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View Full Version : Mathias 034 STK project RS4 + PT6262 !



Audi_S4
07-15-2012, 12:03 PM
Hey Guys , I'm gonna start my build thread cause the time has come for some MAJOR changes in my B5 ownership [:D]

I'm in the first batch of the 034 STK so very happy to share my build project with you guys for the next couple months!

I sold my ENTIRE S4 engine to a fellow member on a UK forum including just about everything on the car going from K04's to AWE downpipes, JHM FMIC, RS4 airbox ...just name it I sold it. At this moment the only thing left in my garage is my S4 with an empty engine bay , an RS4 gearbox , a DTS and some other minor parts I kept [:D]
I purchased a FULL OEM RS4 Long block without turbo's, manifolds and stuff like that and that's gonna be the heart of this all , this is on the way as we speak so should be here somewhere next week and ready to go to the machine shop!

First off I wanna thank Max@034 for answering my (I think 110 emails) for the last couple weeks [:D] but in return I also made his seller balance go UP ALOT for the last few weeks so we made eachother happy [:D]

Let's go ...

Engine : OEM RS4

Pistons : OEM RS4 (New rings + hone)
Rods : Integrated Engeneering + ARP bolts
Bearings : Glyco 034
Main studs : ARP
Heads : OEM RS4
Valves : Supertech Inconel exhaust valves
Springs/Retainers: Supertech Titan
Headgaskets : 034 0.5 Comp drop
Inlet Mani + TB : OEM RS4
Injectors : EV14 Bosch 750cc
Coils : TFSI coil conversion with 034 adapters
Exhaust : New style SSAC 2 x 2.5inch cat-back
Clutch : Southbend Extreme 6 puck Graphite / 16lb steel flywheel
Manifolds : 2.8 V6
Catch Can : AMW OCC


Turbokit = Full 034 Single Turbokit

Turbo : Precision PT6262 A/R .63 Ballbearing
Intercooler : Precision 750hp
Intake : 034 Intake + Carbon Shroud

Additional stuff :

Full service timing belt kit + metal thermostat housing
034 Motorsport engine mounts
RS4 FDP Gearbox
ESP DTS
JHM shifter Trio
RS4 Propshaft
RS4 Rear Diff
Advanced 4:1

Hoping to make 550whp on pumpgas (98oct) and around 600whp on Meth. The methanol kit will need to wait tough cause I'd first like the car to be running like a champ without problems and dialed in perfect on pumpgas before spending any more money [:)]

This is where I'm at right now! Should have taken a before pic but this is literally the cleanest I could get the engine bay! The difference before and after is EPIC , damn that thing was dirty! I am gonna spray, paint and coat some stuff but it's very clean and degreased right now

http://i45.tinypic.com/359a4pz.jpg

http://i50.tinypic.com/2qvxyqa.jpg

http://i47.tinypic.com/1zf7g93.jpg

http://i49.tinypic.com/4loepl.jpg

AudiForeman
07-15-2012, 01:53 PM
subscribed .


I cant wait to see progress of this. if you dont mind me asking how much for the rs4 gearbox? rs4 engine? and where did you buy it? UKebay?

UkuRiSh
07-15-2012, 02:10 PM
nice list of parts good luck man subscribed !!!!

Audi_S4
07-15-2012, 02:14 PM
subscribed .


I cant wait to see progress of this. if you dont mind me asking how much for the rs4 gearbox? rs4 engine? and where did you buy it? UKebay?

I live in Belgium so I have these parts for sale around here from time to time

Audi_S4
07-15-2012, 02:19 PM
nice list of parts good luck man subscribed !!!!

Thanks man! Really excited to see what it will do!

s4930
07-15-2012, 03:09 PM
subscribed! your gonna be my online guinea pig lol im hoping to be able to have a setup similar to yours!

Audi_S4
07-15-2012, 04:06 PM
With pulling the engine and stripping everything I was suprises what a mess the whole A/C is and how stuff is involved with that + the weight of the compressor and everything got me thinking of ditching the A/C but I'm a bit undecided on this .... Anyone know how much weight the full A/C setup is if you take EVERYTHING away ?

Bri_Guy1988
07-15-2012, 04:09 PM
YESS !!! Such a good guy to buy the kit I know you will update and keep uys well informed! Good luck and mucho HP to you.

howardfootball
07-15-2012, 04:43 PM
With pulling the engine and stripping everything I was suprises what a mess the whole A/C is and how stuff is involved with that + the weight of the compressor and everything got me thinking of ditching the A/C but I'm a bit undecided on this .... Anyone know how much weight the full A/C setup is if you take EVERYTHING away ?

