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Thread: B5 V8 Swap

  1. #521
    Veteran Member Four Rings Nollywood's Avatar
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  2. #522
    Senior Member Three Rings
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    I donít know.....

    Not sure if I should
    1) Add my X-pipe (2x2.5Ē, 1x3Ē, 2x2.5Ē) , delete resonator, and add dual 2.5Ē inlet muffler.

    2) Hack off one end of the x-pipe and make it two 2.5Ē to one 3Ē Y-pipe that connects to a 2.5Ē or 3Ē resonator.




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  3. #523
    Senior Member Three Rings
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    Wrapped.






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  4. #524
    Senior Member Three Rings
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    The plan...

    Add clamps after cats, which would then have approximately three feet of piping that leads up to where the X-Pipe will take on new residence. Goodbye factory resonator. Iím already looking for a 2.5Ē dual inlet/out muffler.




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  5. #525
    Veteran Member Four Rings Bordom's Avatar
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    Skip the muffler. Just do twin vibrant resonators and party

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  6. #526
    Established Member Two Rings Jsol's Avatar
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    You also need to have the x-pipe closer to the engine otherwise you lessen the effect. Making progress:)

  7. #527
    Senior Member Three Rings
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    Quote Originally Posted by Jsol View Post
    You also need to have the x-pipe closer to the engine otherwise you lessen the effect. Making progress:)
    Yes, you are correct.


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  8. #528
    Senior Member Three Rings
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    I picked up a dual 2.5Ē in/out muffler. Made the ends slightly larger so my pipes can slide in tight. It was the only thing that costed me a hundred bucks. I still need to replace my rear 02 sensors and their harnesses. #almostthere




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  9. #529
    Senior Member Three Rings
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    B5 V8 Swap

    Good start of the weekend.

    Took out the old resonator and muffler.



    I also started to repurpose the old hangers. Theyíre still in good shape. Only needed to shave of a bit of their surfaces to fit and tack weld in place.



    Rear hangers on the muffler are done.




    Now I just need to figure out my 90 deg turn forward of the muffler, maintaining clearance while routing forward, and how to set up the next hanger with reinforcements for two pipes instead of just one.




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    Last edited by king84; 03-16-2018 at 08:52 PM.

  10. #530
    Senior Member Three Rings
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    I need to smoothen out my welds, check for holes, and add reinforcements. I have two more turns before it connects to the front half. I also have one more hanger to install.




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  11. #531
    Veteran Member Four Rings Bordom's Avatar
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    Are those pipes touching? If they are you'll run the risk of them vibrating together and you'll get rasp. I'd space them out more so you'll get a deeper more mature sound

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  12. #532
    Senior Member Three Rings
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    Quote Originally Posted by Bordom View Post
    Are those pipes touching? If they are you'll run the risk of them vibrating together and you'll get rasp. I'd space them out more so you'll get a deeper more mature sound

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    No. Thereís nearly an inch of separation. It looks different from a side view. The way I routed them forward was to ensure thereís enough clearance from any other assemblies (rear drivetrain/rear suspension/rear mounts).

    I plan to add reinforcements to ensure they wonít vibrate together, or bend unexpectedly. My old V6 exhaust had reinforced routes as well.



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  13. #533
    Senior Member Four Rings
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    Quote Originally Posted by king84 View Post
    I picked up a dual 2.5Ē in/out muffler. Made the ends slightly larger so my pipes can slide in tight. It was the only thing that costed me a hundred bucks. I still need to replace my rear 02 sensors and their harnesses. #almostthere




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    Thatís a X section muffler correct? Looking forward to more updates.


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  14. #534
    Senior Member Three Rings
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    B5 V8 Swap

    Quote Originally Posted by Ephry73 View Post
    Thatís a X section muffler correct? Looking forward to more updates.


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    Oh yes it is.... Iol. Its pretty much an X-pipe within the muffler itself. It makes me question my plan to install my X-pipe after the cats. Iíve already deleted the resonator and Iím considering I can just make it straight the rest of the way without my X-pipe.




