Max's B5 A4 Race Car Build Thread

[SleeperAvant]

Sexy!

[melomandn]

Gonna be sick man, do you have any more info or just some good links about making power with the VVT? All I've been able to find is guys speculating about it.

Would love to see some real world results!

[Operator]

I don't think we have a 2.0TFSI intake manifold in the works, just too much stuff going on.

Just don't forget about us!!!!

The build is looking TOPS!!!!!!!

[034Motorsport]

More news! Cams and tubular manifold have been decided, right from the get go.

Super excited to be running a set of the new CAT factory degree'd 3658 camshafts; these have all the power advantages of the 3658's, but without the need to get them degree'd by a machine shop (incredibly expensive). The factory timing marks have been developed with years of Bob Q's dyno testing on a BAT 1.8T. You obviously can still adjust via an adjustable cam gear, but now you have the option of simply dropping a factory cam gear onto them and you'll be in a great place for a turbo motor.

Will post pictures of the tubular manifold construction soon, hopefully be done in 1-2 weeks.

Man this is getting expensive!

Sexy!

Thanks Steve! It's awesome to have to start thinking about small meaningless things like what color I want my valve cover, because it's actually getting close to being finished.

Gonna be sick man, do you have any more info or just some good links about making power with the VVT? All I've been able to find is guys speculating about it.

Would love to see some real world results!

I can definitely pull up some back to back dyno results for you, it makes a HUGE difference in low and top end power, although it is easier to work with when using something like our 034EFI SEMS, where the VVT is made an easily programmable general purpose order. But massive gains can still be made with the factory Motronic system too.

On our 2.0L Time Attack motor, we gained over 30whp at various parts of the curve (primarily down low and up top), and this is with CAT 3658 Billet cams. We of course had to heavily machine for the additional valve clearance, as you can see I did on mine. On our big GTi-RS mid engine project car, which is running a 3.0L APB single turbo motor, we made the mistake of not machining enough clearance into the pistons and had the tough choice of limiting timing, or disabling VVT.

From a powerband standpoint, it would have been more beneficial to run very little timing, but enabling VVT; however the car was designed for big power and to hit over 900whp like we did, it was more beneficial to just dial on straight timing versus the VVT, as power in the low/mid band wasn't important and more power was gained up top with pure timing.

Just don't forget about us!!!!

The build is looking TOPS!!!!!!!

You know, I was actually wrong; we have been developing one and will release it later this year, but it's taking a back seat to a lot of other current projects. It will be geared towards BAT cars, not K04 stuff, whereas our 1.8T manifold actually has good gains on a stock turbo all the way up to a BAT.

[melomandn]

I can definitely pull up some back to back dyno results for you, it makes a HUGE difference in low and top end power, although it is easier to work with when using something like our 034EFI SEMS, where the VVT is made an easily programmable general purpose order. But massive gains can still be made with the factory Motronic system too.

On our 2.0L Time Attack motor, we gained over 30whp at various parts of the curve (primarily down low and up top), and this is with CAT 3658 Billet cams. We of course had to heavily machine for the additional valve clearance, as you can see I did on mine. On our big GTi-RS mid engine project car, which is running a 3.0L APB single turbo motor, we made the mistake of not machining enough clearance into the pistons and had the tough choice of limiting timing, or disabling VVT.

From a powerband standpoint, it would have been more beneficial to run very little timing, but enabling VVT; however the car was designed for big power and to hit over 900whp like we did, it was more beneficial to just dial on straight timing versus the VVT, as power in the low/mid band wasn't important and more power was gained up top with pure timing.

I would love to see some back to back dyno's. I've always thought that the VVT could be very beneficial on our cars but you really never hear of anyone doing it. If you could post up anymore info or anything that comes up during your tuning period that'd be awesome!

[un1ko]

More news! Cams and tubular manifold have been decided, right from the get go.

Super excited to be running a set of the new CAT factory degree'd 3658 camshafts; these have all the power advantages of the 3658's, but without the need to get them degree'd by a machine shop (incredibly expensive). The factory timing marks have been developed with years of Bob Q's dyno testing on a BAT 1.8T. You obviously can still adjust via an adjustable cam gear, but now you have the option of simply dropping a factory cam gear onto them and you'll be in a great place for a turbo motor.

Will post pictures of the tubular manifold construction soon, hopefully be done in 1-2 weeks.

Man this is getting expensive!



