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Big Boost
05-17-2010, 09:56 PM
I know this is long overdue, but I promised myself that I wouldn't begin a build thread until the project was 50% complete.

The short story. 2008. Stage 3. VAST. Prince. Mike. Michigan. Neil. Milwaukee. Awesome. Misfires. WTF! CEL? WTF? New program. Cool. Misfires!! Help! Again. Neil. Cool! Loving. Life. Summer. Base file. 12.2@116mph. Pump gas. VAST! 2009. Winter. Hit. Pot hole. Shit. Totaled! Sell parts. Prince. "Dude...Race Car!" Me. "Hey honey, do you care if I build a race car AGAIN? It won't cost THAT much?!" Wife. Says. Yes. America! FUCK. YEAH! 034. Javad. Issam. Dan. VR6! Conversion? What!?! Damn. I. Need. That. Shit. In. My. Life. Must. Pull. Engine. And. Trans. Leng! Keng! Two brothers. Milwaukee. Hell. YEAH. Transmission. Rebuild. Local. Ben. Import Automart! Fabrication? Local? Jon. Best friend. Yes! Waiting. On. Parts. Took. Forever. 2010. Here. It. Is.


Build Sheet Info:



ENGINE

AAA 12V VR6 OBD2

JE FORGED PISTONS 9:1 COMPRESSION 82MM - POLISHED TO REDUCE SURFACE AREA AND CARBON BUILD UP

EUROSPEC FORGED H-BEAM RODS WITH ARP 3/8" ROD BOLTS

ENGINE BLOCK OVERBORED BY 1MM (2.9L)

BALANCED ASSEMBLY

POLISHED CRANKSHAFT JOURNALS

JOURNALS LINE HONED

CLEVITE OVERSIZED MAIN BEARINGS

KING OVERSIZED ROD BEARINGS

ARP MAIN STUDS

ARP HEAD STUDS

MLS HEAD GASKET

02 INDUCTION STAGE 3 PORTED AND POLISHED CYLINDER HEAD WITH PORT MATCHED INTAKE RUNNERS AND PORTED AND POLISHED EXHAUST RUNNERS

1/2" PHENOLIC SPACER WITH DOWEL PINS - PERFECTLY ALIGNED TO INTAKE AND FACE OF CYLINDER HEAD - TOTALLY SMOOTH!

BORG WARNER S400SX3 (S475) TWIN SCROLL T4 TURBO 101MM EXDUCER W/ 02 BILLET ALUMINUM MAP WIDTH ENHANCER

TWIN TIAL 38MM BILLET WASTEGATES WITH 02 BUILT SS 1.5" LONG TUBE ATMOSPHERIC DUMPS

TIAL 50MM BILLET BLOW OFF VALVE WITH STAINLESS FLANGE

02 INDUCTION CUSTOM AIR TO WATER INTERCOOLER WITH HAND FABRICATED END TANKS
CORE SIZE 11X7X6.5 (500.5 CUBIC INCHES)

02 INDUCTION BUILT HOWE FULL SIZE HEAT EXCHANGER WITH CUSTOM END TANKS

SPEARCO WATER PUMP

02 INDUCTION 3” OUTLET ALUMINUM INTERCOOLER PLENUM WITH COOLANT TANK

80MM NISSAN Q45 THROTTLE BODY (MODIFIED)

02 INDUCTION EQUAL LENGTH ALUMINUM LARGE PLENUM INTAKE MANIFOLD

02 INDUCTION CUSTOM EQUAL LENGTH 304 STAINLESS TWIN SCROLL TURBO MANIFOLD

02 INDUCTION STAINLESS STEEL TURBO BRACE

02 INDUCTION 4” 304 STAINLESS EXHAUST WITH DYNOMAX STAINLESS ULTRA FLO 4" MUFFLER

02 INDUCTION 4" 304 STAINLESS DOWNPIPE WITH V-BAND FLANGES

034 EFI STAGE IIC STAND ALONE ENGINE MANAGEMENT 4 BAR ECU WITH UPGRADED FIRMWARE VERSION

034 EFI PLUG AND PLAY VR6 HARNESS

034 EFI RELAY BOARD (4 RELAYS INC.)

6 BOSCH 3 BAR 210LB (2225CC) GENESIS II INJECTORS HIGH IMPEDANCE

034 EFI BILLET FUEL RAIL -10AN INLET/OUTLET

FUELAB 41402 PRODIGY 1300HP FUEL PUMP

FUELAB BILLET ADJUSTABLE FUEL PRESSURE REGULATOR -10 INLET/-6 RETURN

6 034 EFI DIS IGNITION COILS WITH CUSTOM ALUMINUM MOUNTS ON VALVE COVER

034 EFI VR6 SPARK PLUG WIRES - MODIFIED BY 02 INDUCTION

02 INDUCTION CUSTOM ALUMINUM ENGINE MOUNTS

02 INDUCTION CUSTOM ALUMINUM COOLANT HOUSING WITH REMOTE THERMOSTAT

HOWE ALUMINUM RADIATOR MODIFIED BY 02 INDUCTION

OEM MODIFIED ALUMINUM VALVE COVER

TECHTONICS 268 DEGREE CAMSHAFTS

TECHTONICS TITANIUM RETAINERS

TECHTONICS HEAVY DUTY DUAL VALVE SPRINGS

SUPERTECH 42MM (OVERSIZED 3MM) INTAKE VALVES

SUPERTECH 36MM (OVERSIZED 1.8MM) EXHAUST VALVES

OEM LIGHT WEIGHT LIFTERS

PHAETON OIL PAN MODIFIED FOR OIL RETURN PROVISION

TRANSMISSION/DRIVETRAIN

REBUILT 01E TRANSMISSION WITH UPDATED SYNCHROS AND 1-2 SLIDER

034 EFI/ EUROSPEC BILLET MOTORSPORT CLUTCH

034 VR6 TO 01E BILLET LIGHT WEIGHT FLYWHEEL

034 EFI BILLET STARTER

AUDI OEM VR6 TO 01E TRANSMISSION ADAPTER WITH ADDITIONAL MOUNTS ADDED

JHM METAL SHIFTER LINKAGE UPGRADE

JHM SHIFTER STABILIZER BUSHINGS

JHM SHORT THROW SHIFTER

034 EFI STREET DENSITY TRANMISSION MOUNTS

AWE DRIVE TRAIN STABILIZER

APIKOL REAR DIFFERENTIAL MOUNT

APIKOL REAR DIFFERENTIAL CARRIER MOUNTS



Here are some progress pix...........
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/S4WinterShots.jpg?t=1274190068

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03698.jpg?t=1274190442

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03123.jpg?t=1274148610

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03260.jpg?t=1274148760

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03274.jpg?t=1274148809

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/034EFIStageIICStandalone.jpg?t=1274151804

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03134.jpg?t=1274152682

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC01656.jpg?t=1274152755

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC01660.jpg?t=1274152808

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/034MotorsportsLongitudinalVR6to01Es.jpg?t=12741528 71

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03275.jpg?t=1274158054

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03309.jpg?t=1274152917

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03312.jpg?t=1274152998

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03313.jpg?t=1274153036

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03323.jpg?t=1274153124

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03325.jpg?t=1274153156

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/Intakemanifoldwelded.jpg?t=1274153535

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/VR6IntakeManifold.jpg?t=1274153567

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_9813-1.jpg?t=1274153637

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_9812-1.jpg?t=1274153690

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_9840.jpg?t=1274161536

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/VR6StaggeredRunnerIntake3.jpg?t=1274153768

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_9946.jpg?t=1274153834

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_99481.jpg?t=1274153866

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0011.jpg?t=1274153973

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03725.jpg?t=1274154056

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03723.jpg?t=1274154116

dla79
05-17-2010, 10:07 PM
Looks awesome Rob!!

B6JoeS4
05-17-2010, 10:08 PM
http://i90.photobucket.com/albums/k262/Hallu2006/1zqsjnm.gif

Big Boost
05-17-2010, 10:08 PM
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03724.jpg?t=1274154240

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/VR6IntakePlenum.jpg?t=1274154962

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0040.jpg?t=1274155241

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0042.jpg?t=1274155308

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0043.jpg?t=1274155342

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0049.jpg?t=1274155388

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/WeldedIntercoolerCore2.jpg?t=1274155450

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IntercoolerCoreWelded.jpg?t=1274155485

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03799.jpg?t=1274155606

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03802.jpg?t=1274155874

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03803.jpg?t=1274155927

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0177.jpg?t=1274156035

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04040.jpg?t=1274156157

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0208.jpg?t=1274156205

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04058.jpg?t=1274156279

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0219.jpg?t=1274156321


Now I can finally put this 40psi gauge to good use and live up to my screen name!!
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/AUDIS4GAUGEPODDESIGNS073.jpg?t=1274159370


Pilot and Co-pilot (wife) chairs
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/AUDIS4007.jpg?t=1274159309

beemercer
05-17-2010, 10:10 PM
Love that intake manifold. Good work, can't wait to see more.

Militant-Grunt
05-17-2010, 10:15 PM
Siick.

B5stgIII
05-17-2010, 10:18 PM
so sick. Subscribed. Keep up the good work [up]

Raacerx
05-17-2010, 10:24 PM
Really great work there sir.

Whats the intercooler core/fins for?

xxSection8xx
05-17-2010, 10:25 PM
Very nice. That intake is a work of art.

