My "Oh what the hell...I post a build thread" thread

[stunner247]

So I've been lurking around this sight for the last 6 years but never made and intro so here's what I've been up to!

Some of you may know my current car front shows and stuff but I imagine most don't. Before I get to that car I'll start with a little Timeline.

I started with a completly stock silver 98 A4 back in 05. Before I sold the car in 08 it had:
APR Stg III
Carbonio Intake
EVOMS IC
Custom 2.5 turboback
Southbend/AWE Stg III Clutch
H-Sport sways
KW V3's
ECS 13.1 front brakes
034 track mounts





I got the opportunity in 08 to pick up my friends black 98 with 63K, s4 bumper, s4 headlights, gt25, Eibach coils, GHL exhaust and some other stuff. Always wanted a black car so I couldn't pass it up.





When I got the car I wanted to swap all the good stuff from the sliver car to the black car so my friend and I spent the next month swapping everything from one car to the other. I also wanted the black interior from the silver car so I swapped the complete interior front the windows down over too. Then the silver car was gone (sold to my friend who still has it)



Now that all the swapping was done I decided to add some stuff. I got an AWE DTS, ER Comp IC, a new stereo, some 034 trans mounts, 034 coil cover. polished my intake manifold, and powder coated my valve cover



Also got a JHM Shifter, linkage and knob...wow did that make a difference!



Got an ECS rear brake upgrade to match the front



Finally a Euro S4 rear bumper then It was off to H20 at the end of the year.





Up next 2009 and the start of the real fun!

[coolgraymemo]

What type of wheels are those?

[Seerlah]

Also got a JHM Shifter, linkage and knob...wow did that make a difference!

If people only knew!

I also remember your car from this pic. Always loved those wheels and even asked you about them before. My one recommendation, get some type of side skirts.

[stunner247]

What type of wheels are those?

Adr version II

If people only knew!

I also remember your car from this pic. Always loved those wheels and even asked you about them before. My one recommendation, get some type of side skirts.

Oh there's more to come don't worry

[stunner247]

Alright so for 09 I got some Caractere side skirts and then held off for a while so that I could start getting parts for the engine build.

VAG Fair




The APR Stg III kit was fun but I wanted something more so I grabbed a different engine and started building



Block was bored to 82.5 and all internals were balanced and blueprinted by Justice Racing

Raceware main studs



ABA forged crank with Calico Bearings



Supertech pistons and Pauter rods







New oil pump



Ported and polished head
Supertech valves, high lift springs, Titanium retainers
Schrick 252/260 cams
Cat cam gear
new guides and stem seals
SCCH lightened and clearanced intermediate shaft
Autotech lightweight pulley







Out with the old...




In with the new

[stunner247]

Put in an order with Mike Hood




HTA 3076
Ceramic coated exhaust housing
Ceramic coated Fullrace manifold and down pipe
44mm Tial waistgate









034 fuel rail and pressure gauge
-6 an fuel lines
Seimens Deka 630cc's
044 intank pump
Aeromotive FPR set to 4bar



ER Comp intercooler


Fabbed up a open dump waistgate pipe


FX 850 twin disk

[thenj3]

awesome build dude. what will you be doing for tuning? how long did it take for the mani and dp to be made? i'll be purchasing one in the coming days.

[Grip99]

Nice build!! Im putting my FR mani in next Sat. Did you fab up your own intercooler piping turbo side?

[stunner247]

awesome build dude. what will you be doing for tuning? how long did it take for the mani and dp to be made? i'll be purchasing one in the coming days.

Thanks. If I remember correctly it took about 3-4 weeks for them to make it and ceramic coat everything. Running Eurodyne Maestro

Nice build!! Im putting my FR mani in next Sat. Did you fab up your own intercooler piping turbo side?

Thanks. No ER makes a pipe specifically for the Fullrace Mani location

[Grip99]

Great man thanks for the info...Going to look into that.