Thanks Steve! It's awesome to have to start thinking about small meaningless things like what color I want my valve cover, because it's actually getting close to being finished.



I can definitely pull up some back to back dyno results for you, it makes a HUGE difference in low and top end power, although it is easier to work with when using something like our 034EFI SEMS, where the VVT is made an easily programmable general purpose order. But massive gains can still be made with the factory Motronic system too.

On our 2.0L Time Attack motor, we gained over 30whp at various parts of the curve (primarily down low and up top), and this is with CAT 3658 Billet cams. We of course had to heavily machine for the additional valve clearance, as you can see I did on mine. On our big GTi-RS mid engine project car, which is running a 3.0L APB single turbo motor, we made the mistake of not machining enough clearance into the pistons and had the tough choice of limiting timing, or disabling VVT.

From a powerband standpoint, it would have been more beneficial to run very little timing, but enabling VVT; however the car was designed for big power and to hit over 900whp like we did, it was more beneficial to just dial on straight timing versus the VVT, as power in the low/mid band wasn't important and more power was gained up top with pure timing.



You know, I was actually wrong; we have been developing one and will release it later this year, but it's taking a back seat to a lot of other current projects. It will be geared towards BAT cars, not K04 stuff, whereas our 1.8T manifold actually has good gains on a stock turbo all the way up to a BAT.

Are you going with a custom tubular that 034 would fabricate or from another company that already sells them? Is that I remember you guys use to sell them, but not I don't see them on your guys website.

BobQ, I wonder what happened to him. I bought his purple cams, can't wait to see how respond. Nice choice with the 3658's

Can't wait to see some pics!

[biglou]

You got a lot of crazy stuff on ur car


Crack phone

[034Motorsport]

I would love to see some back to back dyno's. I've always thought that the VVT could be very beneficial on our cars but you really never hear of anyone doing it. If you could post up anymore info or anything that comes up during your tuning period that'd be awesome!

Check this out: http://blog.034motorsport.com/category/tuning/

Here is one of the tests;

Are you going with a custom tubular that 034 would fabricate or from another company that already sells them? Is that I remember you guys use to sell them, but not I don't see them on your guys website.

BobQ, I wonder what happened to him. I bought his purple cams, can't wait to see how respond. Nice choice with the 3658's

Can't wait to see some pics!

I am going to go with a copy of our Time Attack tubular manifold. It's shorter than most tubular headers, specifically to be lightweight, and I want to do everything I can to reduce weight in the front of the vehicle. Just by swapping out my Precision intercooler for a lightweight fin model (an Evo intercooler), and the shorter tubular header, should save me about 30 pounds, and that's all in front of the front axle.

BobQ dropped off the face of the planet, but resurfaced last year or so, citing health problems.

I would have considered the Full Race manifold, but it only comes with a T4 flange and with a race car you really need a v-band turbine flange or the turbo will just constantly need to be tightened.

You got a lot of crazy stuff on ur car


Crack phone

Thanks Lou, getting excited to see it all tied together.

[biglou]

I can imagine !


Crack phone

[034Motorsport]

Not much new to report; I've lost some motivation with the project and trying to get back into the swing of things so I can get the motor back together.

Hoping to get the S4 uprights swapped in this weekend from the A4 V6 uprights I had on there. Only reason I am doing so is because my Brembos came with S4 adapters and it's cheaper to swap uprights rather than machining or buying new brackets to fit the A4 uprights.

My goal was also to get the cage done before installing the motor, but I realized I'm going to miss the good weather track days if I keep lagging. I also am hoping to have it running before May 14th before I leave for a 6 week vacation and deplete all my extra funds. =/

All these small motor parts really add up too, like oil pump, guides, tensioner, etc.

[Seerlah]

Yeah, that thing is f*cking sweet. Love the versatility behind the runners with velocity stacks to be used on both the transverse and longitudinal engines. Waiting for release thread and price.

[un1ko]

Yeah, that thing is f*cking sweet. Love the versatility behind the runners with velocity stacks to be used on both the transverse and longitudinal engines. Waiting for release thread and price.

Hmm.. I wonder if 034 is going to add their brand on it?

[034Motorsport]

Hmm.. I wonder if 034 is going to add their brand on it?

Yep. The transverse will be released in a month or so. Longitudinal is probably (realistically) going to be end of the summer. I will hopefully be rocking the prototype on my car well before that though.

