05A$SE BAT Build Thread

[05A$SE]

Hey all,

So as the title states I'm joining the BAT/built crowd.

What I'm starting with:
2005 dolphin gray A4 1.8T 6MT special edition
100k miles - I've had it since 32k
-currently-
GT2871r eliminator
ATP large inlet tip (stock maf)
550 cc inj
Revo BT
Full custom exhaust w/ wideband
Fmic
B5 S4 brakes
ST coilovers
Stage 4 OFE SS clutch -south bend w/ 12lb flywheel

Build:
AWD block-
FSI 2.0 crank
H-beam forged rods
Mahle 83mm
Full arp hardware
Calico bearings

AEB head - ported and polished
Ferrea valvetrain +1mm
QED purple grind cam

Full race exhaust manifold
Gt3582 hta fp
Custom intake manifold
Custom fmic setup
ID1000 cc inj
Maestro tuning suite
Aeromotive fpr
034 fuel rail
Full -6an braided lines
034 high output in tank
Bosch 040 inline w/ surge
*******will add as time goes on ********

Drivetrain: to be announced

[05A$SE]

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[05A$SE]

I'm almost ready to take my block to the machine shop but was wondering what clearances others have run when they had there motors assembled/machined. I'm running forged pistons, I've heard 0.003"-0.004" piston to wall. I'm planning on making big power and want the motor to be solid, however in the class I'm in at school suggests running a larger clearance due to the high expansion rate of forged pistons. I'll take any help or input! I know a bunch of people on here have done the 2.0 build, what did you guys have done and how'd it turn out?

[Wet0willy01]

http://www.audizine.com/forum/showth...l-pump-upgrade

Just a cheaper easier suggestion

[AudiHere04]

Looks like a good start.

[vintagespin]

I'm almost ready to take my block to the machine shop but was wondering what clearances others have run when they had there motors assembled/machined. I'm running forged pistons, I've heard 0.003"-0.004" piston to wall. I'm planning on making big power and want the motor to be solid, however in the class I'm in at school suggests running a larger clearance due to the high expansion rate of forged pistons. I'll take any help or input! I know a bunch of people on here have done the 2.0 build, what did you guys have done and how'd it turn out?

It depends on the piston and the alloy used. Look in Audi Skate Snow's build thread, they are discussing this very topic right now.

http://www.audizine.com/forum/showth...=1#post6995434

[RLB6]

I'm almost ready to take my block to the machine shop but was wondering what clearances others have run when they had there motors assembled/machined. I'm running forged pistons, I've heard 0.003"-0.004" piston to wall. I'm planning on making big power and want the motor to be solid, however in the class I'm in at school suggests running a larger clearance due to the high expansion rate of forged pistons. I'll take any help or input! I know a bunch of people on here have done the 2.0 build, what did you guys have done and how'd it turn out?

With Mahle pistons (4032 alloy), you can run anywhere between .0015 - .0026. I say split the difference and run .0020 to be safe. This will provide a quite motor, essentially no piston slap, and reduce oil consumption.

[Hansi]

I would change the cams to IECVA1, wait getting the turbo; maybe the twin scrolls EFR are available before you finish your build, and start looking for a 01E drivetrain swap.

[Wet0willy01]

I would change the cams to IECVA1, wait getting the turbo; maybe the twin scrolls EFR are available before you finish your build

I'd tend to agree.

However your build plans are very simular to what I have done (Less the 2.0)

[MmmBoost]

I hope you've done your research on what you're getting into with Maestro. It is not for the impatient or the faint-of-heart

[05A$SE]

sorry i didnt make it more clear, i already have all the parts listed above! 01E might be where i end up as far as a tranny but im doing some more then that with the rest of the diffs/axles/etc.

vintagespin and RLB6 - thanks! just what i was looking for, mahle's website kept leading me to dead links with 404 errors , somewhere around .020ish is probably where ill end up, most likely no less then that.

mmmboost - ive done some poking around into maestro's forum a little bit, my next class at school deals with ecu tuning before and after engine modification, and a few of my instructors are spot on with that stuff so i have plenty of resource to assist me thankfully!

i got a decent amount of my stuff from AudiA4_20T. no worries, no internals , theyre all new.

and been drooling over this CLICKY


waiting on a few last parts to get shipped! should have this stuff going soon!

[MmmBoost]

Bosch Motronic is not like any other animal out there. Understanding the tuning process and actually knowing what map to change is a whole different story.

[cpu77]

I hate noisy forged pistons on startup. Makes me think..... dam did I run it too hard the last time I drove it:)

[Hansi]

and been drooling over this CLICKY

Nice.. Looks expensive though
And probably not necessary at your power levels?

[dougyfresh]

I hate noisy forged pistons on startup. Makes me think..... dam did I run it too hard the last time I drove it:)

I've never had any issues like that on the two 1.8T motors I've had with forged pistons.



Build it right and it won't have any issues.

[cpu77]

My only experience has been with a factory 4.6. I had this issue on my 03 cobra.. It came from the factory with forge pistons. It was noisy when cold. They all are. I will let fords SVT division know they can't build engines according to dougyfresh:) I even spoke to some well known engine builders who told me I would need to live with it? Maybe you leave something on the table to not have it? I have no idea as I have limited knowledge. I assumed 1.8ts would sound the same way.

