2005 Allroad Progress / Build!

[Brandon002]

Can't wait to see it in person when I drop your cam lock bar off.

[erroob0977]

Thanks guys! I'm sure hoping to make it to camp allroad next year, We're thinking about making a 1-2 week road trip out of it.

ChicagosPhantom, If they're out of the car I'd be happy to help out!

[Thomas320]

nice job!
The turbo location looks similar to the one on my 7.3L powerstoke.

[ChicagosPhantom]

ChicagosPhantom, If they're out of the car I'd be happy to help out!

Holly....wasn't that serious asking such a thiny,but now....I'll text you in a bit,I think I still have your #...

[erroob0977]

I’ve made quite a bit of progress since my last update! Up-pipe is finished and ceramic coated along with the 2.8 manifolds and turbine housing. The first coat was a bit streaky on the up-pipe so I added another after this and then wrapped it with the “titanium” exhaust wrap. I didn’t get too many in-progress pictures unfortunately but here’s a few from over the weekend.



Here it is installed, with the wastage piping in progress. Since this picture was taken it has been finished and being ceramic coated as well. You get a pretty good idea of where it’s headed here, but it comes down around the trans mount like the stock passenger downpipes and ends with a v-band next to the transmission. That way I can recirculate it into the exhaust or stick a turn down there to dump it to the atmosphere. I like the idea of dumping to atmosphere but I think the novelty will wear off fast (especially during tuning) so I wanted to keep both options open.



Wastegate springs installed, set to crack open at 18-19 psi.



Because of the routing of my manifolds I am modifying the heater core connections, replacing them with -12AN hoses. Here’s one of the modified pipes, I still have to finish the crossover pipe (hopefully tonight).



Brand new air/fuel/spark components here. Bosch factory 1000cc multi-hole injectors, RS4 MAF, and sidefire plugs. I also got some new primary O2 sensors for peace of mind.



I don’t have a picture handy but my intercooler and TiAL QR valve have arrived as well. I went with the (treadstone) TR1235. 12.5”x3.5”x22” core, it’s huge.

[erroob0977]

I'm just about ready to put the engine back in the car! I decided to pick up an AMD clutch (stage 4) to run instead of the 4 puck southbend clutch. That should arrive in a couple days then it's ready to go back in! Of course once the engine is in I still have quite a bit to do (exhaust, intercooler, misc lines, and clutch pedal install) but I'm making progress, hopefully only a couple more weeks until I'm driving it!

Here's the intercooler and intercooler/intake piping. I may have went a little overboard on the piping but I'd rather have extra than not enough when it comes time to get that set up...



Modified coolant crossover pipe is finished and installed with new o-rings.



I had a local hydraulic shop make me some nice AN lines for the turbo oil/coolant.

[A Stupid Turtle]

Very excited to see the outcome...
I come from pushrod motors, and these are the first main foreign shenanigans I'm getting into!

[NuGGet_PuFFer]

Awesome work!

[estomax]

that looks freaking beautiful, can't wait to see it in the car!

[erroob0977]

Thanks! I can't wait to get it in the car and get it back on the road haha.

I had some free time yesterday and wasn't sure what to do so went ahead and painted my spare valve covers to match the 17Z brakes that will be going on the car at some point.
It's "MG Maroon", I chose it since I wanted a red but not the typical bright red people paint their brakes.

[UroTuning]

whoa

[erroob0977]

whoa

Hopefully that's a good whoa! haha


Not too much more progress to report unfortunately. I received the wrong clutch from AMD but as soon as I called them they got the correct one on it's way to me, awesome support there! It should arrive early next week and then the motor will be going in next weekend now!

I got the rear axles torqued down and driveshaft installed. Since I am reusing my A6 driveshaft I had to space the center bearing support down about 1" in order to keep the driveshaft straight. The bearing support bracket does stick down a little bit as a result but based on some quick measurements it looks like it will still be about 1/2" higher up than the exhaust so I won't actually be losing any ground clearance. I would have loved to get a new allroad driveshaft or single piece one but it's just not in the budget at this point so I went ahead and also filled up the center support with window weld to stiffen up the old cracking rubber a little bit.



