Jermunji's B6 Build Timeline

[Jermunji]

I just wanted to start a thread so that say in 5 years I could have an idea of all the work that put into my B6 to get it to be one of a kind.
(*note) It's gonna be pic heavy. enjoy and hopefully you get a few ideas for your own build

Starting off. I bought it in 2013 from an insurance auction for ~2700
an '02 B6 1.8T quattro with less than 20% window tint all the way around.




















Then I got to work:

1. The clutch went out within 3 months of driving it, so I took the opportunity to upgrade to the RA4 clutch kit from ECS to take advantage of the stage 1+ upgrade I knew was inevitable.

2. Came across a guy on CL who was selling his RS4 RSB and 386 injectors for an amazing deal. by the time I got up there the injectors were gone at $80 but I still managed to get the RSB for under $60.

3. The previous owner had removed the stock intake box and replaced it with a cold air intake. Reading around on Cold Air Intakes and the 1.8 blocks everybody said don't do it. Just stick with the Stock box as it was colder than the cone which would be sucking in all the engine heat. Solution? 00black1.8t He makes custom heat shields with all the right cutouts to fit like a glove. $95 and I'm happy to say immediate difference. Drove the car hard one night to test if there would even be any noticeable difference and when I got done I jumped out and popped the hood, the turbo was glowing red and the engine bay was radiating lots of heat and yet the intake side of the engine bay was cold as the air that night. I was blown away how well that heat shield worked. yea I read all about people being able to do this one DIY and for alot cheaper but I had no problems supporting a fellow Az'er who made something unique. Its a good product and IMO def worth the $95.

4. The rear Coolant Flange went out. After being tired of paying mechanics and problems with the brother in law, I decided I would just start fixing things myself from there on out. This job was my first hefty one, pretty much tearing off the top of the engine to get enough space to work with. Glad I decided on the DIY route cause then I started saving a lot of extra cash. It was a good experience and wasn't to bad a job. Also did a coolant flush.

[texasboy21]

What else is planned?

[Jermunji]

First when I get some time, I gotta get this thread up to date with everything I've done to it and the pics to go with it (it'll have to wait till I get the little one put to bed )

Then eventually in no particular order except whatever I find the best deals on first:


Interior

1. Carbon fiber interior from Ocarbon, along with some custom pieces. (like door handles)
2. Carbon Fiber Steering Wheel
3. Replace all interior buttons with b7 chrome style, headlight switch to chrome Passat
4. DONE. P3 digital boost vent gauge, with Analog boost sensor
5. Platinum grey B6 S4 Recaros or RS4 seat swap
6. B7 console swap
7. Black S4 headliner swap


Exterior

1. S4 Door Blades
2. Eurogear Carbon Fiber Hood
3. USP Front Bumper
4. Cupra R Lip splitter
5. DONE.Black out and carbon fiber the headlights
6. Get the Switchback turn signal LEDs to work
7. Roof spoiler
8. Finish custom grill job
9. DONE. LED rear turn signal swap
10. S6 LEDs fog light swap
11. DONE.Depo LED Tail lights
12. DONE. LED interior swap
13. DONE. LED Reverse light bulbs
14. DONE. LED license plate swap
15. Would love to do a glass headlight lens swap if I can ever find one like volx-tuning has for my wife's mkIV GTI
16. Engine covers
17. Roll fenders
18. Battery relocation
19. S4 mirrors
20. Passat windshield washer fan spray nozzle's
21. Replace Stock horn with a train horn
22. Paint it Nogaro Blue


Drivetrain

1. Power Steering cooler upgrade
2. 01E 6 Speed swap
3. Wavetrac rear LSD upgrade $1095
4. JHM Trio Shifter Package $319.50
5. DONE.034 Motorsports Street Density motor mounts
6. DONE.034 Motorsports Street Density tranny mount
7. DONE.Powerflex street series center diff mount bushing
8. DONE.034 Motorsports Snub Mount


Engine

1. DONE. Stage 1+
2. Catch Can System
3. Hose delete
4. Evolution Racewerks intercooler street $845
5. Silicon hose (red) swap out
6. DONE. Silicone TIP (blue)
7. Intercooler hose replacement to Silicone (blue)
8. Magnaflow 14851 mufflers with custom cat back exhaust.
9. DONE. 034 HFC $280
10. Upgraded downpipe
11. Light weight crank pulley
12. New A/C compressor
13. '12/'13 APR Stage II 5 cyl 2.5T block


Suspension

1. Koni Lowering Springs kit
2. DONE.Swap rs4 RSB to 034 with spherical endlinks
3. Powerflex Control arm bushings

Wheels

1. Summer mode: 19" RS6 Reps
2. Winter mode: 18" 5 arm rotors,
3. B6 S4 Rear brake upgrade
4. Stainless steel brake lines all around



just to name a few. I've already knocked a few off my list. all while also working on the wife's GTI build.

