My first Audi - 2001.5 S4 with Custom Single Turbo setup...

[britishturbo]

So I recently picked up my first Audi... a 2001.5 S4 6 speed.
Got it from a friend of mine, he had it parked in his junk yard... it had dropped a valve which put a hole through a piston.

So I towed the car home (Always had a love for B5 S4's)


Then I pulled the engine:


Another friend had a complete running 2.7 from an A6 so I got that from him.

So then came the decision... put the stock engine in and be content with 250HP for a while and then tear it apart when I want more power... Or do it right from the start?

So I did it right from the start.... Over the last month or two I've been building my own custom single turbo setup.
Mocking up the single turbo up pipes (used 2.8 manifolds and 034 Motorsports flanges)

Late night victory - engine installed. And yes I'm doing this outside under my car port... The garage is full with my Eclipse racecar I'm building...


Turbo installed - yes I cut the 2nd firewall slightly for many reasons, but It's going to get boxed back in nicely :)


I'll post more pics and details soon when it's all complete, but here's the first start up of the car :D



Now I need to install my fuel system... :-D


Goal is a 400 to 500 WHP daily driver at first to replace my 350HP daily driver AWD Talon.
I'll build a new motor over the winter with all forged internals, CNC ported heads (I'll port them myself), Billet Intake manifold (again I'll make this myself ;-)) and much much more...

P.S. I'm sure this belongs int he builds and projects sub forum but I don't have enough posts to put it there yet...

[britishturbo]

I have to fly out to Arizona this weekend to help some people setup and tune some Megasquirt's, once I'm back I will hopefully have the car moving under it's own power next week. :-)

[034Motorsport]

From stock to big single turbo! Love it!

Looks like you got your work cut out with the fueling system, but looks like you are doing it right.

What turbo did you go with?

[britishturbo]

Hey Max, thanks I was quite inspired by the 034 STK as you can see... I just couldn't wait to get started lol.
The fuel system shown is the planned final fuel system, but at first I'm just going to run with a bigger pump and injectors until I get my new fuel rails made. Then I'll go with the full system.

The turbo is a custom build based on a Borg Warner S256 w. 0.63 A/R hot side.
Turbo will support about 550 WHP. Should be good to start ;-)
I actually already had it from my Eclipse I'm building...
Here's the state of the Eclipse:

From stock to big single turbo! Love it!

Looks like you got your work cut out with the fueling system, but looks like you are doing it right.

What turbo did you go with?

[s4930]

Wow way to break the ice lol.... Interested in seeing the out come for sure!

[britishturbo]

I'm never happy with stock power... I'll be sure to keep everyone updated :-)

Wow way to break the ice lol.... Interested in seeing the out come for sure!

[coolgraymemo]

These forums need new members like yourself.

[britishturbo]

Thanks man! I appreciate that.
I've been reading AZ for a cpl months now doing research and the like.
OF all the forums for Audi's I think I like it the most!

These forums need new members like yourself.

[kbS42001]

very nice...cant wait to see more

[Monty23]

BEST FIRST POST EVER! Glad to see another close by single setup. We will have to meet up when I finish my build!

What clutch are you running?

[britishturbo]

Fidanza Flywheel and Clutchmaster FX-400 6 Puck clutch





And sure man I always love to meet new people :-)

BEST FIRST POST EVER! Glad to see another close by single setup. We will have to meet up when I finish my build!

What clutch are you running?

[britishturbo]

Btw I must say I feel the B5 s$ platform is very underrated to this day.
I think the problem is not many people push the engine to it's limits in every aspect.
Many people bolt on bigger turbos, but most people seem to not do enough work when it comes to the intake system or the fuel system.

I plan on seeing how far I can push things... I already have port designs ready to CNC and I'm working on my Intake manifold design too...
It doesn't hurt that I build 5 Axis CNC machines for a living ;-)

[britishturbo]

Intercooler setup:


Air to Water... because I can :-P
I like the idea of 3 feet of intercooler system lol.
Ignore the mess and dirt... things are still very much work in progress...

[britishturbo]

CNC port I did myself for my 420A Eclipse project

[haggard69er]

Intercooler setup:


Air to Water... because I can :-P
I like the idea of 3 feet of intercooler system lol.
Ignore the mess and dirt... things are still very much work in progress...

Exact same setup I'm using in my build! consistent iats and minimal pressure loss! Good luck with your build sir!