Big Boost
05-17-2010, 10:26 PM
Really great work there sir.

Whats the intercooler core/fins for?

That's an air to water intercooler core. The air and water tanks will be fabricated by next week. That's why I plasma cut the false firewall out to make room for it.

99ebpsi24
05-17-2010, 10:27 PM
this is going to be absolutely nuts when it's complete. good luck with the build and MAJOR props!

blackbenzz
05-17-2010, 10:32 PM
Noggys are fast. Cool build

Sigma 3
05-17-2010, 10:48 PM
[hail] The fab work!

dla79
05-17-2010, 10:55 PM
That's an air to water intercooler core. The air and water tanks will be fabricated by next week. That's why I plasma cut the false firewall out to make room for it.

Looks hot can't wait to see this in person some time Rob! I ran into your buddy driving around a few weeks back and he was talking about your car :-)

AudiTechS4
05-17-2010, 10:58 PM
looks sick man

Big Boost
05-17-2010, 11:05 PM
Thanks for the kind compliments!! I really appreciate them!! Just a heads up, I am NOT the fabricator. My good friend Jon is. I have begun to learn how to TIG weld and I will say it requires a great deal of practice and patience. I suck at it. Period. Thank God I have a friend like Jon to help a MF out.

More pix...

The trans is rebuilt with the updated parts.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC01673.jpg?t=1274159928

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC01674.jpg?t=1274160039

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC01676.jpg?t=1274160070

S4Rs
05-17-2010, 11:52 PM
Sweet fab skills. Looking forward to following this build just to admire the fabrication.

michael66899
05-18-2010, 12:16 AM
WOW, very impressive build I can't wait to see this thing all finished up. That intake mani is a piece of art, care to post some more specs on the motor, turbo, etc.? Also any eta on when you plan on finishing her up.

revhards4
05-18-2010, 01:12 AM
looking good! Any particular reason you went with a GT42R (looks like a 42R anyway) over something that flows the same but is smaller in frame size for packaging constraints?

bigern45
05-18-2010, 07:17 AM
WOW.. holy shit fabrication batman.. yeah, the guy who did my exhaust wants to help and do something retarded like what your doing, just dont know if i have the time or money right now. im assuming your goals are 750?? ish??
clean build, the fab looks amazing. do you have an eta so that all of us gawking can expect to see some results??

Jason@Addict
05-18-2010, 07:58 AM
Looks great what's the plan for the fuel system?

Big Boost
05-18-2010, 08:02 AM
looking good! Any particular reason you went with a GT42R (looks like a 42R anyway) over something that flows the same but is smaller in frame size for packaging constraints?

I actually began the project with a GT4094R. Looking at the compressor maps versus the 42R and the Borg Warner, it wouldn't flow enough CFM for my HP goal. If I'm not happy with the spool up, the first thing I'll do is change the exhaust A/R from 1.10 to .90 but there will be a trade off in top end power.

As far as the fuel system is concerned, I was going to run dual 044's but I've been hearing about numerous failure rates. I'll research that a little deeper, but right now it's still in the air.

The goal is to have the project finished in late June, early July. This project has amounted to a big "...well, while I'm at it I might as well do this..." since it began in March. I've got quite a few surprises left, but hopefully it will be done in that approximate time frame.

Haenszel20v
05-18-2010, 08:14 AM
This is good. I like what you've done.

AWD87
05-18-2010, 08:34 AM
/drool....I want a vr6t swap so bad

Dan[FN]6262
05-18-2010, 09:43 AM
oh em gee I think I just....

http://ijizzinmypants.com/images/jizzinmypants03.jpg

CrtchRktRcr
05-18-2010, 10:21 AM
Oh dear god.

michael66899
05-18-2010, 10:53 AM
Haha thanks for editing the original post with some details, the first part is pricelss. Good luck man this things gonna be a beast.

LeadFoot944
05-18-2010, 10:59 AM
I cant wait for a Ride....Maybe the Wife (Who REALLY Owns the car) will let me sit in the back seat ?

Must go change pants now..... :)

s4nicetry
05-18-2010, 11:09 AM
Wow that is some incredible fab work there. This car will be a beast for sure!

sfored
05-18-2010, 11:38 AM
As far as the fuel system is concerned, I was going to run dual 044's but I've been hearing about numerous failure rates. I'll research that a little deeper, but right now it's still in the air.



WHAT failures ? Javad turned me onto that as well.. and I am NOT looking forward to any failures ... (crossing all fingers) ... 1 thing i did do on my setup is - I ran freaking expensive check-valves and in line filters on both feeds ... I wonder if the failure is the setup style or the pumps themselves ?

Big Boost
05-18-2010, 11:42 AM
I cant wait for a Ride....Maybe the Wife (Who REALLY Owns the car) will let me sit in the back seat ?

Must go change pants now..... :)

Naw, she has the Yukon for her daily. She knows who wears the pants in the house (looking over shoulder). I must say though, without her approval this project wouldn't have happened. It just would've been done behind her back! :)

As far as the 044's are concerned, I too need to determine if it's an installation error that's causing the problems or is it just a bad batch?

adr3naline fix
05-18-2010, 02:45 PM
Sick build! Nice to meet ya today. You Mil guys have meets at all?

Spooled1.8
05-18-2010, 03:07 PM
Your intro is hilarious.
Your build is epic.
What's your power goals if you care to indulge?

Big Boost
05-18-2010, 03:53 PM
Your intro is hilarious.
Your build is epic.
What's your power goals if you care to indulge?

Thanks!! To me, there was no better way of describing what led up to this project. As far as power goals are concerned, who knows what I'll put down? I have a number, but you know as well as I do that if I said what I expect, controversy will ensue. All I know is that it will be at least as fast as my VAST Stage 3 tune, so I'll start from there.....about 380whp.[;)]

FlaS4
05-18-2010, 03:58 PM
about 380whp

380whp x 2??? Is that what you meant?[:D]

Mattgfx
05-18-2010, 04:02 PM
this is so exciting .
http://www.youtube.com/watch?v=59fPX4CAQwk

RolledMySTi
05-18-2010, 05:38 PM
That's one hell of a build. Good luck with it.

dla79
05-18-2010, 05:54 PM
I actually began the project with a GT4094R. Looking at the compressor maps versus the 42R and the Borg Warner, it wouldn't flow enough CFM for my HP goal. If I'm not happy with the spool up, the first thing I'll do is change the exhaust A/R from 1.10 to .90 but there will be a trade off in top end power.

As far as the fuel system is concerned, I was going to run dual 044's but I've been hearing about numerous failure rates. I'll research that a little deeper, but right now it's still in the air.

The goal is to have the project finished in late June, early July. This project has amounted to a big "...well, while I'm at it I might as well do this..." since it began in March. I've got quite a few surprises left, but hopefully it will be done in that approximate time frame.

If you run a single Bosch 044 and give it it's own power line running to it from the battery then it will perform much better and you have no need for a dual setup like what AMD did on his TiAL 770 build. Many people do not really realize that the 044 can run better if you do this but I will share the info :-)

Big Boost
05-18-2010, 06:20 PM
If you run a single Bosch 044 and give it it's own power line running to it from the battery then it will perform much better and you have no need for a dual setup like what AMD did on his TiAL 770 build. Many people do not really realize that the 044 can run better if you do this but I will share the info :-)

Alex, thanks for the heads up. Do you know what crank HP a single 044 can support with a direct 12V power source?

S4evr
05-18-2010, 06:27 PM
jesus http://www.youtube.com/watch?v=tHZcl2kgRho

dla79
05-18-2010, 06:42 PM
Alex, thanks for the heads up. Do you know what crank HP a single 044 can support with a direct 12V power source?

Nobody has absolute data on it but I would say it could easily support your setup if you are shooting for 700-800 HP if you give it direct power instead of using the shitty harness connection in our car.

Big Boost
05-18-2010, 07:07 PM
Just finished!!! The wastegates are mounted. The dumps are being fabbed right now. Yes, I know they are flanged 38mm and not V-Bands, but I'm ballin' on a budget. I had to cut costs somewhere. Next year I will have TIAL V-Bands, but the Stage 2 version of this set up will be totally different and much more advanced.


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0250.jpg?t=1274231057

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0246.jpg?t=1274231090

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0252.jpg?t=1274231021

Big Boost
05-18-2010, 07:09 PM
Nobody has absolute data on it but I would say it could easily support your setup if you are shooting for 700-800 HP if you give it direct power instead of using the shitty harness connection in our car.

Yeah, I'm going to need at least two then....[evilsmile]

dla79
05-18-2010, 07:20 PM
Yeah, I'm going to need at least two then....[evilsmile]

Ha. I would tell you to call up Price Cobb over at Kelly Moss Motorsports and ask him what they run on those fuel pumps on their race cars. That is all they use so I am sure they can give you some #s.

spokismB5S4
05-18-2010, 07:20 PM
Yeah, I'm going to need at least two then....[evilsmile]

good shit :), cant wait!

1NaudiA4
05-18-2010, 07:36 PM
Looks great!!! I gotta give props to whoever is doing the welding.... those welds look amazing.

On a side not I vote you switch those 1000cc injectors to 1600cc and go with a surgetank/dual 044 set up. Come on now how can you not run on E85, you live in Wisconsin!!

Big Boost
05-18-2010, 07:41 PM
Looks great!!! I gotta give props to whoever is doing the welding.... those welds look amazing.