I'm guessing about 100lbs. That's the common number I see when people take out A/C on any car.

viceprp
07-15-2012, 04:51 PM
That turbo should spool well as a .63 on the 2.8 motor. I know Dan ran into surge problems at 35+psi. Not sure your plans but 550whp sounds like a heavy boosting goal.

RudeJude518
07-15-2012, 05:31 PM
In for updates!!! And pics!!!!

wgarrett
07-15-2012, 05:39 PM
Wow, I can't wait to watch and see progress

S4 00 2.7
07-15-2012, 06:17 PM
This will be quite the project. Eager for results/progress!

Audi_S4
07-16-2012, 06:15 AM
That turbo should spool well as a .63 on the 2.8 motor. I know Dan ran into surge problems at 35+psi. Not sure your plans but 550whp sounds like a heavy boosting goal.

034 hit 570whp with an unfinished tune on race gas on 27psi. I don't plan on running more then 30psi anyways but it should be in the 525-550whp region when finished. RS4 Engine is also a bit more torque'ish then a built 2.8 in the head and cam department , that together with the .63 , RS4 shorter gearbox and the Duall BB'ing option will be alot better spool then what Max his car is doing right now

034Motorsport
07-18-2012, 11:16 AM
That turbo should spool well as a .63 on the 2.8 motor. I know Dan ran into surge problems at 35+psi. Not sure your plans but 550whp sounds like a heavy boosting goal.

Mathias has high flow heads and his motor will be similar to our 2.8L test motor, minus the 2.8L shortblock. But he has the RS4 upper intake components, etc.

We are pretty confident we can hit over 600whp on 110oct at under 30psi, no methanol. The test car did 570whp @27psi before the clutch started slipping, and this was only at 7000rpm. The 4" anti-surge compressor housing should help things too.

93/94 octane with methanol will easily push 550whp. Right now we know it does around 525whp on 91 with meth, and 93/94oct will add a LOT more to that.

On our 3.0L GTi-RS motor (034EFI IIc, CAT cams, tubular manifolds), we did extensive testing of turbos and turbine housings to see the differences in AR's, etc. With a Precision Turbo GT35R, we tested 3 housings ( 1.02, .82, .64), all of which produced the same peak power within ~10whp. The difference was that the .64 housing produce over 100 ft/lbs more torque on some parts of the graph (down low), spooling way faster with better response, and with only ~10whp difference which can easily be changing dyno conditions.

This is a 2.7L motor and our test car is a 2.8L motor, so the .64 housing should be even more geared. While the .82 to .64 housing change will likely be less dramatic then on a GT35R (the 6262 is larger), we have confidence it will show a good improvement all over the range.

While some cars tend to produce more power with larger turbine housings, the Audi 30v motors seem to really like small tight housings.

RudeJude518
07-18-2012, 01:56 PM
Seem to really like small tight housings

Amen brother, amen.

Audi_S4
07-18-2012, 03:43 PM
I just had confirmation my new SSAC 2 x 2.5 inch Cat-Back arrived at Marks place !

At first I'll be very happy if the new motor runs like a champ and the initial setup and startup doesn't give me too much of a headache. From the moment on that it's prooved to be faultless and ready I'll have it tuned to be a monster :)

Audi_S4
07-21-2012, 08:10 AM
New V6 Manifolds arrived yesterday

http://i49.tinypic.com/4loepl.jpg

They do look ALOT better flowing then the 2.7TT versions IRL ! Can imagine they improve spool alot !

Audi_S4
07-26-2012, 06:35 AM
RS4 Engine arrived on pallet this morning and is now safely in my garage = HAPPY :)

Also my RS4 piston rings came in. Damn those Audi stealerships !!! I got a 15% discount true my friends garage and it's still 314€ for the set (6)

Now it's time to take the engine apart and have the block cleaned and honed and assembled with the goooodies !

034Motorsport
07-27-2012, 12:17 PM
http://fototime.com/%7B6E785AF7-7121-4B44-A4B7-31FA334686FD%7D/origpict/IMG_8906A.jpg

http://fototime.com/%7B09C7732F-F047-47D3-B046-FD649FCED439%7D/origpict/IMG_8911A.jpg

Audi_S4
07-27-2012, 05:04 PM
Oh yeah :) Sweetness ...