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  15. #535
    Senior Member Three Rings
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    Almost forgot how much the clutch slave can be a pain to put back in when the system hasnít been bled. Started to put a few things back together as I wait for my 02 sensors to arrive.



    I also cleaned out and replaced some contaminated grease for the CV axels.




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  16. #536
    Senior Member Three Rings
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    Got my sensors in yesterday. Old vs New pic below. Minor difference in appearance. Four sensors for 60 bucks. Weíll see how they hold up. Ready to go OEM just in case.






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  17. #537
    Senior Member Three Rings
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    B5 V8 Swap

    So iíve been thinking....


    I have the muffler end ready and hanging, but everything that I want to route near the differential going forward is my concern. There are two turns I need to deal with before it connects to the aft end of the cats. Thereís space, but not as much I would want for two pipes near the differential brackets. Thereís also one last hanger I need to install.


    Side view pic of muffler inlet on the right, and routing path going to the left:




    My concern is the routing path.
    Pic from where the resonator use to sit, looking forward.



    Turn 1: (Last hanger would sit below the differential bracket.)
    Turn 2: Its kinda tight and probably would need one of the pipes to run a little lower than the other to clear through. I kinda donít like that






    So, I thought I can repurpose my X-pipe, but in halves. Also, Iím repurposing the 3Ē downpipes I partially constructed a few months back. The 3Ē downpipe fits the routing path perfectly.

    My setup would be my two cats to a Y-pipe, which merges to a 3Ē piping. It would route through and split back to two 2.5Ē duals before the muffler.



    Note: To help hold pieces together I used two halves of pipe and clamps. It helps when I need to tack weld straight pipes together.



    I donít think I would lose much in functionality, but weíll see.


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    Last edited by king84; 03-29-2018 at 12:33 AM.

  18. #538
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    B5 V8 Swap

    Itís all tack welded in place and hanging. Aft end will be taken out carefully. I plan to get a pair of exhaust clamps to attach the midsection (after cats).

    NOTE: This is only my tack welding process to set things in place. Iím going to start finishing it off here shortly and fully reinstall it back.

    I donít plan to remove my downpipes for anything else. I do need to route my 02 sensor harness after Im done welding the back half.

    It took a lot of energy, but it was fun.









    I want to slightly relocate this hanger a good inch lower to pull it up. There wont be any more ďlow hanging fruitsĒ once Iím done.













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  19. #539
    Veteran Member Four Rings Bordom's Avatar
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    Interesting approach to the muffler there.

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    IG: 24_et

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  20. #540
    Senior Member Three Rings
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    Only one hanger came off during its removal. Everything else stayed intact. Picked up some band clamps as well.




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  21. #541
    Senior Member Three Rings
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    B5 V8 Swap

    Quote Originally Posted by Bordom View Post
    Interesting approach to the muffler there.

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    I would have kept it dual all the way through, but I ran into a little clearance issue when passing through and near the differential brackets. Iím sure I could have gotten away with it, but it was more of a headache to weld them so close together.


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  22. #542
    Senior Member Two Rings 4Loops's Avatar
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    Wow, certainly a lot of effort, but it shows! Can't wait to hear what it sounds like!

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    1999.5 A4 B5 4.2 Quattro (My V8 Swap Project)
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  23. #543
    Senior Member Three Rings
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    B5 V8 Swap

    And its done and installed. Bolts on the band clamp seem a bit long and I may cut an inch off of each stud tomorrow. Everything aligned and fastened. Nothing hangs too low. Still need to route those 02 sensor harnesses.











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  24. #544
    Established Member Four Rings Joe Jr.'s Avatar
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    You have a lot of work into that exhaust. looks great!
    2001 A4 1.8TQM
    2002 VW TDI 5spd

  25. #545
    Senior Member Two Rings 4Loops's Avatar
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    What magnaflow muffler is that? You got a part number to share? It's not the integrated x-pipe resonator/muffler is it?

