Max's B5 A4 Race Car Build Thread

[Gumby]

It's finally happening.

[gmx]

I think you mean Ct9a (evo7-9) IC? X has inlet entry from top. L shaped.
30psi by 4k rp on a 6262 - Was that on the long stroke 2.1L motor?

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[A4Rob]

What are your power goals with the 6262? I just went with the 5858 which is good up to 700hp, and will be getting a little better spool.

[Raacerx]

I think you mean Ct9a (evo7-9) IC? X has inlet entry from top. L shaped.
30psi by 4k rp on a 6262 - Was that on the long stroke 2.1L motor?

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Nope, I did indeed mean the EVO X, the L-shaped one. That is what we use.

And no, 30psi by 4k is with our current 92.8mm motor. Just goes to show you what happens when you get that ideal efficiency. Even my 2.8L V6 S4 on a 6262 didn't spool as quick, but that is because I was on a far less efficient log style manifold without as nice of a merge.

What are your power goals with the 6262? I just went with the 5858 which is good up to 700hp, and will be getting a little better spool.

Rob, I'm going to be running a 5858, I definitely do not need or want the power of a 6262. I currently have a 6262 and the car will be driven with it for a bit, but it's being traded to my coworker for his 5858 as soon as we finalize his tuning on his S4. Interestingly enough, the 6262 hits 30psi at the same time as a 5857. Granted the new 5858 has a more efficient CEA exhaust wheel, I doubt it will make much of a difference where peak boost is hit. However, I definitely think it will make a different on transient response.

Dynos just don't show the recovery.

[Monty23]

And no, 30psi by 4k is with our current 92.8mm motor. Just goes to show you what happens when you get that ideal efficiency. Even my 2.8L V6 S4 on a 6262 didn't spool as quick, but that is because I was on a far less efficient log style manifold without as nice of a merge.

So 30psi by 4K in what gear? Sick build you got here BTW. I wish I could justify the expense to track a car...

[spindoctor]

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 should have my full race manifold tomorrow and would like to compare the weight to yours.

Let me know when you're ready and I'll put mine on the weighing scale.

[gmx]

Do you have updated blog or pics with it? This is all I recall

Be interesting to see how the X fits

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[Raacerx]

So 30psi by 4K in what gear? Sick build you got here BTW. I wish I could justify the expense to track a car...

Yo Justin. That is in 3rd gear.

And right now it's been quite hard to justify all the money since I haven't driven the car in years. Thankfully I know what to expect when everything is done, and it will be well worth it! Especially since my favorite local track just added 2.5 miles to their already long 3 mile track (Thunderhill). Should be absolutely epic.

I should have my full race manifold tomorrow and would like to compare the weight to yours.

Let me know when you're ready and I'll put mine on the weighing scale.

Most definitely. Post up your weight as soon as you have it, and I shall weigh mine as soon as it is done. Should be tonight or tomorrow. I'm guessing like 5 pounds difference?

Do you have updated blog or pics with it? This is all I recall

Be interesting to see how the X fits

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Old intercooler from the VR6 motor is in your pic. I'll take some nicer pics of the current Evo X setup today or tomorrow. Both the inlet and the outlet positions are blocked off and moved to accommodate the B5 layout, which perhaps I was not clear about; you most definitely can't just bolt on an Evo X intercooler and be done with it hahaha.

We do offer the intercooler to the public, already welded/modified to fit the B5, but it's not something we advertise and I only recommend it for a track specific car that won't ever see traffic.

[Raacerx]

Sigh, got sooooo close, but the manifold didn't get quite finished and my buddy went out of town for a few weeks. Torture just looking at it almost done, I may fire up the TIG and finish it myself if he doesn't come back soon.

On the plus side, I got the S4 subframe all nice and situated in the A4, with our billet subframe bushings installed. This also enabled me to finally bolt on my 355mm Brembos and brake duct shields. Picking up some NACA ducts this month; I'm going to run 2 ducts per side, one for the brakes and one for auxiliary cooling. I'll have the oil cooler on one side of the car and the power steering cooler on the other side, I want as much of the radiator exposed as possible.

Otherwise, the only other change is that I'm back to installing the 6 speed driveline right off the bat. Recently I had decided to keep it 5 speed and just get the car running, but since I had to swap the subframe and everything already, it's just linkage and shifter box and rear diff/driveshaft so it's not much more work. I'm running our Motorsport transmission mounts and Track density motor mounts, I'll eventually throw some Motorsport motor mounts in there.