[OMG_SHARK]

You got PM about the p3 gauge.

[itsmatt33]

i have a ER sport fmic brand new, full LED interior kit brightest one on the market, and a 034 tip for sell.


i also have a test pipe :p

[Samsonite]

Have fun with your money pit I paid over $9000 for mine in 2012 and have put probably $9000 more into it between mods and maintenance and I don't even have a turbo

Also, FWIW yours is not an S-line. B6 S-lines were only available in 04 and 05, aka Ultrasport

Did you get that body damage repaired?

[Jermunji]

i have a ER sport fmic brand new, full LED interior kit brightest one on the market, and a 034 tip for sell.


i also have a test pipe :p

already did the full interior led swap. lol, per your LED thread as a matter of fact.

Have fun with your money pit I paid over $9000 for mine in 2012 and have put probably $9000 more into it between mods and maintenance and I don't even have a turbo

Also, FWIW yours is not an S-line. B6 S-lines were only available in 04 and 05, aka Ultrasport

Did you get that body damage repaired?

nope it is definitely an Sline, or so thats what the dealer told me when I called him to do a vin check on what my cars "packages" were. It has all the pre ultrasport basics like the upgraded sports suspension in red, lowered a but more, aluminum trim, sline badges and steering wheel. Gosh, I wish it were an ultrasport tho then I could of at least got a 6 spd and the body kit for free.

lol, and I've come to peace with it being my personal money pit. I'm already up to at least 7k total invested. And that is w/o getting the body work finished up which will be another 1k. I've decided I'm at least gonna hit the half a million mile club in this.

[OMG_SHARK]

I think paid is right. If I am not mistaken only the 05 USP have an sline badge. I am guessing the previous owner might have done all the mods you mentioned.

[Jermunji]

I was thinkin about that possiblity but like I said when I called the dealer to do a vin check they stated that the aluminum trim/ sport suspension options came with mine. OH I know what it was!!! They said it has the Sline package which might be the differentiation between being and actual "sline" model.

[ShogunR32]

I was thinkin about that possiblity but like I said when I called the dealer to do a vin check they stated that the aluminum trim/ sport suspension options were standard. OH I know what it is. They said it has the Sline package which might be the differentiation between being and actual "sline" model.

Your car is not an S-line. Audi offered the s-line package aka "ultrasport" on the B6 in 04 and 05 only.

[Jermunji]

I agree mine is not an Sline. but I guarantee you that it came with the upgraded sport suspension and aluminum trim from the factory. I just ran another vin check on Audiworld's vin decooder which listed them. I'll post a link to the results.

[ShogunR32]

I agree mine is not an Sline. but I guarantee you that it came with the upgraded sport suspension and aluminum trim from the factory. I just ran another vin check on Audiworld's vin decooder which listed them. I'll post a link to the results.

No need to do that, I believe you that your car came with fishscale trim and sport suspension. The one thing I like about the 02 model year is the rear heated seats.

[Jermunji]

No need to do that, I believe you that your car came with fishscale trim and sport suspension. The one thing I like about the 02 model year is the rear heated seats.

I didn't even know about that until just now

http://forums.audiworld.com/vindecod...inDecoderFarea

My guess is that the aluminum trim was either part of the sport package along with the suspension or they were two independent packages.

[Jermunji]

After changing the clutch and doing a full tune-up I started the process towards finishing the bodywork. I first needed to source out a new rear bumper to have clean lines to be able to line up the quarter panel with when I got that hammered out. I went through 3 different companies including a junk yard before I could actually get my hands on one that was in stock. I was looking for an S4 rear bumper but ended up buying the 1st one I could find for cheap off ebay. $500 shipped including upper/lower sections and the rebar from some junkyard in Ohio. Just happened to be off a USP A4. When it came in I saw the USP sticker on the Bumper and decided that had to go. Why imagine a grill there when I can just DIY it.