Audi_S4
10-14-2012, 10:24 AM
My car is currently at the bodyshop to get a full respray inside and out , in the meantime I bought me

- Quattro GmbH 360x32mm drilled discs
- Porsche 996TT brake calipers
- Braided lines

Got me some more small goodies from 034:

Gates racing timing belt
Metal slave + braided line
SAI blockoff kit

Now waiting for the complete STK to arrive , I'll make pics of all my parts when it arrives ! When it does arrive I'll start tearing down the RS4 engine and bringing everything to the machine shop!

Austonwerner4
10-14-2012, 10:50 AM
What does the SAI Block off do? I thought it was only for auto cars

Audi_S4
10-14-2012, 10:56 AM
RS4 engines have it too. it's a whole system in the back off the engine, it's for emissions but it sucks balls so it needs to go and blocked off with these nice cnc'd plates 034 makes :)

sweets4style
10-14-2012, 03:10 PM
Why would you waste 30 bucks buying plates when all you have to do is get two machinist balls (from any machine shop) for less then 2 bucks. Dabble a bit of loctite red on it. And tap it into the holes. In case you were wondering this is what the factory does with the oem heads. There is no difference between auto and manual heads. One has a pressed in ball and the other doesnt. thats it. So why spend 30 bucks for shiny useless plates no one is going to see.

silverman
10-14-2012, 03:19 PM
^^^ Continuity.

Audi_S4
10-14-2012, 03:21 PM
Why would you waste 30 bucks buying plates when all you have to do is get two machinist balls (from any machine shop) for less then 2 bucks. Dabble a bit of loctite red on it. And tap it into the holes. In case you were wondering this is what the factory does with the oem heads. There is no difference between auto and manual heads. One has a pressed in ball and the other doesnt. thats it. So why spend 30 bucks for shiny useless plates no one is going to see.

I know they are there , good enough for me. There's alot of stuff I "could" make myself or do cheaper but it wouldn't look this nice and in the end of the day it's not your 30$ , there's people spending loads and loads of cash on useless things every day, nothing to worry about if it aint your $

gottaBdope
11-12-2012, 09:11 PM
sooo...updates?

Monty23
11-12-2012, 09:23 PM
He sold his turbo kit.

gottaBdope
11-13-2012, 10:17 AM
He sold his turbo kit.

Well, that's disappointing. Thanks for the repsonse.

034Motorsport
11-13-2012, 11:38 AM
Well, that's disappointing. Thanks for the repsonse.

I'm sure he will update, but unfortunately his new chassis that this project was going in turned out to be wrecked beyond use internally. Audi_S4 decided to scrap the RS4 chassis and the single turbo project and go a different route. Someone else on the forum has purchased the kit and will be receiving it in the new future.

Brens
11-13-2012, 12:34 PM
So this entire project bt the dust?

Anything you can tell us about the chassis' internal damage, Max?

Sent from my ADR6400L using Tapatalk 2

s4930
11-13-2012, 06:42 PM
So this entire project bt the dust?

Anything you can tell us about the chassis' internal damage, Max?

Sent from my ADR6400L using Tapatalk 2

i bought the kit from him but my build wont be as exciting as his unfortunately... he told me that the rs4 he was planning on using was in a wreck and the damage was beyond repair. i dont think any serious damage was done to the engine though as he was planning on pulling it apart and selling it but i could be wrong.

Meow
01-31-2013, 06:55 AM
This coulda been sick... so sad to see projects go under like this.

Audi_S4
03-23-2013, 07:45 AM
Yeah indeed it was kinda depressed but in the end I got good money selling all the parts (good thing I never installed any of the parts and it was all new boxed up)

I bought an A3 3.2 S-Line with DSG gearbox and I have since fallen completely in love with this car. It's almost 10yrs newer than my S4 and feels that way in every aspect. For now I did some minor adjustments like rimz,coilovers but have a pile of parts waiting to be installed and also the just released 034 Single turbokit with a PT5858

The gearshifts of the DSG leave the 01E completely in the dust , some may say it's an automatic and it's a no go for a sports car but I can tell you that from all my friends who have driven my car (even in stock form) every single one was seriously impressed with the gearbox and told me they would love to have one instead of rowing true the gears. Also you gotta admit the 01E just SUCKS :)

Meow
06-04-2013, 01:26 AM
Also you gotta admit the 01E just SUCKS :)

yes, it does. I love the dsg so much more...