[gmx]

Nice, I'm also about to get my V6 subframe with your anodised billet mounts installed. Did you bed them down with anything or just put them straight on?

Hear you about the radiator, I can't find any aftermarket options, not like they'd fit easily anyway without probably cutting up the lock carrier and dealing with the hose attachments.
Are you using Naca ducts in the belly pan/engine shield or elsewhere?

Pics of the new IC setup!

[Raacerx]

Nice, I'm also about to get my V6 subframe with your anodised billet mounts installed. Did you bed them down with anything or just put them straight on?

Hear you about the radiator, I can't find any aftermarket options, not like they'd fit easily anyway without probably cutting up the lock carrier and dealing with the hose attachments.
Are you using Naca ducts in the belly pan/engine shield or elsewhere?

Pics of the new IC setup!

I "massaged" them into place using a combination of a homemade press and a BFH, aluminum is softer than steel.

The naca ducts will go on the side front grills of the S4 bumper. When I do a serious front splitter, I may go from there instead.

I think the radiator will be fine so long as there is ample exposure, but of course that's always at a premium with any front mount intercooler. I definitely won't have a filler plate and that will be cut away.

[Gumby]

You should definitely jump on the tig and finish that manifold up. ;)

Those aluminum subframe bushing were the very first thing I did to my car when I hauled it home. And sweet f*cking Jesus, what a pain in the ass. Even with a press and a die-grinder I almost bent my subframe getting them in.

[Raacerx]

Wish I was confident enough to finish it up, but I need to just be patient; do it once, do it right. I'm sure if the manifold was done, something else would be delaying me anyways.

Mine weren't too terrible to get in, but I haven't done the rear yet (and don't plan to very soon).

This weekend I'm going to relocate the battery to the trunk, and begin the fun task of removing all extraneous wire that I know won't affect operation. Once the car is operational, I'll start really stripping out the extraneous stuff. Too many horror stories of things being removed far before turning the car on, and then not being able to remember what wire was modified.

Carpet is coming out too, that appears to weigh almost 15 pounds on its own. Headliner as well, which is another 5 pounds. So far, I've estimated about 300 pounds of stuff has been removed, and only 50 pounds will be replaced. This is of course before the weight of the roll cage and extraneous breather and fueling items.

[Raacerx]

Brembo 355's are in. Waiting on the exhaust manifold, and then in goes the motor.

[melomandn]

Brembo 355's are in. Waiting on the exhaust manifold, and then in goes the motor.

I <3 big brakes

[Raacerx]

Manifold will be done by the weekend, just got the head's up from the welder!!!!!!!!

I also realized that I need to come up with a bit of a color scheme for the engine. If you know me, I'm not much for aesthetics; function over form any day of the week. However, this car does have a nice brand new casa white paintjob and everything is new, so I'd like the engine bay to at least come out looking pretty nice. I'm tempted just to stick with the wrinkle black formula that has done me well with my past vehicles, but it doesn't cost any extra to put in a little pizazz.

Car exterior is white, wheels are white, roof is black, engine bay is black, hood is carbon. My silicone is all black.

[Raacerx]

Manifold will be done by the weekend, just got the head's up from the welder!!!!!!!!

I also realized that I need to come up with a bit of a color scheme for the engine. If you know me, I'm not much for aesthetics; function over form any day of the week. However, this car does have a nice brand new casa white paintjob and everything is new, so I'd like the engine bay to at least come out looking pretty nice. I'm tempted just to stick with the wrinkle black formula that has done me well with my past vehicles, but it doesn't cost any extra to put in a little pizazz.

Car exterior is white, wheels are white, roof is black, engine bay is black, hood is carbon. My silicone is all black.

Pic from before cleaning up the engine bay.

[Raacerx]

Never thought it would happen;

[viceprp]

Very nice, gypsy! How much!?

[demonmk2]

Wow! Really good work man.

[Raacerx]

Very nice, gypsy! How much!?

Wow! Really good work man.

I had a friend do it for me as a favor, he's a very experienced fabricator and very generous. This whole project wouldn't be possible without help from people like him and companies like Integrated Engineering, JE Pistons, Supertech Valvetrain, Advanced Automotion, and of course...034Motorsport.

I'm building the downpipe on my own, but the manifold I wanted done by an expert. Turned out exactly like the one on the Time Attack car.

[Raacerx]

Quick Update: Things are moving along, slowly of course, but steadily. Dropped the motor into the car last night. Big milestone. Got all the coolant hoses and everything sorted, and most of the breather setup too. Need to upload pictures.