[dougyfresh]

My only experience has been with a factory 4.6. I had this issue on my 03 cobra.. It came from the factory with forge pistons. It was noisy when cold. They all are. I will let fords SVT division know they can't build engines according to dougyfresh:) I even spoke to some well known engine builders who told me I would need to live with it? Maybe you leave something on the table to not have it? I have no idea as I have limited knowledge. I assumed 1.8ts would sound the same way.

You can relay what I said to Ford. I'm cool with that. Maybe they'll figure out how to design and build a real car.

it's the alloys used in every component in the motor.

[cpu77]

You can relay what I said to Ford. I'm cool with that. Maybe they'll figure out how to design and build a real car.

it's the alloys used in every component in the motor.

Well I think that can be said about all automakers! Look at our over priced piles. All these little cheap plastic parts. Not to mention the infamous German over engineering. As if making something more complicated makes it better. I see you own a jeep ever done a stroker in a 4.0?

[05A$SE]

mmmboost - One of my teachers instructing that actual class is a former employee of audi R&D! crazy stuff, would love to be able to get a job like that,

Hansi - yes!, but hopefully i can source some of the parts from my nissan friends, they tend to "bend up" there 240s alot.

Dougy - Your knowledge is awesome


Just a little update - still waiting on engine seals, gaskets, sensors, and the cylinder head to be sent out from NJ to AZ, hopefully this week coming up i can drop off the motor.

[05A$SE]

Finally been making some progress! have been waiting on machine shops for over 3 months to bore the 034 billet mains! Ive moved on and am now sourcing all the odds and ends again!

Does anyone have a good place to get upgraded manifold hardware? intake and exhaust for aeb setup? or sizes possibly?


BTW - Turbo setup has changed to GTX3576R, what a beauty! Got the block on the stand and assembly has begun!

[1ScientisT]

This is where you post pics of said turbo and engine on stand!

[sa_seahawker]

This is where you post pics of said turbo and engine on stand!

no pics, no proof?

[Hammie]

ooh Build thread Fail

[vinny.dtw]

Have fun with the 01E... I'll keep an eye out for this swap.

[05A$SE]

Forgot to mention! My Daily driver honda got stolen with my south bend stage 4 in the trunk and my flywheel! So i decided to upgrade to clutchmasters 850 twin disc kit.

So what's everyones Consensus on this?





I Wasn't to happy to find this so i installed a piston to check the clearances and i'm not to sure what to think.

[sa_seahawker]

With all this big build build accessories, to go cheap on the block seems silly. Looks like a weak point if it even manages to stay together and run. Could lead to a longer deeper crack that could eventually cause a catastrophic failure and ruin all those nice rods, pistons, crank, and other stuff you shucked out dough for.

Just my $.02...source anew block.

[1ScientisT]

I agree. That block is a boat anchor....not hard or expensive to find a suitable replacement!

[05A$SE]

I Talked to machine shop and sourced some opinions through some friends. work is being covered by shop and that block is making a nice coffee table :) possibly a low power application later on in a cabrio or rabbit

[AudiHere04]

still want the meth?

[Black_Pearl_B6]

I don't think it would be a problem, but do you want to risk all that money and time u have into it

[05A$SE]

Nope dont want to see all this go to waste. its been almost a year since i purchased the block and started getting everything around.

With that being said. does anyone have an 06a block in good condition with no damage to it? just looking for block with caps and squirters. thanks!

[RLB6]

OP, not a biggie there. Just need to get that area deburred to remove any sharp edges and smooth it out to keep the skirts from getting knicked up. Also, the rings will never come down that far so no blow-by issues there.

[05A$SE]

RLB6 - Not worth it to me, id rather spend 400 on another block then worry about this every day when i turn the key. i understand your point of view however i dont want any issues that could have been prevented.

STILL LOOKING FOR A BLOCK! PM IF YOU GOT ONE

[05A$SE]

Update - Using My original Block that i had in the car, upon taking it apart found that last year when i had my head redone one of the valve guides was never done properly and had been leaking into cyl 2 causing misfires and popping spark plugs! fun!

as for the "Boat anchor" block, it is, the Nice new billet main caps from 034 were over machined .040 along with that nice cylinder chip. its useless,

So with that being said!

Does anyone have any good info on dual fuel pump installs or pictures of surge tank mounting / wiring etc. thanks guys!

PS tried search on FP stuff

Thanks,
J!

[AudiHere04]

i have a inline pump if you need it.

[05A$SE]

Yeah i have all the parts already for the install.
just curious as to what had already been done for reference thats all. for instance do people run another power wire for there second fuel pump with a relay or they just jump onto stock harness with the other pump? stuff like that. not pumps for sale but thanks anyway man.

[AudiA4_20T]

Yeah i have all the parts already for the install.
just curious as to what had already been done for reference thats all. for instance do people run another power wire for there second fuel pump with a relay or they just jump onto stock harness with the other pump? stuff like that. not pumps for sale but thanks anyway man.

separate relay