Project B5 RS4 Sedan.

[Siena]

Just thought I'd post this on here - the full conversion, parts bought, as well as the surgery process.

As many know, power's not coming courtesy of a 2,671cc Biturbo V6, (though that was my original plan) but an S8 4,172cc V8, initially in n/a form.

[Siena]

First of was finding a base car, it had to be fairly cheap, fairly sound mechanically, all running gear was going to be replaced anyway.

Bodywork wasn't important either, as all panels bar the roof were going to be replaced with genuine RS4 items.

What was important though, was the drive - it had to be quattro, no front track would handle the power I had planned...

So, I located a '96 A4 2,6L V6 QS, for the sum of £500, with about 200,000 miles on the odometer, and her fair share of battle scars.

As collected...

[Siena]

I drove her stock, then began the painstaking task of sourcing genuine RS4 goodies.

After trawling through ebay.de, it became fairly obvious that people parting RS4's in Germany wanted way too much for the parts, and of course, shipping would be a killer.
So, I decided to buy new.

I first ordered the front fenders, rear quarters, and the rear doors.

Front fenders...




Rear doors...



Rear quarters...

[Euro-Tuner]

nice

[Siena]

Next, was the ordering of the RS4 front bumper, Euro S4 rear bumper, RS4 grille, RS4 sideskirts.

RS4 front bumper...




Euro S4 rear bumper...




RS4 sideskirts...



RS4 grille...



RS4 bumper grilles...



RS4 foglamps...



RS4 bumper irons, they are longer than stock A4...

[Siena]

Now, the RS4 front doors only differ from facelift ones, in that they lack mid and lower trims.

So, I decided to buy these used, all that they'd need then, would be to have the 6 little holes welded up, and the lower trim studs ground off.

I bought these...




I also wanted the Euro facelift trunk lid, so bought from the same B5 that liberated its front doors...




I wasn't going to just slap the trunk on as it was, I wanted a subtle B6-style modification, but more of that later.

[Siena]

Then came RS4 cast aluminium mirrors...




Then RS4 one-piece xenon headlamps...




I bought A4 facelift rear tails...



And matching A4 facelift rear bulb holders...



RS4 front clip came next...

[Siena]

My kitchen was gradually filling up with RS4 parts.

Next were RS4 plastic wheel arch liners, left and right, rear...




Then RS4 plastic wheel arch liners, left and right, front...



Then RS4 gas tank flap...



I then realised that the RS4 MUST have wider rear wheel arch wells, to meet the wider arches.

So, I ordered these...

[Siena]

Then came the little bits and pieces, that are easy to over look.

B7 aero wiper arms and blades...




RS4 side repeaters...



RS4 headlamp washer covers...



RS4 headlamp washer pump...



RS4 headlamp washer bottle...

[Siena]

As I previously mentioned, I wanted to subtly modify my Euro facelift B5 trunk, so this happened...




My base car had over 200,000 miles under her belt, so it was obvious the suspension would be shot to hell.

I purchased -30mm Eibach Sport Springs, designed for the heavier RS4. It would lower my car less, but as I planned a larger, heavier engine and 6-speed tranny from the onset, I allowed for that.

Eibach springs...




Then RS4 Bilstein Sport Dampers, ordered from my local Audi dealership...




I also ordered the front lower arms...




...And a complete set of rear bushes...



I fitted the lot before she went in for surgery.

[Jibberific]

Man, you really don't fuck around do you. It's almost like you put a whole car together from scratch.

[goody6691]

man you must have a big yard. i cant wait to see the outcome of this. this conversion is my dream. v8 power in a b5 sounds like fun. good luck, keep us posted.

[Siena]

I then settled on my wheels - BBS RX II's splits, in 8,5"x18" ET 20, with Dunlop Sport 9000's, in 255/35x18, the correct dimensions for an RS4.

I ordered them, and they turned up from Germany 2 weeks later...

[Siena]

I considered RS4 brakes for stopping power, then realised the reason there were so many used parts floating about, was that they're not that great.

So, I went for Audi S8 2003 MY 4-piston Brembos. They're supplied by Audi with pads, but I also got a good deal on Hawke performance pads from the United States.

S8 Brembos with stock pads...




Hawke pads...




Brembos and Hawke...

[Wanted]

So far a great write up! Can't wait to see more

[firstars]

wow, I overlooked so much little cosmetic things to get it done right. only thing I would have done different is wheels. Why not like 18x10s or something on there? You have the room.

[Siena]

Engine originally destined for Project B5 RS4 Sedan...





Recently sold to make way for S8 power...