Finally got my engine stand, so things are moving in the right direction. Now if someone would just buy my Sparco Roadster seats, I could fund the rest of this project! ;)

Looking to have the motor ready to drop in next week or so, as there will be some time to get all the coolant hoses in order. Just need an oil pump and I can button up the pan with the rear main seal. Once the motor is sitting all shiny on the stand, I think that will give me some motivation. Too bad the 30v V6 needs a timing belt job this weekend too so I can sell that thing and have some more funds to do things right the first time.

Of course, I leave for Europe on May 14th; doubtful things will be running before then, and I will be gone for 6 weeks. Anyone want to finish it for me? =D

[un1ko]

Max are you back from Europe? Stop having fun! Get back to work! Lol! Did anyone from 034 worked on your car? Just want to see what good coworkers you have. Lol!

[034Motorsport]

Max are you back from Europe? Stop having fun! Get back to work! Lol! Did anyone from 034 worked on your car? Just want to see what good coworkers you have. Lol!

Yes, just got back a few days ago. Still recovering, both physically and financially.

Need a few weeks to catch back up with work @ 034, and then I will finally continue this damn project.

[A4Rob]

Welcome back. 6 weeks is a long time!

[Operator]

Any update on the intake mani?

[Raacerx]

Welcome back. 6 weeks is a long time!

Oh man, I see the light at the end of the tunnel!

After recovering from a 6 week vacation, I'm back at this project. Finally picked up a new oil pump/chain/tensioner, so it's time to button up the bottom end and get the oil pan on. Engine is on the stand and ready to go back together.

Right now my main focus is getting the car up and running and registered, so I'm holding off on everything else but the car running.

Swapped in the S4 uprights so I can run my Brembo 355's, and finished up the custom engine harness for the 034EFI Stage IIc. Theoretically, the car could be running in a couple weeks, but I've said that about 5 times already hahaha. Need to find some 5-speed V6 axles for the S4 uprights and the 01A transmission that is currently still installed.

Any update on the intake mani?

Nope. Lot of changes are going on @034 and we've got some bigger projects that we need to finish first. I also am no longer on the forums representing 034, I have permanently moved to a R&D and wiring/electrical position.

[Korben007]

R & D soubds more fun then answering questions online all day!

[Raacerx]

lol not like that was my main job before, but it is nice having more time to concentrate on product development.

[DeltaAlpha9]

Damn, that's a pretty sexy intake manifold.

[spindoctor]

Wished 034 release a little more info.

[Raacerx]

Big Shout Out to: 034Motorsport, Integrated Engineering, JE Pistons, and Supertech Valvetrains. This project wouldn't be possible without the help from those companies.

The intake manifold has taken a back seat to some other more pressing projects, unfortunately. I'm trying to light a fire to continue development. Casting is a slow process.

Motor is buttoned up and back together now, however I am missing the large bracket that holds the power steering pump and fan, etc, along with the oil cooler/filter housing. I bought my 06A as a shortblock so it didn't come with any accessories, only motor mount brackets.

[Gumby]

Looks awesome Max! Glad you're making some good progress finally.

If you're on the hunt for an accessory bracket, I have one you can have.

[Raacerx]

Looks awesome Max! Glad you're making some good progress finally.

If you're on the hunt for an accessory bracket, I have one you can have.

You are the man, Matt! Making that process a whole helluva lot easier.

Once I have those items, I can drop the motor into the car and start figuring out all my coolant and breather hoses. The big major item I still don't have is an exhaust manifold; waiting to see if I can get a copy of our Time Attack exhaust manifold, as it's got pretty short runners, but our fab department is quite backed up. But being able to spool a 6262 to 25psi by 4000rpm is hard to argue against and it's a lot lighter than something like a Full Race, so worse comes to worse, I may still have to throw on the SPA manifold and downpipe temporarily. I really want to get this thing running before the cheap track days start in the fall.

Once the motor is in, I can finally get the cage done, and then we are ready for the track. Yesterday I went through all the sphericals in the car and everything is nice and tight.

Spherical lower front control arms, spherical tie rod ends, spherical upper front control arms, spherical upper rear control arms, spherical rear tie rods, spherical sway bar end links. Only thing I don't have are spherical lower rear control arm bushings.

[Raacerx]

Need to time the head, but that's about it. Dropping motor in any day. Then I can start routing my custom breather and coolant setup.



PS. Timing belt is just mocked up on there.

[Korben007]

Looking good Max. Ill definitely be stopping by next time I'm down to check it out.