On a side note I vote you switch those 1000cc injectors to 1600cc and go with a surgetank/dual 044 set up. Come on now how can you not run on E85, you live in Wisconsin!!

I really would love to, but E85 stations are scarce in SE Wisconsin. There is a station right down the street from me that NEVER has any in stock. As a matter of fact, over a month ago they converted it to a diesel pump! It seems that the local gas stations are not so hot on being green. If E85 were readily available I would have absolutely bought 1600CC injectors. I might do a water/meth system in the future instead. That might be overkill with the air to water intercooler, but everything else already is overkill anyway.

S-Power
05-18-2010, 08:14 PM
What are you hoping to put down ?

Reich
05-18-2010, 08:48 PM
Wow... definately a nice job on the intake and exhaust. I know an other VR6 audi that is scared now.[>_<]

Congratulations. That's a major build.

I guess i'll have to ask that same boring question. How many hp are you expecting?

Big Boost
05-18-2010, 09:57 PM
Wow... definately a nice job on the intake and exhaust. I know an other VR6 audi that is scared now.[>_<]

I guess i'll have to ask that same boring question. How many hp are you expecting?


What are you hoping to put down ?

No one should be scared of this car.[;)] Again, as far as quoting a HP number, I just want to improve on anything North of 380WHP. That's where my Stage 3 stopped, and that's my new starting point. Anything above and beyond that will be perfect.

q_dubz
05-18-2010, 11:54 PM
very nice work.

Jason@Addict
05-19-2010, 07:10 AM
If you run a single Bosch 044 and give it it's own power line running to it from the battery then it will perform much better and you have no need for a dual setup like what AMD did on his TiAL 770 build. Many people do not really realize that the 044 can run better if you do this but I will share the info :-)

Actually we have relayed both pumps to straight battery power. You WILL NOT make more than 600whp on a single 044 reliably, and even getting to 600whp would require new lines and very high base fuel pressure. This set-up will require at least a full -8 line running from the pump(s).


Nobody has absolute data on it but I would say it could easily support your setup if you are shooting for 700-800 HP if you give it direct power instead of using the shitty harness connection in our car.

I'd say that many people know what a single 044 will flow - and it's not anywhere near 800hp.

sfored
05-19-2010, 07:38 AM
You WILL NOT make more than 600whp on a single 044 reliably, and even getting to 600whp would require new lines and very high base fuel pressure.

well.. while I agree with your statement "NOT reliably" - I made 650 AWHP on a dynodynamics and ran out of fuel at 710 awhp on the same dyno...on a single 044 on stock lines. .. now upgraded to dual 044s and -8 feed and -6 return and 034 fuel rails ... cant wait to go back to the dyno.

I'd say that many people know what a single 044 will flow - and it's not anywhere near 800hp. ^^^ is over 800 chp

Sales@RAI
05-19-2010, 07:43 AM
fantastic build [up]

dmansr25sd
05-19-2010, 08:23 AM
this is beyond sick
a vr6 build has been my delusional dream for a b6

best of luck, can't wait to see numbers & videos!

ECS Tuning-Audi
05-19-2010, 01:39 PM
How are you milling the aluminum?

And does your wife have equally understanding sisters?!

Nice build!

Layza
05-19-2010, 01:49 PM
Great work Rob!! I can't wait to see this beast on the road!!

Drifters
05-19-2010, 02:04 PM
Late June early July huh? I'm hoping to see this thing finished before then.

Again, when ever you need another set of hands to do some wrenching, just let me know.

kengvang
05-19-2010, 04:06 PM
Bout time you started this thread. no i can keep track on how the car is doing. i'll be there when you first fire her up. i saw the start of the build, i want to see the finished product. love it!!!

FlaS4
05-19-2010, 04:39 PM
How are you going to get the air to the intercooler the way the turbo is clocked now? Looks like it will hit the hood if you don't have an immediate 90 degree bend in it. or are you planning on reclocking the turbo a little?

O2VW1.8T
05-19-2010, 05:05 PM
Amazing build keep up the good work.

GURUMAN
05-19-2010, 05:30 PM
Actually we have relayed both pumps to straight battery power. You WILL NOT make more than 600whp on a single 044 reliably, and even getting to 600whp would require new lines and very high base fuel pressure. This set-up will require at least a full -8 line running from the pump(s).



I'd say that many people know what a single 044 will flow - and it's not anywhere near 800hp.

I ran into problem myself on a single 044 at 540 whp, fuel pressure was decreasing dangerously at over 5k

Big Boost
05-19-2010, 05:34 PM
How are you milling the aluminum?

And does your wife have equally understanding sisters?!

Nice build!

Thanks!

Everything is being done on a lathe along with his extensive tool and equipment set. [;)]

As far as my wife's sister's, neither one of them would understand. Sorry Bro. I got the best one!

Regarding the hood clearance..........


How are you going to get the air to the intercooler the way the turbo is clocked now? Looks like it will hit the hood if you don't have an immediate 90 degree bend in it. or are you planning on reclocking the turbo a little?

The passenger side headlight was removed to take this pic. Take a peak at the clearance between the valve cover and the hood. Notice the hoodliner.
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03393-1.jpg?t=1274311259

Now the hoodliner is removed and notice that up to an extra inch of space is available. There is a rise over run of .5" from the valve cover to 3" where the valve cover is. Imagine where the turbo is. Remember the turbo is sitting kind of low in its resting place. There is over 5" of clearance from where the outlet flange is to to the top of the hood. I have a 3" 90 degree aluminum elbow that will clear the hood by over an inch. Its playing an optical illusion as far as depth is concerned.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03411.jpg?t=1274311348

Leng, Keng....I will let you know when it's time to bring her home and finish 'er up! Thanks for all of your help!!

Big Boost
05-19-2010, 05:38 PM
I ran into problem myself on a single 044 at 540 whp, fuel pressure was decreasing dangerously at over 5k

What fuel set up did you install?

laxman851
05-19-2010, 07:08 PM
Keep up the good work. I look forward to your updates daily.

cosmetically; Are you planning on using any thermal barriers between the hood and the valve cover?

bigern45
05-19-2010, 08:25 PM
you need to look into a pierburg pump. its what bugatti uses to fuel the veyron.. i tried to find you a link, sorry, i couldnt find one. but a number of high whp guys in my area that build/tune audis love them..

Big Boost
05-19-2010, 08:34 PM
Keep up the good work. I look forward to your updates daily.

cosmetically; Are you planning on using any thermal barriers between the hood and the valve cover?

Oh yeah, I will have to for sure. I'm looking at the Dynamat brand Thermoliner, plus coating for the manifold and a thermal cover for the exhaust housing.


you need to look into a pierburg pump. its what bugatti uses to fuel the veyron.. i tried to find you a link, sorry, i couldnt find one. but a number of high whp guys in my area that build/tune audis love them..

Thanks. I'll try to find some info on this ASAP.

ECS Tuning-Audi
05-20-2010, 07:44 AM
The fuel pump questions are a good point. Are you going to stick with the tank or go fuel cell? With all your aluminum milling and welding you (or your friend) could probably whip up a stainless tank pretty easy too.

Big Boost
05-20-2010, 07:56 AM
The fuel pump questions are a good point. Are you going to stick with the tank or go fuel cell? With all your aluminum milling and welding you (or your friend) could probably whip up a stainless tank pretty easy too.

Yeah, I kinda mentioned that to him last night. We both tossed around some ideas, but if possible I would like to keep the factory fuel tank. He might make a new dual in-tank set up. There are three options I'm looking at right now. I'm just waiting to hear back from a couple of people.

Jason@Addict
05-20-2010, 08:27 AM
I ran into problem myself on a single 044 at 540 whp, fuel pressure was decreasing dangerously at over 5k

That's exactly where we run out on a single 044 as well. I think people don't actually monitor their fuel pressure closely during a pull and end up trying to tune around a maxed out fuel pump with artificially high injector duty cycle. It's not until the system is fully maxed out to the point of running lean that they recognize the flow is insufficient - which generally is long after fuel pressure had started to drop up top.

Big Boost you will need a huge amount of fuel.

Rolotuning
05-22-2010, 06:25 AM
Great fab!!

Big Boost
05-22-2010, 03:16 PM
Update. The wastegate dump tubes are finished!!

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0282.jpg?t=1274562867

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0281.jpg?t=1274562942

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0309.jpg?t=1274584190

laxman851
05-23-2010, 09:52 AM
This thread keeps getting better and better.

Storx
05-23-2010, 03:26 PM
wow... keep up the work man...

Big Boost
05-24-2010, 10:41 AM
Update.

The intercooler fab has begun and the first portion is the bottom of the A/W tank. The sump you see is positioned between the firewall and the new stainless steel crossbrace. The water return line spigot sits in front of the crossbrace. Scroll up 3 pix and look at the intercooler placement to see how it will be oriented.
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0291-1.jpg?t=1274718664

RolledMySTi
05-24-2010, 02:40 PM
Freaking gorgeous!

Big Boost
05-25-2010, 05:46 AM
Thanks for all of your positive comments! Here is another update!! The top and bottom water tanks are complete. The filler neck was placed on top as it is the highest point in the water reserve system.



http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0324.jpg?t=1274787480

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0317-1.jpg?t=1274787625

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0333.jpg?t=1274787692

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0331.jpg?t=1274787820

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0329.jpg?t=1274787860

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0332.jpg?t=1274801123

The heater hose spigots will likely have to be modified to clear the outlet discharge side. Plans are to begin the air tank fabbing today.