[stunner247]

No Prob

[stunner247]

So I finally got it running around Nov of 09...kind of. there was alot of trial and error to get the intake and MAF to cooperate. At the time I was running just a eurodyne 630 file with a lightning MAF cause Maestro was not available for the early cars yet. I had to clock the MAF to about 5 different positions and add some flow straiteners to get to the point that I could actually drive the damn thing Needless to say, when Maestro finally came out and Tapp went to a V8 Maf, I made the switch.


I soon found out that the FX850 is a trans breaking machine. After I had about 500 miles on the engine I hammered it on night, slammed it into third and BOOM...bye bye third. I had a 2.8 trans laying around so I threw that in. That lasted about 1000 miles then I screwed first up launching. It would still drive but was making all kinds of nasty sounds.

Video of the last launch I did before the third trans went in. I figured I might as well try and blow it up since it was already Fckt



So I went with the old S4 drivetrain swap. (no pics though)
01E
Rear diff
Drive shaft
Axles
Aluminum uprights
Brakes
Front subframe
New 034 Track mounts
New JHM shifter setup

I figured I wasn't making a drag car and I needed something stronger so what the hell.

Got it back on the road just before it could make it's debut in the Forge tent a SOWO in 2010.



Then it was off to the dyno at RAI to see what it would do...
...And it didn't do much

The best it would put down was 295 whp at 20psi. If I upped the boost, the power actually went down. You could also see that something was going on in the upper RPM range on the graph. I still didn't have my Maestro set up so there was little I could do to figure out what was wrong so I packed it up, went home and parked the car for a while... I was pissed.




Soon after that I got my Maestro file and started playing with it. Got the car running better but not the way I thought it should run. I decided to take a break from tuning and pull everything back apart so that I could redo some of the things I had rushed when I originally put the engine in, and also to upgrade some stuff.

SPP Fan


Deleted my ICM
TT bolt down coils
034 Coil harness
Re-ran my EVAP purge lines
IE dowel pins for the crank pully




Facelift cowl cover



Re-routed and cleaned up my fuel lines



Heat wrapped my other lines



I also plasti dipped my coolant res, power steering res, washer res
Powder coated my upper coolant pipe and cold side IC pipe

I was glad that I had torn it apart and done all of this because I found something out in the process. I decided to take a look at my cams to see if they were timed up correctly and found that I had a 4 window cam sensor installed instead of the correct single window. All of these damn running problems were because of my stupid a$$ when I put the motor together! Swapped the right sensor in and the difference was night and day.

[jaychen]

Sick, I remember seeing that launch and thinking that was one tough car!

Wish we had S4's that got parted out in AUS. Was chatting to a local wrecker the other day, in the 15yrs he has been wrecking euro cars, he has seen ONE B5 S4..

How is your MAF setup ?

[stunner247]

Sick, I remember seeing that launch and thinking that was one tough car!

Wish we had S4's that got parted out in AUS. Was chatting to a local wrecker the other day, in the 15yrs he has been wrecking euro cars, he has seen ONE B5 S4..

How is your MAF setup ?

Wow! One! Thats crazy
MAF is good now that I have the 4.2 instead of the lightning

[thenj3]

o shit i didn't realize that this build is quite a few years old. so have you got your tune and stuff down? dyno it recently?

[JumboBlack1.8]

Nice build.....looks solid

[jaychen]

Wow! One! Thats crazy
MAF is good now that I have the 4.2 instead of the lightning

I actually meant, HOW is your MAF set up? (photo)

[Grip99]

lol..I was talking to Mike Hood today and he couldnt remember when he sold you they mani and turbo.

Glad its running like it should. Any dyno numbers?

[stunner247]

o shit i didn't realize that this build is quite a few years old. so have you got your tune and stuff down? dyno it recently?

Yeah been building it for a while and just decided to share whats been happening. Got the tune pretty much dialed in as much as I can without some dyno time. I plan on getting on the dyno soon though to at least get a base line. have some more stuff in store including a change of engine management.

Nice build.....looks solid

Thanks

I actually meant, HOW is your MAF set up? (photo)

Don't have a pic but ill get one when I'm in there again

[M-Hood]

lol..I was talking to Mike Hood today and he couldnt remember when he sold you they mani and turbo.

