to the body, luckily the car won't be slammed or else this would be a major problem here, we will see. going to try and oval the aluminum straight section of the exhaust to allow for more ground clearance perhaps, need to get it on the ground first and see where we are at.

http://i39.photobucket.com/albums/e164/zerrb/11e4aa16.jpg

i will get that 4" pipe over the rear diff mount and out the back of the car. by oval-ing it. this was a thicker gauge piece that i had lying around, but you get the idea.
http://i39.photobucket.com/albums/e164/zerrb/1f0542db.jpg
http://i39.photobucket.com/albums/e164/zerrb/7bc0bb5b.jpg

got the passenger side IC pipe done too.
http://i39.photobucket.com/albums/e164/zerrb/c9968d6c.jpg
http://i39.photobucket.com/albums/e164/zerrb/e293e4de.jpg
http://i39.photobucket.com/albums/e164/zerrb/f3089c9e.jpg
http://i39.photobucket.com/albums/e164/zerrb/ca970089.jpg
http://i39.photobucket.com/albums/e164/zerrb/4d61b4d8.jpg
http://i39.photobucket.com/albums/e164/zerrb/a1ba8dce.jpg
http://i39.photobucket.com/albums/e164/zerrb/e2b2b60d.jpg
http://i39.photobucket.com/albums/e164/zerrb/38d0e465.jpg

[Dan[FN]6262]

this will sound so gnarly...

[zerb]

I haven't decided on straight pipe or muffler as of yet. We shall see.

[zerb]

bay getting there slowly but surely.

http://i39.photobucket.com/albums/e164/zerrb/68c143f9.jpg
http://i39.photobucket.com/albums/e164/zerrb/6451fed7.jpg
http://i39.photobucket.com/albums/e164/zerrb/7277fb43.jpg
http://i39.photobucket.com/albums/e164/zerrb/5633c285.jpg

[s3apra4]

Nice color contrast!!! [up]

[zerb]

Thank you. Its really starting to look goo as its all coming together. I feel like much less of an asshole too for spending a bunch of money on all black hardware, lol.

[zerb]

http://i39.photobucket.com/albums/e164/zerrb/97c0062a.jpg
http://i39.photobucket.com/albums/e164/zerrb/22cda801.jpg
http://i39.photobucket.com/albums/e164/zerrb/4fb84c2a.jpg

[howardfootball]

Diggin' it man. Can't wait to see this thing run.

[Clewe]

So sick, can't wait to see the outcome.

[zerb]

getting closer.
http://i39.photobucket.com/albums/e164/zerrb/209bdecf.jpg
http://i39.photobucket.com/albums/e164/zerrb/ee9747ca.jpg
http://i39.photobucket.com/albums/e164/zerrb/6ffa565b.jpg

[zerb]

finally got the exhaust squared away today with the help of a friend, who will be welding it up tomorrow hopefully. once thats done, the car is 95% complete. wires just need to be connected in the interior for gauges and ecu stuffs. shifter needs installed. brakes bled. fluids put in the motor. and then its go time. oh, and then to just finish up some bondo sanding before painting the car. PUSHING, hard to boot, to make it to wateriest next sunday, but we shall see.

http://i39.photobucket.com/albums/e164/zerrb/IMG_0279.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0280.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0284-1.jpg

[Sales@RAI]

3652s this time around?

[zerb]

3652's this time around yes sir.

[Doctor]

Define Porn, I heard back then.

Okay, - PORN IS NOW DEFINED.

Well Done Sir.

[Sales@RAI]

3652's this time around yes sir.

Very Nice [up]

I'm happy that they're finally going to be put to good use.

[zerb]

Define Porn, I heard back then.

Okay, - PORN IS NOW DEFINED.

Well Done Sir.

Thank you sir.

And put them to good use I will, I hope.

[GOODBYNAAIR]

This is Awesome!! looking for an up date[drool] ?? Great work[up]

[zerb]

http://i39.photobucket.com/albums/e164/zerrb/IMG_0310.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0311.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0314.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0315.jpg
http://i39.photobucket.com/albums/e164/zerrb/IMG_0313.jpg
http://i39.photobucket.com/albums/e164/zerrb/bd45627a.jpg

[zerb]

http://i39.photobucket.com/albums/e164/zerrb/C35176E6-A3F7-4920-BA69-5BFC0F85EFF1-2687-0000030AAA7D5089.jpg
http://i39.photobucket.com/albums/e164/zerrb/AABE4032-4502-4F1C-A8F8-3DDBBA084487-3547-00000396A343C49F.jpg
http://i39.photobucket.com/albums/e164/zerrb/D8AFD496-9E5D-4C4E-8A72-E8BF1295C45F-3547-00000396A7C190BE.jpg

[zerb]

got some pictures taken by a local photog this past wednesday at a meet. these are just the versions i pulled off of facebook, i should be getting the full hi-res files emailed to me today or tomorrow.

http://i39.photobucket.com/albums/e164/zerrb/284930_430468076999983_1337162208_n.jpg
http://i39.photobucket.com/albums/e164/zerrb/424766_430468066999984_1340145535_n.jpg
http://i39.photobucket.com/albums/e164/zerrb/399027_430467993666658_1989198866_n.jpg
http://i39.photobucket.com/albums/e164/zerrb/405817_430468023666655_1189306309_n.jpg
http://i39.photobucket.com/albums/e164/zerrb/207074_430467973666660_1707679439_n.jpg

[Doctor]

Looks really badass to say the least.