ECS Tuning-Audi
05-25-2010, 03:06 PM
Good call with the filler neck addon. Still looking awesome!

O2VW1.8T
05-25-2010, 07:44 PM
Wow again makes me want to start on my VR6 build again. Great job everything is looking good.

Sales@RAI
05-25-2010, 11:42 PM
Wow again makes me want to start on my VR6 build again. Great job everything is looking good.

you would say this lol

Rolotuning
05-26-2010, 09:28 PM
Amazing fab!!!

Dan[FN]6262
05-27-2010, 03:46 PM
became a fan

Big Boost
05-31-2010, 11:29 AM
Memorial Day Update.

http://www.audizine.com/gallery/data/500/S4_VR6_Intercooler_Charge_Pipe.jpg

http://www.audizine.com/gallery/data/500/medium/S4_Turbo_Discharge.jpg

http://www.audizine.com/gallery/data/500/medium/S4_Intercooler_End_Tank.jpg

http://www.audizine.com/gallery/data/500/medium/S4_Intercooler_End_Tank_front_view_2.jpg

JDM EJ1 95
05-31-2010, 11:45 AM
nice work! maybe i can come see this thing when its done.

Big Boost
05-31-2010, 12:25 PM
nice work! maybe i can come see this thing when its done.

Actually, once it's done I need to go to Chicago. I'll connect with you once it's close to being done. Who knows, maybe some of the Milwaukee crew might roll down with me?

Layza
05-31-2010, 01:44 PM
Rob how long tell your car is done? If my car is ready buy then I'll roll down and i'm sure others will to.

Looks like things are coming along great. It's going to be a beast and a work of art when it's done...

sean1.8t
05-31-2010, 01:48 PM
Top notch!

GURUMAN
05-31-2010, 04:17 PM
Amazing Work !

Das General
05-31-2010, 04:34 PM
Looks baller so far!


What are the plans for a rad, considering your rad support is.... well 90 percent gone?

GURUMAN
05-31-2010, 05:04 PM
Looks baller so far!


What are the plans for a rad, considering your rad support is.... well 90 percent gone?

Ya ? I will face same problem with my V8 !

NYEuroTuner
05-31-2010, 05:14 PM
Memorial Day Update.

http://www.audizine.com/gallery/data/500/S4_VR6_Intercooler_Charge_Pipe.jpg



Simply Amazing [up] Looks sick.

Big Boost
05-31-2010, 07:08 PM
Rob how long tell your car is done? If my car is ready buy then I'll roll down and i'm sure others will to.

Looks like things are coming along great. It's going to be a beast and a work of art when it's done...

Thanks! I'm still shooting for late June, early July.


Looks baller so far!


What are the plans for a rad, considering your rad support is.... well 90 percent gone?

LOL. The radiator should be mounted later this week or so. I'll post pix as soon as it's finished.

ECS Tuning-Audi
06-01-2010, 11:59 AM
I'd love to see this in person. I'd roll over to Chicago for a meet up, got friends and fellow Dubbers that I need to visit there anyhow.

q_dubz
06-01-2010, 12:37 PM
this thing WILL eat babies for food/fuel. Absolutely amazing.....

EB Turbo
06-01-2010, 01:25 PM
BigBoost,

Are you purging Argon when welding the stainless? If so please post pics of your setup.

EB Turbo

Big Boost
06-01-2010, 10:25 PM
I'd love to see this in person. I'd roll over to Chicago for a meet up, got friends and fellow Dubbers that I need to visit there anyhow.

I'll keep in touch with you and let you and everyone else know an exact date. A GTG would be cool.


BigBoost,

Are you purging Argon when welding the stainless? If so please post pics of your setup

EB Turbo

Yes, but there were no pix taken for that process.

Big Boost
06-02-2010, 07:37 AM
With the air to water intercooler dominating the rear area where the false firewall used to be, there was no where to place the 034 coils. Until now...........

http://www.audizine.com/gallery/data/500/medium/VR6_Modified_VC_for_034_coils.jpg

http://www.audizine.com/gallery/data/500/medium/034_Coils_mounted_on_VC.jpg

http://www.audizine.com/gallery/data/500/medium/034_Coils_mounted_on_VC_side_view.jpg

The spark plug wires will have a very short run to each plug and the wiring to the coils will look clean. Form and function...killing two birds with one stone!

Haenszel20v
06-02-2010, 07:57 AM
is that gonna clear the hood? If so, it'll be damn tight as the angle of the hood comes VERY close to the front end of the valvecover.... perhaps you magically have more room that I, though.

bigern45
06-02-2010, 07:57 AM
your fab looks amazing, so clean and pro..

i thought in an earlier pic, the front of the engine was like 1/2 inch away from the hood of the car???? those coils have to be cutting it DAMN close!!!

Haenszel20v
06-02-2010, 08:04 AM
http://www.moddedmustangs.com/forums/attachments/exterior-parts/13247d1203458565-99-04-6-cowl-hood-image_00075.jpg

Big Boost
06-02-2010, 08:07 AM
is that gonna clear the hood? If so, it'll be damn tight as the angle of the hood comes VERY close to the front end of the valvecover.... perhaps you magically have more room that I, though.

It clears by a 1/2". Someone thought that the IC discharge pipe wouldn't clear either and it does so by over an inch. Taking off the underhood protection really provides a bit more clearance.

http://www.audizine.com/gallery/data/500/medium/034_Coils_hood_clearance.jpg

Haenszel20v
06-02-2010, 08:11 AM
you seem to have way more hood clearance than I. Is the webbing/structure on the underhood side removed?

Big Boost
06-02-2010, 08:27 AM
you seem to have way more hood clearance than I. Is the webbing/structure on the underhood side removed?

No, the only thing removed was the hoodliner, otherwise the hood is completely stock. Do you have a B5 or B3/B4 chassis?

speeding-g60
06-02-2010, 06:15 PM
first saw it on MG, lots more pictures here.

Haenszel has a B5 A4, BTW.

and FWIW, i run dual 044's without problem on mine, although its a lowly 4cyl 20v.... haha. but it has a little power :)

and the injector duty cycle ( 4 X Bosch 1600's ) is only 65% logged on >600 AWHP pull.... but i would like to hear these 044 junk rumors too....

geeky
06-02-2010, 09:27 PM
O.O can I say, I WANT!!!!

[up] keep up the awesome work.

PSU S4
06-02-2010, 09:38 PM
all i can say is wow and this is amazing!! I give major major props to you for all the work, time and MONEY you are putting in this car. Cant wait to see more pictures and read about more updates you have. Having friends who can weld is great huh? Good luck
cheers

boy412
06-03-2010, 11:39 AM
I am very jealous of your fabrication skills. Nice work...cool thread!

seanj130
06-03-2010, 12:04 PM
Busted a nut, only wish i could pull something like this off.

guy022077
06-04-2010, 07:47 PM
i am gathering parts for this very thing, doing what i know how to do while i learn what i dont. Considering how much work this is and awesome you guys are getting this done, it is clear to me that i am not ready to start this yet. Nice work, nice work.

EB Turbo
06-09-2010, 01:46 PM
How come you guys dont use pencil coils? Suzuki GSX-R, and even AEM sells then as a kit with connectors and pins. They hide really nice in the spark plug holes.

EB Turbo

Big Boost
06-10-2010, 07:17 AM
I went with the 034 direct coils because they produce 100kV per coil. Besides, if 034 achieved over 900awhp on a 24V and USP hit over 800awhp on a 12V using 034's coils, why use anything else?

AudiSportB5S4
06-10-2010, 08:02 AM
With that little clearance, you don't worry about the engine moving a bit with all the power? You better have some serious mounts!

Haenszel20v
06-10-2010, 08:09 AM
With that little clearance, you don't worry about the engine moving a bit with all the power? You better have some serious mounts!
I feel like mine has less clearance than that, and w/the stern mounts there's not even a mark on the underside of the hood. It surprisingly moves very little really.

Big Boost
06-10-2010, 08:42 AM
With that little clearance, you don't worry about the engine moving a bit with all the power? You better have some serious mounts!

That's over a half inch of clearance believe it or not! The mounts will be very serious. ;).

Haenszel20v
06-10-2010, 10:15 AM
yeah, your mounts are pretty much 2 pieces of poly, some washers and a bolt, right?

Big Boost
06-10-2010, 07:30 PM
yeah, your mounts are pretty much 2 pieces of poly, some washers and a bolt, right?

Notice, I said they WILL be. The existing mounts will be discarded and completely new ones are being made.

Remember, these are 034 solid mounts that were modified from solid mount to using poly bushings. Again, new units are being made from scratch that will allow for the A/C compressor to be used on the passenger side.

JDM EJ1 95
06-10-2010, 07:38 PM
Actually, once it's done I need to go to Chicago. I'll connect with you once it's close to being done. Who knows, maybe some of the Milwaukee crew might roll down with me?


sounds good, i know a bunch of honda guys up there but not many audi/vw guys.. let me know when you make the trip.

diabolical1
06-11-2010, 11:20 PM
great work so far.

EB Turbo
06-13-2010, 09:58 PM
We did a 500hp 12v with the pencil coils. We didn't try for any more. but this was well over 3.5yrs ago. They worked really well and it made the install really clean.

EB Turbo



I went with the 034 direct coils because they produce 100kV per coil. Besides, if 034 achieved over 900awhp on a 24V and USP hit over 800awhp on a 12V using 034's coils, why use anything else?