3. Sitting low, I drove over a speed bump in a culdesac my front lower valence came off. I hear crunching backed up and gathered the piece together putting the valence back on but found out I had just run over one of the bumper grills in the process. Reading through the horror stories on the forums I realized I came out lucky and needed to get a skid plate on ASAP. Had to go Evolution Thor Skid Plate through Bora Parts. I got a deal from them for under $250. (actually it was WAY better than that )

Took some of the leftover grill I had from the custom USP rear bumper job and got to work making lower grills for the front to have a continuous look. came out exactly like I wanted. Sometime I just need to do the same with the main grill.

[Jermunji]

Next up I decided to do a full LED swap thanks to mi familia. Interiors, License plate, and Reverse bulbs all got swapped out for whiter and brighter LEDs. Followed itsmatt33's thread to the T ftw.

[Jermunji]

And after reading a few threads about 2.0T coils I figured I can't beat $15.80 a piece, so I swapped over to 06E905115E
and thanks to my fellow AZ'ers I saved $80 on the coil pack bolt downs.

[Jermunji]

Next I wanted to do something about the mirrors. I already got problems seein people sometimes cause the tint is so dark. I figured some blue tinted heated wide angle mirrors from parts4euro would do the trick. They did nicely.

[Jermunji]

Then it was on to the headlights. Thanks freeloader700 for paving the way on this one.
Valeo D1s projectors, TSX-R clear lens, matte black shields, and Osram D1S 5000k CBI'S





I still need to get out one of these nights and aim them properly

[Jermunji]

Then with the brake light being on for the past 1500 miles and feeling the degrading stopping force my brakes had, I took advantage of Adams Rotors Thanksgiving sale to do a B5 S4 front brake upgrade with new over slotted rotors, used calipers, and Stoptech Street Performance pads for the front and back for $500.

[Jermunji]

Came across one of these so I figured "eh why not?"

[Jermunji]

And that just about gets me to today. I been turning my attention from my car to focus on the wifes lately.
But This is what I gotta deal with next. Tryin to decide whether I wanna go the $500 DIY, or at least $900 shop on the steering rack

[SJorge3442]

DIY FTW! You've done everything else so far. Why not be able to say that you did everything yourself? I hear the rack is only an afternoon job. Shit. After pulling a trans out I feel like any job is an afternoon job... Keep it up. You also reminded me that I need to follow the "led the f out your car" thread.

[Elliott]

In the original post it looks like the rear quarter panel is smashed in. Did you repair this yourself?

[Jermunji]

In the original post it looks like the rear quarter panel is smashed in. Did you repair this yourself?

My brother in law hammered it back out, and I need to have it Bondo'd, smoothed out, and repainted to look straight again. With everything else that we have going on I've had to set the finish work aside on it Noticed a few weeks ago the metal started to rust but my wife was not wanting to drop $1k to get it looking OEM again, so I just did the good ol $7 plastidip after sanding it back down as a nice temporary solution.

[Elliott]

That makes sense for a 12 year old car. Looks pretty straight in the photo, working out rear QPs is not an easy task.

[Willënskraft]

I like your three toned car lol jk, what color do you want painted in the future?

[freeloader700]

Man I want those brakes! I need to start planning on getting some when I need to do the fronts again.

When do you think you are going to start on the rear QP, this summer?

[n7plus1]

And after reading a few threads about 2.0T coils I figured I can't beat $15.80 a piece, so I swapped over to 06E905115E
and thanks to my fellow AZ'ers I saved $80 on the coil pack bolt downs.

]

whered you get these so cheap?

[n7plus1]

And that just about gets me to today. I been turning my attention from my car to focus on the wifes lately.
But This is what I gotta deal with next. Tryin to decide whether I wanna go the $500 DIY, or at least $900 shop on the steering rack

i picked up a refurbed rack from rackdoctor for something like 250. diy...isnt TOOO bad...its not fun neither.

[freeloader700]

whered you get these so cheap?

Pretty sure Amazon, prices have since went up

AMAZON 06E905115E

[customa4]

whered you get these so cheap?