I also cleaned up the engine bay while it's empty. A little degreaser went a long way in there. I also cleaned out all the rain drains to prevent any clogs and flushed out the heater core with some CLR for good measure. You can also see the fire sleeve I put over the power steering line to protect it from the exhaust manifold heat.

[erroob0977]

It’s about time for another update here, it’s getting real close to being ready! I was really hoping to fire it up by tonight but doing things right always takes more time than you'd expect.

My AMD clutch arrived just before last weekend and I got that installed, it looks great and I’m sure it will last much longer than the 4 puck Southbend I was going to run.





The allroad now has the correct number of pedals! Before installing the clutch pedal I whipped up a little adjustable clutch stop to make driving with the high engagement point a bit easier. I always found myself pushing the clutch in quite a bit farther than necessary so I figured why not…





Installed new axle flanges for the Advanced Automation heavy duty/TDI axles. That hose barb on the wastegate it just there so the axles don't kick any grease or anything up into the open hole there.


All ready to go back in the car! Before I put the motor back in, it slipped my mind that the engine in the allroad sits at a different height in relation to the frame rails than my old A6 so I had to swap out all the coolant lines on the front of the engine once I got the engine in.


Engine is back in the car here with the painted valve covers. Unfortunately when I was tapping the valve covers for the AN breather lines I cracked one so I had to get a little “creative” to keep that from leaking for the time being. It's just a hairline crack in the breather port, the valve cover itself is fine. I’ll clean up my other set and just weld in AN bungs after the cars back on the road.



I’m trying something new with my breather system as you can see in that picture. I forgot to get any pictures of the inside of the crankcase valley cover but I welded in a series of aluminum plates with increasingly smaller perforations to help pull the oil out of the air. The blowby all enters on the right side and flows in a U shape through the screens and I’m pulling vacuum from the downpipe with a Vibrant e-vac scavenger. All the oil collected will drain back down into the oil pan.

I went ahead and just installed my stock intake manifold (ported to match the 2.8 heads) for now. That will give me time to do a little plenum work on my RS4 manifold after the car is on the road again. I’ll install that at the same time I switch valve covers since I’ll need new VC>Crankcase breather lines (which require removing the intake manifold with how I’ve got it all set up). I also installed the 034 rails with my new injectors just to be sure everything fit nicely, and it does!


I couldn’t get a good focused picture here but this is why it’s important to get good injectors. All the intake ports looked like this with the middle valve nice and clean and the the two side valves covered in deposits. It shows that my drilled injectors were just pouring fuel straight down to the middle valve and the fuel wasn’t being evenly mixed with the charge air. The new injectors should fix that!


I started to lay out the wiring harness but I wasn’t happy with how the OEM one was going to fit at all. This is roughly how it was going to be routed but I pulled it back out so I can redo it. I’m going to change the lengths of some of the wires and remove all the plugs for things that I no longer have in my car. I may set it up so I can run all the passenger side wires behind the firewall and then out through the unused grommet instead of over the intake manifold.


Held the intercooler up in place to see how that would fit, I’ll probably have to trim the bumper support a little bit but other than that it should fit in there pretty well!

[A Stupid Turtle]

Predictions for power output or quarter mile times?

[erroob0977]

I'm expecting the power to be in line with my old SRM turbos, where I'm really hoping this setup will shine in comparison to those is in the spool and transient response departments. I had about 550 whp (E85) running 30 psi tapering to 28 by redline before, which I was really happy with. The GTX3576R can run 35 psi out to redline so I could make more than before if I really wanted to but I doubt I'll push it that high so I can keep my block intact.

As far as 1/4 times, I really don't know. I doubt I'll have everything all ironed out before the tracks close this year but next spring I will definitely figure out. It's not intended to be a track car, this will be my daily driver once it's finished, but I'd bet I'll be somewhere in the 11s, especially with anti-lag/NLS.

[n8henn]

Sick build man! I love the attention to detail! Impressive!

[A Stupid Turtle]

Turbo location is saweeeeet

[erroob0977]

Sick build man! I love the attention to detail! Impressive!

Thanks!

Turbo location is saweeeeet

haha yeah it looks like it means business up there! I can't take credit for that location though, as I'm just roughly copying the turbo location in the 034 STK & the few single turbo guys from before the 034 kit.