.Mad Hatter.
06-14-2010, 04:00 AM
wow...the fab work looks very impressive.

ECS Tuning-Audi
06-14-2010, 09:37 AM
This is the ultimate summer movie teaser...

We need more updates! I can't wait to see where this is at this week.

Big Boost
06-14-2010, 03:05 PM
LOL. My fault for keeping you in suspense! I was playing the "parts waiting game" again. Fab should begin again tonight or tomorrow!

ECS Tuning-Audi
06-14-2010, 03:09 PM
Alright, hopefully I'll get some sleep tonight then!

EB Turbo
06-14-2010, 09:39 PM
OK, I found the pic. My mistake this car was built in late 2002. 500whp. selectable maps(high and low octane) and then it had a boost trim with 5 levels. MKIII Jetta. daily driver.

EB Turbo


http://img.photobucket.com/albums/v489/turbo74/VR6Turbo.jpg

NYEuroTuner
06-16-2010, 02:22 AM
LOL. My fault for keeping you in suspense! I was playing the "parts waiting game" again. Fab should begin again tonight or tomorrow!

Cant wait to see her finished. Your doing topnotch stuff brotha. [up]

Big Boost
06-18-2010, 11:50 AM
Cant wait to see her finished. Your doing topnotch stuff brotha. [up]

Thanks! Work should begin this weekend as some parts that were supposed to be here earlier this week have still not shown up. It's typical though. I can't wait until it's finished and tuned. Then it's off to the bodyshop for some minor repairs.

Big Boost
06-23-2010, 09:43 AM
It sure is nice having the necessary parts I've been waiting for to continue with the project. This weekend we're scheduled to continue. What's left? The intercooler tank and throttlebody, the complete exhaust, alternator bracket, radiator and heat exchanger mounts, A/W plumbing, new engine mounts, and making a few more solid connections for the engine/VR adapter/transmission.

Waiting for parts has set me back at least two weeks. Now it's looking closer to late July, early August.

Big Boost
06-27-2010, 08:43 AM
UPDATE!

The main radiator mount is finished. It is iso-mounted between the new fabbed bumper mounts. The heat exchanger will be mounted in front of the radiator along with a SPAL fan I purchased from VAST when I was Stage 3.

http://motorgeek.com/gallery/main.php?g2_view=core.DownloadItem&g2_itemId=95821&g2_serialNumber=2

Getting closer. Mounting the radiator was one of the major obstacles along with figuring out a solution to protect the radiator, heat exchanger and engine (not to mention MYSELF and the family) in a frontal collision. I'll post pix later of that set up.

http://motorgeek.com/gallery/main.php?g2_view=core.DownloadItem&g2_itemId=95827&g2_serialNumber=2

Notice the space between the radiator and the inner edge of the front bumper. There is decent enough room to mount the heat exchanger there. The bumper and support will have to be cut back a little to mount the SPAL fan.

http://motorgeek.com/gallery/main.php?g2_view=core.DownloadItem&g2_itemId=95833&g2_serialNumber=2

The mounts are iso-mounted using high density rubber. The beauty of this mounting system is that it will be quick and easy to remove the radiator. Look REAL close to the radiator mount on the drivers side, particularly what it's attached to. That should provide a partial clue of the frontal system design.

http://o2induction.com/images/Builds/Big%20boosts%20VR6%20BAT%20Build/IMG_0536a.jpg

Also, if you take a close look, the throttle body is finished and the aluminum inlet tube has been made. The driver's side air tank is the last remaining part that needs to be completed and the A/W system is finished.

http://o2induction.com/images/Builds/Big%20boosts%20VR6%20BAT%20Build/IMG_0547a.jpg

http://o2induction.com/images/Builds/Big%20boosts%20VR6%20BAT%20Build/IMG_0545a.jpg

Here are some quick shots of the fabbed billet fuel rail mounts.

http://motorgeek.com/gallery/main.php?g2_view=core.DownloadItem&g2_itemId=95840&g2_serialNumber=2

http://motorgeek.com/gallery/main.php?g2_view=core.DownloadItem&g2_itemId=95846&g2_serialNumber=2

JDM EJ1 95
06-27-2010, 09:09 AM
looks great!

Turbo Nerd
06-27-2010, 04:39 PM
woah make sure you have a vid on the first start.

Matador
06-27-2010, 07:08 PM
Was wondering why you ran the wastegate dumps forward and down instead of back toward the firewall?

Haenszel20v
06-27-2010, 07:13 PM
Was wondering why you ran the wastegate dumps forward and down instead of back toward the firewall?

significantly more room.

ECS Tuning-Audi
06-28-2010, 09:34 AM
Are you going to shield the radiator from the manifold? Can't tell in the pictures but it looked a bit close for comfort?

Big Boost
06-28-2010, 10:05 AM
Are you going to shield the radiator from the manifold? Can't tell in the pictures but it looked a bit close for comfort?

There is a good 3" between the intake manifold and the radiator. If there is too much radiant heat emitting from the radiator a shield will be made to keep ambient temps down.

RAI Motorsport
06-28-2010, 10:31 AM
very cool project, cant wait to see this in action. beautiful fab!

revhards4
06-28-2010, 09:40 PM
not a fan of the 12v vr6 but this setup is going to deliver for sure!

Big Boost
07-01-2010, 08:31 AM
UPDATE!

The heat exchanger is iso-mounted in front of the radiator. The 16" SPAL fan has been test mounted and will be in front of the heat exchanger. It will be permanently mounted once the bumper orientation is figured out.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0614.jpg?t=1277989175

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0583-1.jpg?t=1277989175

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0586.jpg?t=1277989175

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0584.jpg?t=1277989175

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0571.jpg?t=1277989796

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0566.jpg?t=1277989796

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0553.jpg?t=1277989796

Nebone
07-01-2010, 01:51 PM
I can't stop staring at this!

Big Boost
07-02-2010, 11:01 AM
UPDATE!

The heat exchanger is now iso-mounted directly in front of the radiator. A SPAL fan provides airflow to both units. A new front bumper cross member was made for improved structural integrity as well as being reinforced to further protect both the heat exchanger and radiator units. The bumper cross member will duplicate the factory mounting points for the attachments points for the bumper cover. This part of the bumper fab will begin this weekend amongst other things.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0647.jpg?t=1278086697

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0646.jpg?t=1278086696

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0644.jpg?t=1278086696

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0640.jpg?t=1278086696

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0635-1.jpg?t=1278086696

ECS Tuning-Audi
07-02-2010, 11:15 AM
Very nice as always!

beemercer
07-02-2010, 11:35 AM
Just plain ridiculous, incredible work [up]

Matador
07-02-2010, 02:17 PM
Jesus that heat exchanger is HUGE! It's like 3 times the size as the one HPAs using with their kit. Very nice!

RolledMySTi
07-02-2010, 04:51 PM
This build is like porn. I almost feel dirty checking it out. Keep up the great work.

JDM EJ1 95
07-02-2010, 07:05 PM
dammit, i totally forgot to ask you to come see this thing, i was in milwaukee picking up another stupid ass project and it slipped my mind completely..


but yea, i came back with a suzuki samurai with a 240sx motor hahahaha


i cant wait to see this thing on the road man, extremely talented guy you are.

BENI_BOY
07-02-2010, 07:17 PM
so much win in this project! i love you (no gay)

GURUMAN
07-02-2010, 08:35 PM
Wow man, what an inspiration for my front end, the GM engine is long...

Big Boost
07-03-2010, 09:40 AM
This build is like porn. I almost feel dirty checking it out. Keep up the great work.
That's funny as hell! It's not HD 3D porn, but hopefully it comes (or should I say cum) close. Bad joke....


so much win in this project! i love you (no gay)
LOL. You mean NO HOMO! You love the project, not me....right ; !!



i cant wait to see this thing on the road man, extremely talented guy JON IS.
Correction! Remember, my welds look like hell.

Thanks for all the compliments and support fellas. Again, it's much appreciated.

Layza
07-04-2010, 11:27 AM
Dam Rob, this think is looking fucking awesome!! I can't wait tell it's done.......

Big Boost
07-07-2010, 07:30 AM
The core support/front crossmember is almost finished!

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0704.jpg?t=1278480711

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0673.jpg?t=1278480711

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0699.jpg?t=1278480711

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0680.jpg?t=1278480711

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0687.jpg?t=1278509461

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0675.jpg?t=1278509461

ECS Tuning-Audi
07-07-2010, 08:38 AM
Pure art! Are you worried about an impact and an aluminum support? I love the entire project and all the craftsmanship, just curious why you didn't go very high gauge steel to protect your art behind it?

Big Boost
07-07-2010, 09:00 AM
Pure art! Are you worried about an impact and an aluminum support? I love the entire project and all the craftsmanship, just curious why you didn't go very high gauge steel to protect your art behind it?

The OEM bumper utilizes approximately a 1/4" thick piece of aluminum as a protection measure and its strength was severely diminished when it was cut to provide clearance for the previous front mount intercooler. This unit is stronger than what I previously had due to using a frontal 1" thick square bar stock and it is significantly lighter than steel. Also, it will be reinforced from the bottom when it is mechanically connected to the body. It should be very strong once its finished.