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  26. #546
    Senior Member Three Rings
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    Quote Originally Posted by 4Loops View Post
    What magnaflow muffler is that? You got a part number to share? It's not the integrated x-pipe resonator/muffler is it?

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    It does have an X-pipe within, but I dont have a part number handy right now.


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  27. #547
    Senior Member Three Rings
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    Quote Originally Posted by Joe Jr. View Post
    You have a lot of work into that exhaust. looks great!
    Thanks. This how low it use to hang.




    And now.....





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  28. #548
    Senior Member Three Rings
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    Got the uprights back in along with the CVís bolted to the transmission. Trimmed off the studs on the band clamp and routed the 02 sensor harnesses.



    Decided to hack off the excess amount of unused mounting material on the cover plate. Also, the waterline closest to the manifold will probably get a new 45 or 90 deg aluminum fitting thatíll keep the waterline away from all that heat. I may even make a thin layer of heat shield to protect it all.




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  29. #549
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    B5 V8 Swap

    In the midst of putting things back together, I decided to ďimproveĒ a waterline port. The waterline hose routing is a bit too close to the manifold. I should get the 90/45 deg aluminum fittings by today or tomorrow.







    I did try to weld and form some aluminum pipes to see how it would look. Thought about welding it to the block, BUT I would have to worry about impurities and contaminants. I would rather change out the barb fitting with and adapter. Then put a long 90 or 45 degree barb fitting.




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  30. #550
    Established Member Four Rings Joe Jr.'s Avatar
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    following along...lots of work. looks good!
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    2002 VW TDI 5spd

  31. #551
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    Long and overdue update.



    I replaced my transmission mounts. Thanks 034.




    Decide to go back to OEM lines and just carefully adjust them for proper clearance. Picked up a whole set for a bargained price.


    Iím FINALLY 100% done with the exhaust system. I installed (welded) the tail pipes. Gave it the burn look as well.



    Oh, and I realized a while back that the engine sat a bit off by a degree. I removed both engine brackets, removed the band clamps on the exhaust, adjusted the engine, slightly relocated the mount hole for the driver side bracket, reworked some welds, prepped and cleaned, and repainted with a heat resistant coating. Ran out of time to reinstalling the brackets and mounts, but iím at least happy that i can progress forward now to putting the front end back together.
    .



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  32. #552
    Senior Member Two Rings 4Loops's Avatar
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    Looks good! Have you had the chance to drive it around a little?

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  33. #553
    Senior Member Three Rings
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    I did try to drive it last year before I took apart. It ran rough because of the sensor location on the bell housing, and I still needed to sort out the wiring. Iím trying to reassemble it now, but Iím running into ďsmallĒ issues such as tapping a hole for the driver side engine bracket.





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  34. #554
    Senior Member Three Rings
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    Resolved the stripped hole issue.







    #b5v8abzswap


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  35. #555
    Senior Member Three Rings
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    Almost forgot how low it sat. Ready to put it all back together.






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  36. #556
    Active Member One Ring A4 2.5TDI's Avatar
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    just read your whole thread and i must say i am amazed by your build and you attention to details this old audis are the best cars ever built. Upgrading and improving them in any way is very nice.
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  37. #557
    Veteran Member Four Rings Bordom's Avatar
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    Start up video with those downpipes!

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  38. #558
    Senior Member Three Rings
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    Today is Heater Core Day!





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  39. #559
    Senior Member Two Rings 4Loops's Avatar
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    Sent from my SM-G900W8 using Audizine mobile app
    1999.5 A4 B5 4.2 Quattro (My V8 Swap Project)
    2002 Jetta TDI ALH
    2000 C5 A6 Partout (<--click here for link)
    2007 GL320 CDI

  40. #560
    Senior Member Three Rings
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    Taking out the dash took 3-4 hours.






    Hopefully, everything goes back in place without any extra or missing screws.






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