Note large throttle body - no problems getting air in there when I later go forced induction...



Rebuilt 2000 S4 6-speed tranny. I also bought a 6-speed from a wrecked Allroad 2,5TDI, and robbed it of the 5th and 6th gears in my S4 box.

Now geared to do 37.5mph per 1,000rpm...

[Siena]

wow, I overlooked so much little cosmetic things to get it done right. only thing I would have done different is wheels. Why not like 18x10s or something on there? You have the room.

I'll probably go for 9,5"x18" with 265/30x18.

A lot of B5 RS4 boys here have gone the 10" route, and regretted it, as the handling was awful, and the cars tramlined like mad.

[Siena]

Manual V8-engined Audi's were never imported to the UK.

So, I had to have a flywheel custom made...






Weight? 7,2 kilos. Stock Audi S8 item is 13,5 kilos.

[Siena]

Engine is not being run on the stock Bosch Motronic EMS, although it was supplied with the EMS, ignition key so I could use it, if I wished.

The stock system isn't flexible enough to run turbo applications. The most you could do would be to run bigger injectors, map the ECU to alter the duty cycle, and retard the ignition, to avoid detonation.

I wanted a system flexible enough to cope, that also employed a MAP sensor, that way, the timing can still be aggressive enough to make good power, yet still retard on WOT / full boost.

I've ordered my system, and the wiring harness is being modified as we speak.
I'll be running the engine on the ground, no exhausts, just stock S8 headers!
God help my neighbors.

[VTAudiA4]

You are one talented mechanic to do most of the mechanical work yourself. It makes you appreciate your car even more. Great car you have and I cannot weight to see what kind of numbers you plan on making with a forced induction setup.

[Siena]

My car went into the bodyshop on the 17th November 2007, and was ready for collection on the 29th January 2008.

My B5 sliced open, all her tired old bones showing...



More pictures...

[onemoremile]

I am continually impressed. You need a new neighbor?

[Siena]

She began to look less like a wrecker sometime early January...

[Siena]

I am continually impressed. You need a new neighbor?

Lol, the more B5ers, the merrier.

[Siena]

At last, she's done, and back home where she belongs...

[wwb4]

Nice project.....and nice quality work! You are currently already running the S8 engine/motor correct?

[Siena]

And some in Sepia. Note the suspension has settled a fair bit lower...

[Siena]

Nice project.....and nice quality work! You are currently already running the S8 engine/motor correct?

S8 motor is not yet up and running.

She's still running the stock 2,6L V6.

[Siena]

Will keep you guys updated.

Exhaust is still the stock one, will be upgrading once the engine's in.
It'll require a custom one anyway, in stainless steel.
I plan to have a dual exit, single oval either side, RS6-style.

While the wiring harness is being completed, and the EMS is being configured, I need to start looking at clutches.

You guys in the States may be able to help me out here.

Who knows? I may be of use to you too sometimes, the UK's full of RS4 parts...

[wwb4]

S8 motor is not yet up and running.

She's still running the stock 2,6L V6.

Got ya.

Also, really like the color.......roof compliments the car well IMO.

[Siena]

Got ya.

Also, really like the color.......roof compliments the car well IMO.

Thanks buddy.

[djwimbo]

I knew your car was great looking, I didn't know you were going that extensive on the project.
I gotta give you a lot of credit on this thing. I looks amazing, and I love the trunk lid.

[Siena]

Thanks for your compliment!

[boringb5]

Pure art work!! I would have never thought about using the rs4 qtr panels on the sedan.
I'm super envious.

[JumboBlack1.8]

can´t wait to see this when its done......a v8 with just headers is gonna sound like a MONSTER....please make vids when ur all done. The project looks masterfully done so far, great work

also, i´m in spain right now, and I´ll be in Barcelona and Pamplona next week backpacking with a friend......would it be too much to ask you to drive it down here to let me take a look?????

[boringb5]

How do the B7 wipers fit? Does the passenger side hit anything? Oh and

[Siena]

How do the B7 wipers fit? Does the passenger side hit anything? Oh and

B7 wipers have larger shafts.

I turned a couple of steel inserts, to adapt them to the smaller B5 spindles.
The passenger side doesn't hit anything, screen trim etc.

[Nebone]

Beautiful! Great story line there. I'm glad B5s can be found for so cheap in Europe. I might have to find me one when I'm living in Germany next year.

[Autonimus]

Gotta say...simply awesome!! One of the best, if not the very best, B5s I have ever seen!! Everything I would do if I won the lottery and had your master modding skills.

Awesome work!!!