[hendrj5689]

Looks awesome! Can't wait to see how everything finishes up!

[AudiNFS]

I wanna come by too! I rode in edge motors single turbo S4 and that thing was a monster.

[britishturbo]

I wanna come by too! I rode in edge motors single turbo S4 and that thing was a monster.

Give me a month or so to get it all done and running well :-)

[britishturbo]

Billet Aluminum Intake Plenums I made for a certain Lamborghini project at work recently... Took me 80 Hrs to make these bad boys!
Hopefully my S4 intake will be as sexy ;-)

[britishturbo]

Turbo Up Pipe - I even welded in bungs for the factory EGT probes.
I figure they are a great feature, so why get rid of them!

[bgzs4]

I feel like a poser reading this thread. Good stuff.

[AudiNFS]

Wow, that is some impressive stuff IMO. I can't wait to see how your build turns out!

[Monty23]

What is the thought behind putting a flex pipe on only one side of the up pipe? I would assume you would want a flex pipe on both sides....

[britishturbo]

What is the thought behind putting a flex pipe on only one side of the up pipe? I would assume you would want a flex pipe on both sides....

Same reason for 034 only using one, all you are really doing is dealing with the expansion of the engine. When the engine heats up the banks will actually grow and move the exhaust manifolds ever so slightly further apart. If you didn't have a flex section the up pipe would crack.
This should take care of that problem.

[s4930]

Noob question but what goes in that small opening on the up pipe?

[britishturbo]

Noob question but what goes in that small opening on the up pipe?

That is the flange for the Tial wastegate.
You can see it installed here:

[s4930]

That is the flange for the Tial wastegate.
You can see it installed here:

Thanks! your work looks super legit, I'd love a custom mani from you no homo

[britishturbo]

Thanks! your work looks super legit, I'd love a custom mani from you no homo

lol thanks. I don't know about offering manifolds for people yet though, with 034 introducing their STK I think that would be the best solution for most people... But I never say never ;-)

[Monty23]

lol thanks. I don't know about offering manifolds for people yet though, with 034 introducing their STK I think that would be the best solution for most people... But I never say never ;-)

He is most likely talking about an intake manifold. And fyi, don't talk about selling anything unless your an advertiser or its in the classifieds or you may get in trouble.

[Austonwerner4]

That is the flange for the Tial wastegate.
You can see it installed here:

How did you plug the back of your intake manifold?
I pulled out the 3 pieces and am going to tap threads to full them with plugs.

[britishturbo]

How did you plug the back of your intake manifold?
I pulled out the 3 pieces and am going to tap threads to full them with plugs.

I'll probably be using all but one of them which I will just cap.
When I make my billet intake though I will have more ports than I'll need threaded just to be safe.

[Monty23]

Noob question but what goes in that small opening on the up pipe?

Wastegate.

Same reason for 034 only using one, all you are really doing is dealing with the expansion of the engine. When the engine heats up the banks will actually grow and move the exhaust manifolds ever so slightly further apart. If you didn't have a flex section the up pipe would crack.
This should take care of that problem.

thanks

[britishturbo]

Another future plan / experiment I have planned is testing a Megasquirt vs Motronic ecu.
I'm a big Megasquirt guy, I've built and installed many many units through the years.
I'm going to make a harness adapter that will let me unplug the factory ecu and plug in a Megasquirt.
Only other changes needed will be the Throttle Body and removal of MAF sensor.

But that's down the road...

[caliskate12]

DROOL

[s4930]

Yea I meant intake mani... And we must also beware of AZ secret police ....

[britishturbo]

Yea I meant intake mani... And we must also beware of AZ secret police ....

Haha beware the Gestapo? lol ;-)

[Tec_Nine]

mother of god, that is such a great job on everything i can honestly say im jelous

[britishturbo]

mother of god, that is such a great job on everything i can honestly say im jelous

lol why thank you :-)
I'm pretty anal about things though, I see lots that I could have done better... but the urge to move forward and get her driving keeps winning...

[Don Supreme]

Welcome to the community, great project and great work.

I am also happy you didn't create the thread until you were this far a long.... you're legit.

[britishturbo]

Welcome to the community, great project and great work.

I am also happy you didn't create the thread until you were this far a long.... you're legit.

Thank you!
And yeah I have been lurking here since I first got the car and Google'd "Audi S4 Upgrades" lol but figured I would wait till I was almost there and had everything figured out.