[Sales@RAI]

I love this car.

[zerb]

thanks guys! car feels super strong this year with the new cams...ive been driving a slow daily all year but im really gonna say at the 26 psi we are at now it feels like 32ish with last years cams. hopefully more and more boost and street logging, then to the track to see what she can do!!

[Dan[FN]6262]

hell yes!!

[ryankkoenigsman]

DAMN. That is awesome. I love to see the older audi's put to good use.

[zerb]

car has been running well. upping the boost little by little, shooting to make it to a test and tune this coming week. should be a good time.


http://www.youtube.com/watch?v=sBc9d73sVYc&feature=plcp

http://www.youtube.com/watch?v=rMCKKGwJH5c&feature=channel&list=UL

http://www.youtube.com/watch?v=1zmoKOorI60&feature=channel&list=UL

[zerb]

cars out for the season, locked up the 1-2 shift collar in the 01e last pass at the track. ill let the video do the rest of the talking.



http://www.youtube.com/watch?feature=player_embedded&v=nmDI3hicTjo

[GOODBYNAAIR]

[:D][:D][:D][up] Very cool Car man!!!

[zerb]

http://i39.photobucket.com/albums/e164/zerrb/0941A510-8933-45FF-B981-CE038CA7AC21-2817-0000024594B2A62E.jpg

[Dan[FN]6262]

fuck yeah!!! awesome man!

[zerb]

6262;8051026']fuck yeah!!! awesome man!

thanks man, those 52's really woke this thing up.

[Dan[FN]6262]

thanks man, those 52's really woke this thing up.

That's great to hear. I could definitely tell a difference when I switched from the 52s to the 58s

[zerb]

6262;8051362']That's great to hear. I could definitely tell a difference when I switched from the 52s to the 58s

dont get me wrong, the 58s pulled up top for sure. but i wouldnt use anything but these 52s on a car that had a 64mm or larger strapped to it. this thing now just pulllllllllllllls up top until you let off, and it feels like it would pull forvever.

[zerb]

Car gas been torn apart for the winter again. It needed a trans rebuild and a different clutch anyway. Going to change the almond wrinkle powdercoat in the engine bay too, the color I like the wrinkle was just a bitch to keep any sort of clean. So I figured while I'm at it ill make it a shade darker brown too. Making a new catch can setup as well. Wet sanding and buffing the awful paint job I mustered last summer. And powdercating the wheels white as well as ditching the 255 kdw2s and stepping up to 275 MT radials. The 255s were just cutting it last year and we didn't even get to crank the boost up, so safety first, lol. Turbo will be a 6766 from a 6765 as well, car was smoking a bit last season and once I pulled the downpipe off I knew why.
http://i39.photobucket.com/albums/e164/zerrb/2C53A93D-704B-43F8-956A-A3A6E020D93E-6830-000007DC9B997E95_zps33ccea63.jpg
http://i39.photobucket.com/albums/e164/zerrb/14046D07-713B-46E2-A130-8536811F63F2-6830-000007DCA680F179_zpsbba973d4.jpg

Photoshop of what the wheels should look like
http://i39.photobucket.com/albums/e164/zerrb/9cd0517a7052bb1532ebc27c1b577de4_zpscfcca8cc.jpg
http://i39.photobucket.com/albums/e164/zerrb/8569745C-E0E9-43FF-9FED-635205C59333-2805-0000029930C641FE_zps4c79ca46.jpg
The new browner engine bay pieces color
http://i39.photobucket.com/albums/e164/zerrb/5adfd8aef5aceb2b2bccb2d311cd3d60_zps74b50e2a.jpg
And one white wheel I just did to make sure I liked it
http://i39.photobucket.com/albums/e164/zerrb/AD99B9F0-C466-49FD-9E5C-4156627FDEDB-6622-00000129DD220729_zpsfd702dab.jpg
http://i39.photobucket.com/albums/e164/zerrb/A8CB94C9-6AAB-4495-A2E4-8EEEAC5AF89F-6857-00000131585D8B2D_zps11fda380.jpg

Stay tuned for some more eye candy once things get back together. And then some racing once its all ready to go!!!

[Dan[FN]6262]

This is definitely in the top 3 of my favorite builds. [up]

[zerb]

Thanks dude!