Click With shipping I'm not sure which would be cheaper, Amazon or GAP.

[Jermunji]

I like your three toned car lol jk, what color do you want painted in the future?

I want to get it looking stock silver again, then I want to vinyl wrap it to a gunmetal gray or matte grey.

Man I want those brakes! I need to start planning on getting some when I need to do the fronts again.

When do you think you are going to start on the rear QP, this summer?

Yep. My order is:
1. Fender for wifes GTI
2. Send wife back to Mexico and bring her back so we can get her permanent residency status
3. Skid plate for GTI
4. Replace Steering Rack
5. Fix Fender

whered you get these so cheap?

They were on special on the home page at www.Genuineaudiparts.com
I'm thinking about buying 6 more before they change their specials. I had to buy a few extra parts so the $9.50 shipping ended up being cheaper the GAP route for me

[Jermunji]

ehh I figured why not just leave the extra dust protection. They fit perfectly snug and actually are a pain to pull out. plus just cutting the original ones off and slipping them right up snug to the originals on the red tops were nothin. That's how I seen em do it on the original thread so figured if it ain't broke don't fix it.

[Jermunji]

After taking the car in today, they disconnected the rear left caliper from the e-brake line as the caliper was seized up and the e-brake wire isn't budging either. They wanted to quote me a full caliper replacement and e-brake cable as well. Got me thinking. If I do that I might as well just upgrade the rears to compliment the fronts that I just did. So my question is: what would be a suitable upgrade that would work nicely as far as not drastically changing the braking bias to compare with the B5 S4 fronts?

just the B7 A4 rears or could I do B6 S4?

[n7plus1]

thanks fellers.

[Willënskraft]

Wrap huh, why not plasti dip gunmetal grey right noww .

[Spike00513]

Same exact thing happened to me recently. P/S fluid all over the drivers side bottom of the car. It's not a $500 DIY at all. You can do it for as little as 50$ if you get lucky with a junkyard steering rack and haggle a bit, or you can do it for around $200 with a warrantied, re-manufactured RackDoctor steering rack. Many forum members, including myself, went with RackDoctor. You could even rebuild your own rack. My car originally came with a Koyo(steel) but I chose ZF(aluminum) for the replacement. I've read that any B6 or B7 rack will work as the mounting points are all the same.

If you do go with RackDoctor, the banjo bolt washers come with the rack and are copper. The OEM washers are aluminum and a few bucks at the dealer.

You're looking at around an afternoons worth of work. A whole day at the very most. Or pay a shop $1400 to do it.


An OEM Audi re-built caliper with a lifetime warranty is $60 at NAPA. Mine were sticking a bit so I rebuilt and cleaned them. What do you mean by the "e-brake wire isn't budging"?

[Jermunji]

Was there any noticeable difference between going zf from your koyo? I checked out rackdoctor and they are very reasonable. Even when disconnected the e-brake cable isn't receding back into its sleeve. If u pulled on the handle wheres the other one contracts a bit, this one doesn't exert any pressure on the caliper

[Spike00513]

IMO, the steering in my new ZF feels a little stiffer but maybe it's just me or there's another explanation for this, such as my pump starting to fail, air in the system(hope not, I bled it per Bentley), etc.
Other than that, I don't know of any differences. The mounting points are all the same, the fit is the same, etc., but one is steel while one is aluminum, and they look different on the body. Idk if their ratios and internals are different. Rich at RackDoctor seems to know a lot about the details, like which year Koyos were good and which were bad, when who switched to a more corrosion resistant coating, etc, but I chose ZF out of brand preference. Maybe that was a mistake, we'll see.

ZF:
(Doesn't come with steering damper IRL, has the same hose layout and mounting points as Koyo, interchangeable)
Koyo:

[SlickFix]

what would be a suitable upgrade that would work nicely as far as not drastically changing the braking bias to compare with the B5 S4 fronts?

just the B7 A4 rears or could I do B6 S4?

Either would work, of course. I'd go with whichever one is cheaper.

As far as the steering rack, it's a PITA job, but I helped a buddy do his 1.8 rack and it wasn't too bad with an extra set of hands. Wouldn't want to try it solo, though. At least the 1.8 leaves you enough room to grab the new rack and maneuver it in from the engine bay.