ECS Tuning-Audi
07-07-2010, 09:29 AM
The OEM bumper utilizes approximately a 1/4" thick piece of aluminum as a protection measure and its strength was severely diminished when it was cut to provide clearance for the previous front mount intercooler. This unit is stronger than what I previously had due to using a frontal 1" thick square bar stock and it is significantly lighter than steel. Also, it will be reinforced from the bottom when it is mechanically connected to the body. It should be very strong once its finished.

Good to hear, thanks for the follow up. I hadn't realized that was 1" thick bar! Once again, love this project!

Sales@RAI
07-07-2010, 01:56 PM
wow

SummitS4
07-08-2010, 11:37 PM
i need more pics cuz im about to cum!!! lol

NYCVR6
07-09-2010, 12:10 PM
Looks awesome... You're going to need more fan than that, i have 3 electric fans on mine.. One big one and one small one pushing and another small one pulling, my car was still overheating in traffic, so i put a inline electric water pump to keep things moving in traffic..

Big Boost
07-09-2010, 12:37 PM
Looks awesome... You're going to need more fan than that, i have 3 electric fans on mine.. One big one and one small one pushing and another small one pulling, my car was still overheating in traffic, so i put a inline electric water pump to keep things moving in traffic..

Justin, you know we were all pulling for you to get through your ordeal! I'm glad you're feeling better and how are you doing?

We can talk fans and shit later......

Again, I'm glad you're back man. I didn't have anyone to "discuss" things with!! LOL.

import automart
07-09-2010, 03:45 PM
Rob, WOW!!! WOW!!!!

Hyphy
07-09-2010, 04:20 PM
Man....fabalicious!

Sales@RAI
07-09-2010, 11:36 PM
Looks awesome... You're going to need more fan than that, i have 3 electric fans on mine.. One big one and one small one pushing and another small one pulling, my car was still overheating in traffic, so i put a inline electric water pump to keep things moving in traffic..

Justin, hells yea for posting again [up]

NYCVR6
07-10-2010, 08:52 AM
Justin, you know we were all pulling for you to get through your ordeal! I'm glad you're feeling better and how are you doing?

We can talk fans and shit later......

Again, I'm glad you're back man. I didn't have anyone to "discuss" things with!! LOL.

Thanks so much bud, i was actually discharged yesterday so i got to sleep in my own bed with my fiance again which was great. I still have a long road ahead, but its great to be out of the hospital. Thanks so much for the thoughts, i know all you guys were pulling for me. The build looks so sick by the way.

Thanks Clint!!!

diabolical1
07-11-2010, 11:45 AM
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0699.jpg?t=1278480711

i must say, with all of the other gorgeous and top notch stuff you have going on with this build, i'm probably most impressed by this multifunctional custom bumper support piece. your friend (Jon, i think you said) has crazy skills! props to you both.

diabolical1
07-11-2010, 11:56 AM
... i have 3 electric fans on mine. One big one and one small one pushing and another small one pulling, my car was still overheating in traffic, so i put a inline electric water pump to keep things moving in traffic..

just curious about a few things, but i suppose most of them are contigent on if you have an actual temperature gauge, so that's my first question: do you have one?

if so ...
(1) what kinds of temps did you see at moderate load/throttle before adding the electric pump?
(2) what kinds of temps did/do you see after adding it?
(3) do you run an oil cooler as well?
(4) just to clarify, are you running only an electric water pump or are you running it in tandem with the stock mechanical pump?

thanks.


oh and i'm glad to hear that you're out of the hospital. will you need rehab or no?

Big Boost
07-13-2010, 06:58 AM
It's looking as if the build should be completed by next month. The next step will be to have it tuned. I can't wait.....

NYCVR6
07-14-2010, 12:19 PM
just curious about a few things, but i suppose most of them are contigent on if you have an actual temperature gauge, so that's my first question: do you have one?

if so ...
(1) what kinds of temps did you see at moderate load/throttle before adding the electric pump?
(2) what kinds of temps did/do you see after adding it?
(3) do you run an oil cooler as well?
(4) just to clarify, are you running only an electric water pump or are you running it in tandem with the stock mechanical pump?

thanks.


oh and i'm glad to hear that you're out of the hospital. will you need rehab or no?

I only am working with the factory gauge, but in traffic it starts to overheat unless i give it gas and get the water pump spinning. So when im moving along the temps are fine. I havent ran it with the booster pump yet, but im running it in tandem with the stock pump. Yes i run an oil cooler. Thanks for the thoughts about getting out of the hopital, i have a fairly long road ahead, i have rehab and a lot of follow up doctor appointments.

Haenszel20v
07-14-2010, 12:42 PM
I only am working with the factory gauge, but in traffic it starts to overheat unless i give it gas and get the water pump spinning. So when im moving along the temps are fine. I havent ran it with the booster pump yet, but im running it in tandem with the stock pump. Yes i run an oil cooler. Thanks for the thoughts about getting out of the hopital, i have a fairly long road ahead, i have rehab and a lot of follow up doctor appointments.

Are you on stock ecu? My stock gauge reads "190" all the way up until the autronic reads 240*....... NOT GOOD.

NYCVR6
07-14-2010, 12:57 PM
Are you on stock ecu? My stock gauge reads "190" all the way up until the autronic reads 240*....... NOT GOOD.

I run ViPec V88, Ray Hall split from Autronic and started his own company. We've logged it and it's pretty accurate with the stock gauge, a little off but nothing like yours.

Haenszel20v
07-14-2010, 01:43 PM
Nah I'm just sayin its crazy the span that the stock gauge stays.at 190 for.

diabolical1
07-15-2010, 10:29 AM
thanks for the reply NYCVR6.

Haenszel20v,
yes, a 50 degree lag/dead time is pretty crazy. i'm sure it would probably vary from car to car, but it's still pretty unnerving.

Big Boost
07-19-2010, 08:11 AM
UPDATE!!

The throttle cable and the accelerator pedal are done. The cable was made from two cables. Part of the cable was from the unit 034 provided me along with a LOKAR unit I already had. Even the black factory triangle that fits on the firewall was used. It fits like a OEM unit!

The water pump for the AWIC system is mounted and the hoses have been positioned. The water flow path runs in the opposite direction of the air flow path. The water pump first sends the cooling medium from the heat exchanger to cool the intake manifold through a channel underneath the plenum (approx 1 liter of volume). Next the medium flows to the AWIC. After that, the compressor discharge pipe has been modified and now incorporates an intercooled plenum around it. It is designed with an internal baffle that swirls the water around the neck 360 degrees and exits directly into the heat exchanger. It is designed to reduce the inlet temperature before the AWIC and thus to further reduce the entire intake temps.


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0890.jpg?t=1279546162

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0889.jpg?t=1279546162

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04725.jpg?t=1279812752

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0888.jpg?t=1279546162

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0885.jpg?t=1279546162

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0816a.jpg?t=1279546401

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0817.jpg?t=1279546401

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0820.jpg?t=1279546401

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0820a.jpg?t=1279546401

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0821.jpg?t=1279546401

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0877.jpg?t=1279546719

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0886.jpg?t=1279546719

http://o2induction.com/images/Builds/Big%20boosts%20VR6%20BAT%20Build/IMG_0887a.jpg

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/Undershot.jpg?t=1279547835

Haenszel20v
07-19-2010, 08:22 AM
What's going on with the turbo outlet pipe? Why is the water routed through that?

Big Boost
07-19-2010, 08:25 AM
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0819.jpg?t=1279553226

There is over a half inch of clearance between the discharge plenum and the hood.

laxman851
07-19-2010, 10:43 AM
So are you or your friend going to open a shop soon or something... goodness.

skinnytirez
07-19-2010, 11:06 AM
i'd give them my business...just read all 5 pages of this; i want one!

Great job kids!

Turbo Nerd
07-19-2010, 02:24 PM
Pure sex. What's left to do, doesn't look like much?

colt45
07-19-2010, 02:47 PM
god damn this is an awesome build. cant wait to see the finished product.

ECS Tuning-Audi
07-19-2010, 03:07 PM
Pure sex. What's left to do, doesn't look like much?

Looks like the plumbing from the AWIC to TB is all that is left in terms of hardware. Can't wait for an excuse to pop up to Chicago and visit this build and some other dub friends!

Big Boost
07-19-2010, 06:43 PM
Pure sex. What's left to do, doesn't look like much?

The project is getting closer to being finished, but there are still some things left to do.
Here they are in no particular order except for the number 13. That happens 24/7!


1. Alternator bracket
2. New engine mounts
3. Thermostat housing
4. Catch can
5. Exhaust with cut out
6. Skid plate
7. Splitter
8. Longblock assembly
9. Wire the standalone
10. Finish the intercooler end tank
11. Install the fueling system
12. Tune for pump and race gas
13. Hide receipts from wife and enjoy life!!


Looks like the plumbing from the AWIC to TB is all that is left in terms of hardware. Can't wait for an excuse to pop up to Chicago and visit this build and some other dub friends!

When it's close to being ready, I'll hit you up and arrange a time we all can get together. Some of the Milwaukee crew said they would roll down with me.

A4 TSCHUSS
07-19-2010, 06:50 PM
Thing is insane, I just pray it gets a good tune after all this work.

Turbo Nerd
07-19-2010, 09:00 PM
Not sure I'd you mentioned it but which standalone are you going with 034's? That's not to bad of a list to be done, btw love number 13 haha goodluck man looking good.

Big Boost
07-20-2010, 07:56 AM
Not sure I'd you mentioned it but which standalone are you going with 034's? That's not to bad of a list to be done, btw love number 13 haha goodluck man looking good.