I also decided to just stick with the stock B5 S4 clutch for now; I'll pull the tranny out in Feb for the Tilton, just have to keep it low boost until then. Next track day is in January, and it will be raining most likely and a shake down experience anyways, so power will not be needed.

Next week, towing the car down to work so I can fabricate the downpipe, and...then...the moment of truth will arrive. Harness is just about done.


I decided, partially for future reference, to add a current and future mod list:

1997 Audi A4 1.8T Quattro (salvage title)
06B block w/ 2.0TFSI Forged OEM Crank, new oil pump, etc
ARP head stud kit, main stud kit, crank bolt, cam bolt
JE 82.5mm 9.0:1 pistons, custom machined for additional valve lift
Integrating Engineering Tuscan Lightweight rods
034Motorsport coated bearings throughout
AEB big port head, stock AEB cams
Supertech complete valvetrain, stock valve diameters
Stock AEB intake manifold, 30v V6 DBC 70mm throttle body
Integrated Engineering manual timing belt conversion
Moroso billet sandwich plate w/ large oil cooler core
034Motorsport power steering cooler

Precision 6262 vband .63 AR turbo (hoping to sell for a 5858)
034Motorsport custom Time Attack vband tubular exhaust manifold
Tial MVR 44mm wastegate, watercooled
Mitsubishi EV010 stock front intercooler, modified for B5 use (exceptionally lightweight)
034Motorsport billet electronic boost control valve
034Motorsport billet diverter valve (used as blow off valve)
3.5" single muffler exhaust (still need to build downpipe)

034EFI Stage IIc standalone
Custom Mil-Spec engine harness w/ Raychem DR-25
034Motorsport Wideband controller
3-wire S4 coilpacks
DW 1000cc EV14 fuel injectors
Fuel Lab adjustable FPR
Dual Bosch 044 fuel pumps and surge tank, stock in tank pump
Stock fuel rail

Built 01E Transmission w/ RS4 3rd/4th gear
4:1 diff
240mm Steel Conversion flywheel
Stock B5 S4 clutch
S4 front axles
S4 driveshaft and rear diff
S4 shift linkage, shifter box, short shifter
S4 front subframe and uprights
034Motorsport Billet Subframe bushings in front
Brembo GT 355mm 4-piston front brake kit
Brake bias adjuster
034Motorsport 300mm S4 rear brake kit
Metal master cylinder, metal slave cylinder, -3AN braided clutch line
034Motorsport Track Density motor mounts
034Motorsport Track Density transmission mounts
034Motorsport Poly snub mount
034Motorsport Track Density diff carrier bushings

Spherical front upper control arms
Spherical rear upper control arms
Spherical front tie rod ends
Spherical rear tie rod ends
Spherical front and rear sway bar end links
034Motorsport rear sway bar
Stock S4 front sway bar
Custom valved Koni struts
034Motorsport strut mounts

Status custom carbon fiber racing seat
Front and Rear strut bars (until cage)
Fiber Images vented carbon fiber hood
S4 bumpers and side skirts
Partially gutted interior (still has power windows, but locking pump, etc gone)
Work Emotion CR-Kai 18x8.5" rims
Continental Grand Am 245 wide slicks (measure over 265)
Front fenders have been slotted for additional tire clearance and engine bay venting

Immediate Incoming Mods (next 1-6 months)
Tial Q blow off valve
Full SCCA roll cage (in 2 stages)
*1st stage: interior cage, SCCA legal
Tilton twin disc cerametallic clutch
034Motorsport 7.25" 9lb flywheel
Front fiber glass splitter
Rear splitter
APR GTC200 wing
Aluminum uprights
Cat 3658 camshafts

Future Mods (6-18 months)
Dry sump oil system
CNC ported cylinder head
PSI Ohlins TTX36 suspension
Alcon pedal box
Relocate driver seat 12-18" rearward
Full SCCA roll cage
*2nd stage: tie into engine bay and trunk, major weight removal
ATL 12 gal fuel cell
Fire suppression system
RS4 replica front widebody fenders
RS4 replica side skirts
Rear bolt on fender arches

[BrucexL33]

awesome! Just curious if this car will be still be registered or track dedicated only? Would love to see it someday! I look forward to seeing more updates!

[Raacerx]

Dedicated track car, trailer queen, although it may technically be "registered" for the street so that I can enter more classes.

The car will be down at 034Motorsport in the next week or two where I'm finishing everything up.

[BrucexL33]

Sweet! I may be picking up some stuff from there soon hopefully I see your car there.