[erroob0977]

More progress over the weekend!

I modified the harness so that I could route the passenger side wires behind the firewall instead of over the intake manifold which ended up being surprisingly easy! Finished product:



With the battery in the stock location, and my new routing of the harness and heater core lines it was getting very cramped behind the secondary firewall so I’m going to relocate the battery to the trunk. I’ve already got everything for that leftover from my old A6. I went and picked up a new Optima Redtop which will fit perfectly in the drivers side trunk compartment (with a little tweaking of the bracket in there).



I got my upper intercooler piping nearly finished, I just need to weld on the MAF, MAP, and TiAL QR flange on. I’ve got 2.5” piping over the top of the intake manifold, transitioning to 2.75” piping over the valve cover and down to the intercooler. The piping will all be 2.75” on the intercooler to throttle body side.
The intake is 3.5” with a 6” bellmouth before the filter. The bellmouth is to help straighten the airflow to make up for the short run of piping between the filter and MAF.





All thats left now is to get the battery installed, finish the intercooler pipes, and install the fuel lines and other hoses about the engine!

[estomax]

way cool! how do you think the coolant reservoir is gonna do with that downpipe right there?

[erroob0977]

I'm a little concerned but I think it will be fine. The downpipe has both ceramic coating and the exhaust wrap to keep heat in and I put a gold reflective lining on the part of the reservoir closest to the downpipe. So between all that and the 1"+ air gap it should be fine. I am going to keep an eye on it though if it looks like the heat is starting to damage or deform it then I will find an alternative. If it ends up being okay there then I will pick up a new OE one to clean up the engine bay since the one I've got is pretty discolored. A lot of other STK guys run the VW bubble shaped reservoirs so thats always an option but I think the stock one fits much better in our engine bays so I'd prefer to stick with it.

[A Stupid Turtle]

The bubble goes in that same place or overy on the passanger side?

[erroob0977]

Generally the same place, but since it's got a much smaller footprint you can move it forwards and away from the downpipe a couple inches. It would sit roughly where the front half of the stock coolant reservoir sits.

[RubiRock]

love this build, nice work

[erroob0977]

It’s alive!! Not 100% road worthy quite yet, although I did take it for a quick spin around the block! The clutch was amazingly smooth and easy to drive for a 6 puck, and it’s not broken in all yet either.

I wish I could say it started right up with no problems, but I spent most of yesterday diagnosing a no-crank issue. It ended up just being a bad ground on the frame rail (just had to clean it up with a wire brush), of course I didn’t realize that until after I had already replaced the starter. But after that little problem was fixed, it fired right up and ran great!

Here’s what the engine bay looks like right now. Fuel line routing isn’t final but will do until I’m ready to run new lines from the fuel tank.




Battery has been relocated to the trunk, it fits nice and snug in the bracket I modified. I still have to clean up the power line and run in nicely, I just tossed it over the backseat temporarily so I could fire up the car.


Took advantage of the extra space behind the false firewall for my FPR and a Zeitronix flex fuel sensor. I still need to decide where I’m going to put that gauge, I may make some thing to replace the ashtray. Not sure yet.


I did end up having to notch the crash bar slightly to get the bumper to fit over the intercooler, but nothing major. Unfortunately my passenger side fog light didn’t fit with the intercooler piping, I’ll have to order some more piping and redo the lower intercooler piping on that side at some point.


Don’t mind the little leak, it appears my windshield washer tank has a crack in it.


Only things left to do now are to get my Zeitronix ZT-2 setup installed (AFR, boost, fuel pressure, & EGT), and to get the exhaust sorted out. I have a dual 2.5” from my old A6 with vibrant resonators and mufflers that I need to adjust a bit to work, and also make a mid pipe to connect it to the downpipe and wastegate piping.

love this build, nice work

Thanks!

[estomax]

looking good, is that 2 AWG battery cable? i hope it is at least 2, that is as small as i felt comfortable with my 1JZ powered lexus when i relocated, that has a 1.4kw starter. how many kw is the starter on these cars?

[erroob0977]

looking good, is that 2 AWG battery cable? i hope it is at least 2, that is as small as i felt comfortable with my 1JZ powered lexus when i relocated, that has a 1.4kw starter. how many kw is the starter on these cars?

