So, the long and short of the situation is that what was supposed to be a simple turbo CHRA replacement has spiraled wildly out of control and turned into a major project because I just can't leave well enough alone.
A little background: Bought wrecked 01' s4 6 speed for dirt cheap with the intention of swapping the drivetrain to another car with a blown motor/turbos/whatever. About 8 months later found said car with blown turbos. Also an 01' s4 6 speed and dirt cheap as well. Bought it sight unseen from a few states away and sent my buddy (who I will refer to as Tyler from here on) with cash and a trailer to go pick it up. Kid I bought it from had not the slightest idea what he had because Tyler called me on the way home and told me I was going to shit a brick when he got back with the car. Refused to tell me anything beyond that. So he gets back and I go check the car out a few days later. Look it over and it's pretty much what I was expecting to see for a 15 year old car. Popped the hood, started poking around and then commenced with brick shitting because as it turns out the car was a full blown stage 3 with fueling and genuine borg k04's.
After a substantial amount of white boy high fiving we decided we should probably start doing diagnostics on the car. It had a multitude of issues, obvious misfire, major boost leak, dead primary o2 sensors, and all the other things that come along with a neglected b5. Corrected all the issues and took it out for a drive. The car succeeded in scaring the hell out of me when I did a 2nd to 3rd pull. I'm not used to cars that throw you back in the seat in a straight line, well, at least at the time I wasn't, that has since changed. It pulled strong and made 24psi with almost zero smoke so me and Tyler are looking at each other wondering if the damn thing even has a blown turbo. Well that question was promptly answered because after a few more pulls it started throwing smoke heavily. Take it back and pull the lower intercooler hoses, plenty of oil where it shouldn't be.
Fast forward a few months and I get the motor and trans yanked out, separated and the motor on the stand. My other buddy (who I will refer to as Chris from here on) and I start tearing into the motor because like I said I can't leave well enough alone and wanted to make sure it was solid before committing to putting it back in the car. Well the deeper me and Chris dug the more we found and eventually we were staring at a bare block. Started out with "well I just want to pull the valve covers, upper and lower oil pans to reseal everything." First red flag was that the pass side cylinder head had been replaced and looked brand new. Ok, well we'll just pull the heads and make sure everything is alright. Pull the pass side head and cylinder #1 piston is not looking so good. Possibly foreign object sucked into cylinder, who knows but the top of the piston was all chewed up. All sorts of sharp edges that could create a hot spot and cause that cylinder to detonate. Well shit, lets pull the oil pans. Get them off and the oil pickup screen is about 75% blocked with what I can only describe as a carbon chip like substance along with a piece of a circlip and some excess silicone gasket maker. Onward with removing all the pistons/rods and the main caps. All the crankshaft journals look pristine, phew got lucky.
So begins a lot of tedious measurement taking. Four hours later, crank journals are all spec'd out, no taper or out of roundness, main bores are good, no taper or ovaling, cylinder bores are a bit of a different issue. Not bad for taper top to bottom on the load axis, but #1 was nicked up and could really use an overbore. Ok, well mahle makes an 81.5mm piston kit for these motors, perfect I'll get that. Nope, out of stock until the end of january according to everyone I called(which I later found not to be true, how ironic). So I guess lets go all out with an 83mm set of je slugs and while I'm at it might as well buy a set of pauters to go along with them; arp main and head studs, sure why not and fuck it while we're in there might as well re-do the heads and ditch the factory valves.
Currently everything has arrived and the block and other bits are going to the machine shop. I've been thinking that I'm building one hell of a setup to push some pj k04's so started looking into turbo upgrades. Frankenturbo was never an option, SRM was briefly, got stuck on the JHM rs6-r for a while and then started looking into gt28 options. Found that ATP offers a few gt28 based eliminator turbos for these cars with somewhat similar characteristics to the tial 770's and that got me thinking. I've seen plenty of setups using tial 770's and a handful of custom external gate gt28 setups, but I couldn't find a single person (other than on the a4 single turbo side of the forum) running an internally gated ATP gt28 eliminator kit. That concerns me. I'm sure there is a reason but I can't figure out what it is. So guys, help me out here. I'm looking to make a decision in the next few weeks and I'm tempted to go with one of the gt28 eliminator kits from ATP.
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