[Raacerx]

Well...that sucked. I realized I forgot to reset the stupid SAC mechanism, so I took it apart and not wanting to go use a press, I did the "drop a tire down onto it" method which worked great until I slipped with the jack and dropped the entire weight of a truck onto it and...broke the pressure plate.

Time to either find another used pressure plate, or perhaps go with a B7 RS4 clutch kit.

[Korben007]

I have a brand new jhm B7 rs4 stage 3 kit for b5 fitment sitting in a box here

[Raacerx]

I would need to get a new flywheel. Let's talk about that B5 RS4 pressure plate you got. I just need something to hold me off till I can justify the Tilton.

[Raacerx]

Been struggling to get some work done on the car.

She comes off the jackstands tomorrow.

[Raacerx]

Well I tried my hardest to get this thing running before I moved and life got crazy, but I started to rush stuff so I stopped and have been storing the car at my folks, which is unfortunately 1.5 hours from me.

Changing careers, moving into a place without a garage, and trying to buy a house have left me with little time, money, and motivation to finish the car so she will likely sit until the summer.

And as terrible as it could be, there's a slim chance I may even dump the project before it is finished; found a house I'm in love with, but its beyond budget and there's no way I'll be racing for the next few years if I take on this obligation.

My A3 is also about to hit 170,000 miles so I'm preparing for the maintenance on that thing, although my company car arrives next month wooooot!

Cheers.

[un1ko]

In a way I'm sorry to hear that you won't finish your project anytime soon, but good luck in your career change. I hope some day you get her done.

[Raacerx]

Amazingly enough, I actually got some work done on the car a couple weekends ago.

I still need a transmission mount bracket for my 01E, need to finish fabricating the downpipe, intercooler piping, fabricate seat brackets, and I need to finish the wiring harness. And roll cage.

New job is going better than expected and I have my company car now, so I'm back to the plan of keeping her, although I will likely hold off on the cage until next year so I can at least drive it a bit this year.

[redline380]

need pics on the work done

[Gumby]

^what he said.

Glad to hear you're still at it man. keep us updated on the project.

[Raacerx]

^what he said.

Glad to hear you're still at it man, keep us updated on the project.

Should have a new spot for her soon as well. Then things will move much faster. My goal is to get it running, so I'm going to skip some steps. I'm also totally willing to sell my built new transmission or trade for a stock 01E; I wouldn't mind freeing up some funds for more important things than good gear ratios.

Oh and pictures will follow when it's visible from the outside that I've done anything. ;)

[Nzila8]

Should have a new spot for her soon as well. Then things will move much faster. My goal is to get it running, so I'm going to skip some steps. I'm also totally willing to sell my built new transmission or trade for a stock 01E; I wouldn't mind freeing up some funds for more important things than good gear ratios.

Oh and pictures will follow when it's visible from the outside that I've done anything. ;)

What happened??!!

[RallyeBourne]

I feel we need an update.

[Raacerx]

Perhaps it's time for an "update" so to speak. 3 steps forward, 5 steps backwards.

The engine has left and gone to a better home, where it will finally see serious track time. I should be able to get behind the wheel of it too, which would be awesome. It hurt bad after investing so much time and money, but I'd rather it get used than sit in my garage waiting for me.

However, the project does not die; she just won't have much horsepower for a bit. I'm looking to toss a stock motor in there (maybe some rods if its cheap enough) and just have some fun. My A3 has been taking a beating with track time so I need to get this thing working. Should come out weighing about 2700 pounds, which doesn't need a lot of power behind it to get some good lap times. Brakes, 01E transmission, and everything else stayed. I won't be doing any major engine or power work until the full cage is done and everything else is dialed. Glad I kept my old AEB shortblock and harness, as I may just throw those back in the mix to keep it simple.

If anyone has some 01E transmission brackets (not the rubber mounts, the actual cast aluminum brackets), let me know. I could use an extra set.

In the meantime, here is a video from Laguna Seca a couple weeks ago, and Thunderhill a month before that.

[0000 V8]

If anyone is curious to see where Max's vision was transferred, check out where the motor is at now in its new home! Max's is still very much a part of this build and we both can't wait to see it finished.

Justin's B6 Race Car Build Thread

[Raacerx]

Thanks for posting that Justin! So glad it went to a good home.

Unfortunately, the rest of project is being scrapped. Real life has hit me, I am neck deep in a remodel, and I don't want the project to just sitting. Hopefully goes to a good local home like the engine.

[fail] sigh