Sent from my SCH-I545 using Tapatalk 4

[AudiForeman]

Are is looking great Max, I bet your getting excited. It took a few minutes to catch up with you thread, I have been out d the loop for a while, I tryif to get my project back on track myself. Keep it up buddy.

[Raacerx]

Finally, the exhaust manifold has begun! Gracious thanks to my boss, I will have a finished copy of our B5 Time Attack exhaust manifold very shortly. This is the exact manifold I wanted, and will help keep me on track for basically copying our Time Attack motor down to a T.

Looking good Max. Ill definitely be stopping by next time I'm down to check it out.

Sent from my SCH-I545 using Tapatalk 4

Dropping the motor in this weekend if you're around. Probably tow it down to work next week and begin fabbing up all the coolant and breather stuff.

[Gumby]

Yes! That's the update I've been wanting to see! That manifold looks beautiful Max. Can't wait to see this thing running.

[rvca3112]

This thread is bonerjams. Keep us posted!

[un1ko]

Finally, the exhaust manifold has begun! Gracious thanks to my boss, I will have a finished copy of our B5 Time Attack exhaust manifold very shortly. This is the exact manifold I wanted, and will help keep me on track for basically copying our Time Attack motor down to a T.




Dropping the motor in this weekend if you're around. Probably tow it down to work next week and begin fabbing up all the coolant and breather stuff.

Max - I love that manifold! Can't wait to see everything finished!

[Raacerx]

Thanks guys. I'm very excited. I've got a meeting with a roll cage builder next week to get a full quote and start the prep work. I decided that I am doing the cage in 2 stages. The first stage will still be a full SCCA approved cage, the second stage will involve tying in the trunk and the engine bay and trussing/gusseting everything, as well as the frame for a fuel cell. I'm doing 1.75x.095 and this is one of the few items where I'm not copying our B5 Time Attack car.

My cage should end up significantly lighter and less redundant due to the actual geometry and construction, as well as the the larger but thinner wall tubing.

Also, I don't think I mentioned it but I'm running a stock OEM Mitsubishi Evo 10 intercooler. This is what we run on the Time Attack car because it is incredibly light and is a fin-style instead of a bar and plate. It weighs about 15lbs lighter than a comparable sized bar and plate, and is very good at cooling so long as there is ample air flow. On the dyno, it's not very effective, but this ain't a dyno queen. 15 pounds saved that far in front of the front axle does a lot for suspension tuning and eliminating the inherent understeer the chassis will always be fighting.

[Gumby]

Also, I don't think I mentioned it but I'm running a stock OEM Mitsubishi Evo 10 intercooler. This is what we run on the Time Attack car because it is incredibly light and is a fin-style instead of a bar and plate. It weighs about 15lbs lighter than a comparable sized bar and plate, and is very good at cooling so long as there is ample air flow. On the dyno, it's not very effective, but this ain't a dyno queen. 15 pounds saved that far in front of the front axle does a lot for suspension tuning and eliminating the inherent understeer the chassis will always be fighting.

Smart move. I just had one in my hands a couple weeks ago. I never realized just how much lighter that thing is then a comparable aftermarket unit with cast end tanks. I've seen the numbers, but it really put it into perspective. Those things are really really light for it's size.

[$teady$upreme]

wow can't wait to see this beast running.

Any idea what dimension is the evo X fmic?

[Raacerx]

wow can't wait to see this beast running.

Any idea what dimension is the evo X fmic?

I'll go find out for your right now David.

The core is 19"x11.5"x2.75"

[Raacerx]

Will be done mid-next week.

[Raacerx]

It's finally happening.

[Doctor]

Didnt see that. I had my FULL RACE Mani for sale. Oh well.

I love fab pictures, who doesnt :)

[Raacerx]

Didnt see that. I had my FULL RACE Mani for sale. Oh well.

I love fab pictures, who doesnt :)

I assume it was a T3 though yes? All the full race stuff I've seen was a 4-bolt style flange, and I had to have a v-band. Time and time and time again I see T3 style flanges have issues at the track. The v-band solves the loosening from vibration issues and also gives infinite clocking so that downpipe fitment is more lax.

The Full Race is also a long tube header and weighs a significant amount. I wanted to keep this manifold as light as possible, and I'm also very familiar with the performance since this is a copy of our race manifold on our Time Attack car. 30psi by 4000rpm on a 6262...I don't think I can ask for much more.