I have 034's Stage IIc standalone with the plug and play harness.


Thing is insane, I just pray it gets a good tune after all this work.

I'm in the process of looking for an excellent tuner right now. And yes, that receipt will be hidden too......

Big Boost
07-20-2010, 05:15 PM
http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/VR6ShortBlocklowres-1.jpg?t=1279666149

Here is a quick shot of the shortblock. It is a 2.9L with JE 9:1 polished pistons and Eurospec rods. Honestly, I suspect that 034, Eurospec and Integrated Engineering rods are all the same. I might be wrong, but after weighing IE and Eurospec units I found that they weigh EXACTLY the same. The good thing is that all 12 rods were dead on the same weight. Visibly they look the same too. I've seen these rods support well over 1000chp so I feel confident but at the same time I probably justjinxed myself.

On another note I decided to upgrade to 288 TT cams. I need a little more, OK a lot more RPM than the 268's will provide. The head is getting resurfaced and the longblock should be assembled this weekend. I'm going to use the mock up VR6 already in the caras a spare to build over the winter. I intend to build that engine with a little higher compression, internal coatings and a few other tricks. It's inevitable that something is going to give sooner or later so I might as well be prepared.

sean1.8t
07-20-2010, 06:57 PM
It's inevitable that something is going to give sooner or later so I might as well be prepared.

SMART! [up]

Haenszel20v
07-20-2010, 07:30 PM
Be careful with the 288's, especially if you've decked the head and/or block, they're already ultra close.

Mcstiff
07-26-2010, 01:15 AM
Update?!?

Big Boost
07-26-2010, 07:23 AM
Right now, three separate things are being fabbed. The thermostat housing/coolant system, alternator bracket and new engine mounts. I'll update as soon as all three are complete!

Big Boost
07-30-2010, 09:23 AM
Here are some new pix showing the beginning fabrication of the machined upper alternator bracket and the aluminum plate that will function as the lower alternator bracket, power steering bracket AND driver's side engine mount. The driver's side should be completed by Sunday or Monday at the latest.


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04739.jpg?t=1280495864

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04736.jpg?t=1280495864

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0908.jpg?t=1280495864

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0907.jpg?t=1280495864

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0906.jpg?t=1280495864

Haenszel20v
07-30-2010, 09:42 AM
All this stuff is super neat, but now it really seems like you're just trying to find things to make. The OEM bracket worked just fine???

Big Boost
07-30-2010, 09:49 AM
Not really. Remember, the alternator had to be relocated due to the size of the intake manifold. At this point, many things have been made because of function, it just happens that the form looks cool. I can't apologize about that. Besides, this is a build thread....LOL.

Big Boost
07-31-2010, 10:07 PM
Update! The driver's side engine mount/alternator and power steering bracket is complete!

This was the previous starting point for the combo alternator bracket, power steering bracket and the driver's side engine mount.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0907.jpg?t=1280495864



Next, is the actual engine mount welded to the plate. Notice the upper alternator bracket.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04868-1.jpg?t=1280635907

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04829.jpg?t=12806349522

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04823.jpg?t=1280633805



This is the lower alternator bracket that was just welded onto the main assembly.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04859.jpg?t=1280633596

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04854.jpg?t=1280633596

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04852.jpg?t=1280640324

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04857.jpg?t=1280640324

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04873.jpg?t=1280635572


A pass through hole was drilled and chamfered to reach the inner bolt connecting the bracket to the block.


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04874.jpg?t=1280637071

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04851.jpg?t=1280633596

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04905.jpg?t=1280634335


All stainless bolts were used on the mount plate and power steering pump front and rear. The alternator stainless bolts still need to be sourced.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04888-1.jpg?t=1280635907

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04904.jpg?t=1280636339

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04850.jpg?t=1280640324


This is the base for the passenger side mount. Fab work should begin in the next couple of days.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04909.jpg?t=1280636986

Big Boost
07-31-2010, 10:10 PM
The Fuelab components were ordered on Friday. After the passenger side engine mount is complete, the focus will switch solely on the cooling system until that's complete. The alternator and power steering pump will be rebuilt or replaced with new units.

The exhaust fab will begin after the engine mounts are finished.

This is the elbow for the 4" downpipe.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04907.jpg?t=1280639653

Sigma 3
08-01-2010, 03:30 AM
Looks Really good.

O2VW1.8T
08-01-2010, 02:32 PM
wow amazing build, wish i had skills with a tig welder.

GURUMAN
08-01-2010, 07:08 PM
I'm stoked with all that alu, really impressed !

Big Boost
08-02-2010, 09:43 AM
Update! The driver and passenger side engine mounts are now complete!!

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0933.jpg?t=1280762861

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0938.jpg?t=1280763238

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0963.jpg?t=1280763238

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0994.jpg?t=1280763238

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0995.jpg?t=1280763238

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0971.jpg?t=1280763238

Here's the underboob shot!

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0984.jpg?t=1280764801

http://www.o2induction.com/images/Builds/Big%20boosts%20VR6%20BAT%20Build/IMG_0969a.jpg

AudiSportB5S4
08-02-2010, 09:54 AM
Holy crap..

I was about to type, what were your intentions with the car, then I read your very first post... HA, that's funny.. Gotta love Prince's advice... Surprised he didn't get you into a Mustang!

Big Boost
08-02-2010, 10:11 AM
Actually, believe it or not, this is will be a daily driven street car. Next year my goal is to put AC back into the car! It's really more fun to have a car that you can drive 9 months out of the year.

nefkntym
08-02-2010, 11:33 AM
So much win!!! This build thread is Awesome!!!

sean1.8t
08-02-2010, 07:12 PM
the awesomeness of the work is simply awesome!!

Big Boost
08-03-2010, 07:50 AM
Update! The 1/4" thick aluminum skid plate is finished. This part will protect the oil pan against the very thing that was the cause of this project, a pothole! I don't know the origination of the oilpan, and I waited over three weeks for this one, so anything that can protect it is a great benefit. Anything that can be done to reduce downtime is also a plus!

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1012.jpg?t=1280839533

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1011.jpg?t=1280839533

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1010.jpg?t=1280839533

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1009.jpg?t=1280839533

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1007.jpg?t=1280839533

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1005.jpg?t=1280839533

nizmosx
08-03-2010, 12:39 PM
HAWT

Don Supreme
08-03-2010, 01:13 PM
This car isn't even an Audi anymore *lol*...

Amazing stuff.

AudiSportB5S4
08-03-2010, 01:47 PM
Haha so much welding, it's great.

I'm buying a Panzer plate soon, looks like you made your own!

S4-ORCE
08-03-2010, 01:51 PM
Incredible, great job

2kblacks4
08-04-2010, 01:57 PM
Build looks amazing!

Thanks again for selling me the fueling kit!

Big Boost
08-05-2010, 10:02 AM
UPDATE! The idler pulley has been machined of out aluminum goodness with a double roller bearing assembly!!
I am getting the full set of Gruven pulleys now just because.......


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1019.jpg?t=1281023453


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1018.jpg?t=1281023453

Sales@RAI
08-05-2010, 01:21 PM
Big Boost, I say you go big and just make your own engine

Dan[FN]6262
08-05-2010, 01:26 PM
^^^^^^^^

Sigma 3
08-06-2010, 03:20 AM
Yeah This using a pre exsisting engine is really sub par. You should make a W 10!

joemomma
08-06-2010, 09:26 AM
amaazziinngg work bro!!!! what kind of tig welder are you using?

Big Boost
08-08-2010, 09:23 AM
Update! The cooling system fab has begun.


This is the machined waterneck for the cooling system. The ID of the waterneck will be blended by hand so it will be perfectly gasket matched.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04834-1.jpg?t=1281279538


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC04831-1.jpg?t=128128085879538



The water pipe is angled down to clear the 4" downpipe.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1024.jpg?t=1281280572


This aluminum spigot feeds the interior heater core.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1029.jpg?t=1281280572


The silicone hose will need to wrapped to protect it from the radiant heat of the turbo manifold.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1032.jpg?t=1281280572

A4 TSCHUSS
08-08-2010, 09:49 AM
What does your friend who is doing the welding and fabricating do on a day to day basis? Does he run a performance shop or just a regular welding/machine shop that does whatever?

Big Boost
08-08-2010, 10:03 AM
amaazziinngg work bro!!!! what kind of tig welder are you using?

He's using a Miller Dynasty 350. Here is the info.

The welder.
http://www.millerwelds.com/products/tig/dynasty_350/

The supplier.
http://www.weldspecialty.com/




What does your friend who is doing the welding and fabricating do on a day to day basis? Does he run a performance shop or just a regular welding/machine shop that does whatever?

He's a hobbyist that loves doing quality work. He has a regular 9-5 job and afterhours he designs, fabricates and TIG welds for numerous projects. Anyone care to join the waiting list? (JK!!...I don't want the mods puttin' the smack down on me......)

O2VW1.8T
08-08-2010, 12:11 PM
Wow im in love with this build.

Matador
08-11-2010, 09:45 AM
I don't think that skidplate is going to do much for you. It'll buckle/break right at that angled weld. I think this is where a press brake would've been the best bet. That, and the R owners have been having issues with stuff punching THROUGH the Panzer plate and into the oil pan anyway, and there is very little clearance there I see. What you may want to end up doing is design and fab up a steel pan instead, and use a press brake to get the angles you're looking for.[up]

QWKDTSN
08-12-2010, 05:27 AM
This is the craziest most awesome fabrication project I have ever f***ing seen.