Glad its running like it should. Any dyno numbers?

This build goes back a bit. lol

How is the car and how have things been Gunner?

[stunner247]

lol..I was talking to Mike Hood today and he couldnt remember when he sold you they mani and turbo.

Glad its running like it should. Any dyno numbers?

Yeah its been a little while. It was a display on Mike's website for a while. No dyno numbers right now other then the 295 when it was running like crap. Hope to get it on there soon

This build goes back a bit. lol

How is the car and how have things been Gunner?

Things have been going good. Cars running decent now. I had it out at the track once in October but only got one run in. It was the first time I had it at the track since the new motor went in so I pussed it off the line. Ran a 13.4 at 114.

[stunner247]

Last April I picked up some Artec Turbo P's in need of some help.

18x8 front
18x10 rear







Got my boy to paint the centers the metallic Black from the new Audi's (don't remember the name of the color). He also colormatched the adapters for me...30's front, 15's rear

Installed new lips to replace the damaged ones

Had to clearance the wheels and the calipers to fit over my Stoptech's

[donkeysaudi]

I'm liking the way your build is turning out. very nice

[Grip99]

Gunner, what size is that SPP fan and is it wired to a switch?

You find it affective? This might be great for Humid/Hot NYC traffic....

-Pete

[stunner247]

I'm liking the way your build is turning out. very nice

Thanks

Gunner, what size is that SPP fan and is it wired to a switch?

You find it affective? This might be great for Humid/Hot NYC traffic....

-Pete

It uses a 14in Spal fan and they give you an adapter plate to bolt in place of the old fan clutch. I have mine running through a manually adjustible thermostat controler that I got from Jegs http://www.jegs.com/i/Derale/259/16769/10002/-1 Allows me to pick what temp I want the fan to come on. I works well. My secondary fan crapped out so I'm running soley on the SPP one at the moment. The only time the temp started to creep up was when I was sitting in stopped traffic for 2 hours in 95 degree heat but it never got dangerously hot.

[Grip99]

Ahh link didnt work, but if its anything like the Afco racing electric fan switch then i know what your talking about.

Im thinking of picking up a Zirgo 16" dia , push/pull fan for the engine/oil cooler. I have to measure out the diameter. Also its 4in thick. Not sure it will clear the motor lol. 3630 cfm

But some how i think 14" is the right size and its 1/2 in thinner. 2,785 cfm

[stunner247]

Ahh link didnt work, but if its anything like the Afco racing electric fan switch then i know what your talking about.

Im thinking of picking up a Zirgo 16" dia , push/pull fan for the engine/oil cooler. I have to measure out the diameter. Also its 4in thick. Not sure it will clear the motor lol. 3630 cfm

But some how i think 14" is the right size and its 1/2 in thinner. 2,785 cfm

Yeah the Afco is basically the same thing.

2785 cfm with the 14in is more then enough. Mine flows 1038 and works pretty well but I need to get a new secondary fan too for peace of mind. You could probably get the 16in in that opening with a little trimming but the main concern is the depth. Don't know the exact thickness of mine but I would say that it's not more then 3in. I have about a 1/2 clearance between the back of the motor and the idler pully that the fan clutch used to be bolted to.

[stunner247]

Before the wheels went on I got some Canadian S4 bumper grills then got a Cupra lip After



Also decided the beef up the rear diff with some mounts

Apikol Race front mount
034 rear cross member with Stern bushings

(crappy cell pic)

[M-Hood]

Ahh link didnt work, but if its anything like the Afco racing electric fan switch then i know what your talking about.

Im thinking of picking up a Zirgo 16" dia , push/pull fan for the engine/oil cooler. I have to measure out the diameter. Also its 4in thick. Not sure it will clear the motor lol. 3630 cfm

But some how i think 14" is the right size and its 1/2 in thinner. 2,785 cfm

Has to be thinner then 3". You don't need a fan with a really high CFM.