Yeah it's a 2 awg cable going to the trunk, I left the alternator/starter wiring the same as stock (looked like about 4 awg). This was the 034 Motorsport battery relocation kit wiring I pulled out of my old A6 so I've been using it a couple years now with no problems. I'm not sure about the draw from the starter but the alternator is 140A (1.8-1.9 kW).

[erroob0977]

I’ve gotten a chance to drive the allroad around a little bit now, and this thing spools amazingly fast! I’m seeing 20 psi at 3200 rpm, and thats with virtually no tuning (no N75 duty cycle and very low timing). For reference my old rs6/k24 set up at it’s best (and on E85) made 20 psi at ~3800.

I still have a few gremlins to track down so I haven’t taken it past 4k but it feels great up to that point. I think my IAT sensor under the intake manifold needs a new o-ring since I hear a small leak from under there and I’m having a rough idle, I think caused by that leak (Idles perfectly with MAF unplugged).

I’m also having a very weird issue where my car thinks it’s one gear higher than it is while logging. I’m running an A6 trans/diff with the correct values in my ECU for that, and I have corrected the vehicle speed ratio for the larger rotating diameter tires on the allroad. It’s not actually causing any problems but if anyone’s got any ideas what could be causing that, that would be very helpful!

[ChicagosPhantom]

It's been over a half year now since last update.Hope everything is well and your build isn't on a back burner,neighbor...

[NuGGet_PuFFer]

It's been over a half year now since last update.Hope everything is well and your build isn't on a back burner,neighbor...

Word.

[erroob0977]

Sorry for the lack of updates guys! I got a bit burned out after spending a couple months banging my head against the wall trying to fix the couple issues it had (while still needing to drive it everyday). I ended up buying a Q5 and the allroad has just been sitting on the driveway waiting for me to feel like working on it again.

I had ran into a few problems that I had to hackishly solve, and despite that it was running very good (and just on a base tune). No matter what I did I could not get the car to run with a MAF. I tried Bosch, Hitachi, HPX in both draw-through and blow-through but it would barely idle and die everytime I let off the gas. Normally that would point to a boost/vac leak but there were none to be found other than a slight leak through the TiAL wastegates (normal according to TiAL, and if that had been the problem blow-through HPX would have fixed it). I ended up coding out the MAF which I hated doing but I needed to be able to drive it... Also strangely with the 18 psi springs in my TiAL wastegates, I had a base boost pressure of 38 psi (No N75 duty cycle, I tried multiple N75s... with no N75 base boost dropped to 31 psi).

I only took it to about 4000 rpm (since at 30+ psi the one fuel pump I had in there wasn't enough especially with the stock lines), but the GTX3576R spooled amazingly fast. In hindsight I should've went with the 1.01 AR housing instead of the 0.83 because I did get some part throttle surge.

A few logs here that I dug up; Here's how quickly this thing spooled. 30 psi before 3500 rpm, this was with no N75 installed so just wastegate pressure.


Compared to my old SRM K24s.


It felt very quick, despite having virtually no timing (Lots of power still on the table)


In December I had to do emissions and could not get it to pass to save my life... For some reason it would not start the SAI test. It passed everything else and I had it properly coded to pass SAI if I could only get it to start the test.

[erroob0977]

Unfortunately the time has come to part this car out. Some rust spots came through the paint last winter which took away the last of my motivation to get this thing running properly. It's just been sitting collecting dust for the last year, time to make room for a new dedicated track/fun car...

The fueling components, RNSE, motor & brakes are already gone/spoken for. If anyone is interested in the single turbo setup, a 6 speed swap kit (w/ JHM shifter bits & TDI axles), or anything else shoot me a message.

[B5in]

Sorry to hear that you are giving up on it

how much for the clutch kit shipped to Chicago, IL 60607?

[erroob0977]

Sorry to hear that you are giving up on it

how much for the clutch kit shipped to Chicago, IL 60607?

Sent you a PM.

[jaycurn]

Sorry to hear this!

[codyandrson]

How did you run the dual pumps? Did you use SRM dual pump hangar or make something custom?