Every time I come back I can't believe the new steps you've taken!

Big Boost
08-12-2010, 11:13 AM
I don't think that skidplate is going to do much for you. It'll buckle/break right at that angled weld. I think this is where a press brake would've been the best bet. That, and the R owners have been having issues with stuff punching THROUGH the Panzer plate and into the oil pan anyway, and there is very little clearance there I see. What you may want to end up doing is design and fab up a steel pan instead, and use a press brake to get the angles you're looking for.[up]

Actually, it will. It is a 1/4" thick aluminum versus 1/8" like the Panzer plate or it's upgraded .200" size. It was relief cut, then break bent and finally welded on both sides. Trust me, it's stronger than it looks. Also, there are 3/8" nuts welded to the rear frame and also mechanically attached to the front core support. I wanted an aluminum plate versus steel because of the weight factor.

Matador
08-12-2010, 07:22 PM
Ah OK. From the pic, yeah it just looks like plates welded together at a joint. Good stuff.

q_dubz
08-12-2010, 07:24 PM
Ah OK. From the pic, yeah it just looks like plates welded together at a joint. Good stuff.shut your face!

Big Boost
08-12-2010, 10:39 PM
Ah OK. From the pic, yeah it just looks like plates welded together at a joint. Good stuff.

Thanks!


shut your face!

Let's keep it clean!

Matador
08-13-2010, 09:03 AM
shut your face!

You shut your whorish mouth sir!

It's cool, we know each other. Sadly. [:p]

Big Boost
08-13-2010, 10:42 AM
You shut your whorish mouth sir!

It's cool, we know each other. Sadly. [:p]

If I knew it was like that, then I would've told both of your mom's that I'm running late for the threesome (in my Sean Connery voice of course!).............(JK)

q_dubz
08-13-2010, 10:03 PM
You shut your whorish mouth sir!

It's cool, we know each other. Sadly. [:p]

wait who are you again? :p

Big Boost
08-16-2010, 10:09 AM
Back to the previous program.....

Playing the parts waiting game.....again.

nefkntym
08-16-2010, 10:26 AM
What are you waiting for this time?

Raacerx
08-16-2010, 11:10 AM
Good lord I didn't look all the way through this before. Thumbs up!

CLOUT
08-16-2010, 04:57 PM
Every update of this build is a pleasure to read. Great fab work, you and your friend should open up a shop.

Alkivar
08-16-2010, 10:13 PM
i'm surprised you didnt decide to go dry sump for oil considering all the other crazy work you've done... was there a reason for this other than cost?

Big Boost
08-17-2010, 08:04 AM
What are you waiting for this time?

Mainly fuel components and a bunch of other odds and ends....literally.


i'm surprised you didnt decide to go dry sump for oil considering all the other crazy work you've done... was there a reason for this other than cost?

If I was involved in endurance racing I would consider it, but right now it's not even close to being in the budget. Maybe in the near future, but not now. I have in mind some improvements for the car, but I need to get it up and running first.

Big Boost
08-25-2010, 08:41 AM
Update. Let the games begin......again. I just received the Fuelab Prodigy 1300hp rated fuel pump and adj. regulator.

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC05106.jpg?t=1282744970


WAAAAYYYYY back when this project first started, this was all I envisioned.....a clone ATP manifold and a GT4094R with an aluminum intake box welded to the stock VR flange. Also, I planned to use the 034 engine cradle, a head spacer on the stock block with only 25psi max along with the 034 Stage IIC standalone. I figured about 600 crank HP at best.


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/DSC03391.jpg?t=1282745166



It's funny how things change so quickly! The question that started this build was "What do you REALLY want to do?" Well, you see it right before your eyes! This is the stuff dreams are made of! I can't wait until I can drive it and experience what it feels like.

I will say this, Jon skills are absolutely ridiculous! I find myself just staring at the car thinking the whole time to myself "Damn, this is nuts!" I took a few of my friends to see the car and their mouths just dropped. It looks way better in person. My friends are now even more hyped than I am, and that's hard to beat. Damn, I can't wait!!!




http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0971.jpg?t=1282745015


Everyone is telling me that if this car doesn't produce the times I'm shooting for, the car needs a driver mod. LOL. We'll see.....
More updates are coming soon!

ECS Tuning-Audi
08-25-2010, 09:51 AM
Love the update. I've read the whole thread but may have missed it: Why two wastegates?

AAAA
08-25-2010, 10:21 AM
b/c the vr has headers split in 2 pieces, 3 on each side so if he made his exhaust mani like i think he did he kept that design, hence 2 wastegates-one for each set of 3 runners

Don Supreme
08-25-2010, 10:27 AM
Love the update. I've read the whole thread but may have missed it: Why two wastegates?

twinscroll

AAAA
08-25-2010, 10:31 AM
twinscroll

well i thought that would be a given, otherwise no point in having 2 exhaust manis. when are you gonna man the fuck up and get some turbos

ECS Tuning-Audi
08-25-2010, 10:55 AM
b/c the vr has headers split in 2 pieces, 3 on each side so if he made his exhaust mani like i think he did he kept that design, hence 2 wastegates-one for each set of 3 runners

They look like they are both mounted on the collector though? Could be a bad angle. Anyhow, this was my thought too if they are on two separate headers.

Haenszel20v
08-25-2010, 11:04 AM
The collector is split. Twin scroll flanges have a split down the middle.

http://i75.photobucket.com/albums/i303/trustdestruction/HCF%20DIYs%20and%20FAQs/T6TwinScrollFlange.jpg

Big Boost
08-25-2010, 11:18 AM
Love the update. I've read the whole thread but may have missed it: Why two wastegates?

The turbo is a twin scroll unit and the manifold is divided into 1-3 and 4-6 to utilize the design. Each scroll has it's own independent wastegate and 3 tubes feeding each one.

Here is a good pic showing the design

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_0250.jpg?t=1282755551

ECS Tuning-Audi
08-25-2010, 12:38 PM
yep that clears it up!

Big Boost
08-26-2010, 02:10 PM
UPDATE! The thermostat housing and coolant system is complete!!

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1145.jpg?t=1282853083


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1149.jpg?t=1282853083


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1144.jpg?t=1282853083


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1156.jpg?t=1282849353


http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1157.jpg?t=1282853083

ECS Tuning-Audi
08-26-2010, 02:26 PM
~art

Reich
08-26-2010, 08:20 PM
Man.... that's simply amaising. Completly art like stated above.

sean1.8t
08-28-2010, 01:06 PM
the little details like that are what put this project beyond over the top!

Alkivar
08-28-2010, 07:51 PM
jesus tapdancing christ this thing looks amazing... what is your 1/4 mile time goal 8's?

Big Boost
08-29-2010, 10:51 AM
jesus tapdancing christ this thing looks amazing... what is your 1/4 mile time goal 8's?

If this car hit an 8.XX, I think I would die. Literally, as soon as I got the timeslip.....BAM....I would drop dead.

Here's what it looks like to date..............

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1167.jpg?t=1283098714


This is the updated "TO DO" list.

1. Alternator bracket - Done
2. New engine mounts - Done
3. Thermostat housing/coolant system - Done
4. Catch can
5. Exhaust with cut out - In process
6. Skid plate - Done
7. Splitter
8. Longblock assembly - In process
9. Wire the standalone
10. Finish the intercooler end tank - Done
11. Install the fueling system
12. Make more mounting provisions from block to adapter to trans
13. Tune for pump and race gas
14. Smooth out engine bay and paint
15. Hide receipts from wife and enjoy life!! - Ongoing battle

Big Boost
08-30-2010, 10:04 AM
UPDATE!

Problem. I couldn't find a tight radius 90 degree 5" to 4" reducer silicone hose for the turbo inlet.

Solution. Jon made one out of aluminum!

The turbo inlet pipe is complete!

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1209.jpg?t=1283183545

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1205.jpg?t=1283183545

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1203.jpg?t=1283183545

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1220.jpg?t=1283183545

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1186.jpg?t=1283183545

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1182.jpg?t=1283183545

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1193.jpg?t=1283183545

http://i1026.photobucket.com/albums/y325/robbie40/VR6%20Turbo%20Conversion/IMG_1194.jpg?t=1283183545

ECS Tuning-Audi
08-30-2010, 11:37 AM
[SIZE=3]Solution. Jon made one out of aluminum!

Of course!

skinnytirez
08-30-2010, 02:17 PM
Will you please finish this already ;)
I can't wait any longer for videos...
love all the custom work; keep it up!
I wish i could have aluminum parts just appear when i couldn't find a silicone one...

Sigma 3
08-30-2010, 02:39 PM
Of course!

Funny[:D]

Thanks for all the updates!

Nebone
08-30-2010, 09:02 PM
If it does not hit 8.xx? Solution? Replace more with aluminum!

laxman851
08-30-2010, 09:37 PM
I almost don't want you to finish it (not really). I only say that because I love seeing what you're going to do next, and when this thread is old and fades, then gets brought back to life in 2014 i'm going to cry.

Big Boost
09-09-2010, 01:51 PM
Jon just got back from a much needed vacation and pretty soon the ball will start rolling again on the build. Overall, there really isn't too much more to do. Of course there will be a surprise or two left, but maybe by the end of this month to early next month it should be finished.