This one is plenty. It is 16", 2.5" thick, 1610 CFM and only $99.
http://www.summitracing.com/parts/BCI-75014/

Pretty sure that is the one I have in my car, when I have it running for a few minutes my FMIC is cold to the touch.

I am using this controller or one just like it. I also have another relay wired before it so I can turn on both my fans with a switch inside the car.
http://www.summitracing.com/parts/HDA-3653/

[stunner247]

I am using this controller or one just like it. I also have another relay wired before it so I can turn on both my fans with a switch inside the car.
http://www.summitracing.com/parts/HDA-3653/

Mike, How do you have the relay set up? I'd like to do this one I get another fan.

[M-Hood]

Mike, How do you have the relay set up? I'd like to do this one I get another fan.

Pretty sure this is how I have the relay setup, but I can always check it if you need.

The 2nd relay acts like a bypass of the adjustable fan controller switch. So it gets the battery supply wire going to 87 and 85, 30 goes to 12v wire that goes from the fan switch to the fan. Spot 86 on the relay goes to the switch inside the car that just gets grounded. So when the switch is changed the ground triggers the relay which sends power directly to the fan or fans.

Might want to use a 4 plug relay, if you use a 5 plug the center spot (87a) will have power when the adjustable fan control switch powers the relay. Just make sure to tape up the relay really well or use a relay harness plug instead of just connectors.

[stunner247]

Gotcha, Thanks

[M-Hood]

Gotcha, Thanks

That is one way of doing it, I will have to take a look but pretty sure the following is how I actually did it using a 5 plug Bosch relay.


The 2nd relay goes on the wire going to the fan from the adjustable fan controller. You cut the line, put the end coming from the fan controller to spot 87A and the end coming from the fan to spot 30. You then run 12v from the battery to spot 87 and 85. You still put the ground wire coming from your switch in the car to spot 86 to activate the relay.

Doing it this way allows only 1 wire to power the fan at a time and you can turn the fan on any time even if the key is off. If you want the switch inside to only control the fans when the key is on then a wire from a ignition source needs to be ran to plug 85 on the 2nd relay instead of power from the battery, but you still want to keep 87 connected to the battery.

[Grip99]

That is one way of doing it, I will have to take a look but pretty sure the following is how I actually did it using a 5 plug Bosch relay.


The 2nd relay goes on the wire going to the fan from the adjustable fan controller. You cut the line, put the end coming from the fan controller to spot 87A and the end coming from the fan to spot 30. You then run 12v from the battery to spot 87 and 85. You still put the ground wire coming from your switch in the car to spot 86 to activate the relay.

Doing it this way allows only 1 wire to power the fan at a time and you can turn the fan on any time even if the key is off. If you want the switch inside to only control the fans when the key is on then a wire from a ignition source needs to be ran to plug 85 on the 2nd relay instead of power from the battery, but you still want to keep 87 connected to the battery.

Im not a fan of taking up my Ic's priceless GPO's, lol, but is there any way my standalone can control the fan? I was under the impression that it could and its possible to set it.

[M-Hood]

Im not a fan of taking up my Ic's priceless GPO's, lol, but is there any way my standalone can control the fan? I was under the impression that it could and its possible to set it.

I am sure it is possible since it is just a signal to activate the relay.

[stunner247]

Ok so I had the TT 4wire coils in and they were better then the stock AEB ones but I still had to close the gap on my plugs to .24 to keep it from breaking up at high rpm. I decided to get IE's coil addapter and through in some 2.0 fsi coils.





Was able to open the gap back up to .28. No more misfires at high RPM and it idles alot smoother. I'll chalk that up as a win!

[Grip99]

Nice.

Have you ever run Bosch F6DTC plugs? I found they are great for high boost and no gapping required.

[stunner247]

No but I might give them a try next time I through plugs in her, Thanks

[GR-RALLYE]

I'd definitely recommend the f6DTC also, best I found after messing around with a few others on my setup.

Where you got that dump exiting at?

[stunner247]

Dump routes down infront of the right axle and exits behind the subframe