Project Stormtrooper, Less is More...

[nefkntym]

I was a bit hesitant in doing a thread for this. I was kind of back and forth about the purpose and the time involved. Being that this iteration has a completely different purpose and there was so much I have wanted to do to the car over the past few years that have nothing to do with performance, I figured why not.

I think the last few iterations of the car were more about performance and less about common sense and the result of that thinking left me with something that I really didn’t want in the end. The whole be careful what you wish for, you just might get it scenario.

Earlier this year I started pulling my VR6 out of the car. Actually it was something I was toying around with late last year, I started buying 2.7T parts back in November-December and I kept working on the VR6 just for the sake of doing it. I guess I just wanted to drive it once after I got the car running last Halloween, but the more I worked on it, the more I hated working on it and started looking for reasons to not work on it when I finally had chance. Things like pulling my Racedeck flooring out of the garage to pressure wash it, building shelves in the garage, going to get drawers and cabinets for the garage and building that. Hell I even put time into putting together a Café table and bar stool setup for the garage over finishing the last few things on the VR to drive the car. I guess the writing was on the wall.

I started out this year thinking this car would be something I was going to simplify and make available to my kids to drive. They might be able to drive it one day, but it is not going to be anytime soon. This one is for me and this will be my Less is More, Keep it Simple Stupid…thread.

The goal here is:

~stock 2.7t, no internal mods
~simple turbo upgrade
~off the shelf down pipes or piggy pipes (eliminates anything not stock flanged)
~recycle the ER intercoolers and the B7 RS4 exhaust I already have
~stay within the confines of my existing A340 or unused Walbro 450 in-tank fuel pump and OE sized fuel lines
~spend as little "new money" as possible, preferably none at all and just finance this by selling no longer needed parts
~finish unfinished projects like RNS-E install, OE Bluetooth and Sat Radio install.
~get rid of steering column gauges
~Daily drivable and 91 Octane
~no more endless builds
~more driving, less wrenching!!!
~remember Less is More and K.I.S.S.

The parts are:

~BEL 2.7T from '03 manual Allroad
~SRM K24s
~SRM inlets and downpipes
~Aeromotive A340 fuel pump
~EV14 550cc injectors
~ER sidemounts
~Magnaflow B7 RS4 Exhaust
~TTV flywheel
~Ringer Racing/Clutch Masters Stage 4 Clutch

Just a basic run of the mill stage 3 install.




What I was coming from...



In January, I got a lead on a BEL 2.7T longblock with ecu and harness from a manual car for $650. Even better is was at a Audi recycler here in town. I boned out of work early and went to the local Uhaul to get a trailer, but then I had to swing by the house get some plywood and ratchet straps first. Luckily, I did the trailer hitch wiring install the day before because I knew I would eventually have to get a trailer.

First time having a trailer hooked up to my Volvo.



I was able to get the engine and get it home before it started snowing again...





but not before I could return the trailer.



I slowly started taking it apart for maintenance. I realized I had to get some APB valve covers because I was going to swap to the newer coils. They showed up with a partial burgundy-ish red wrinkle finish. I pressure washed them and then painted them silver. After a few days, I decided to paint them red instead.



By this time, I had already taken everything off that I needed for maintenance. I am getting rid of the SAI for good and the I pulled the exhaust manifolds for cleaning and some flame proof.



I think there was a slight leek from the lower pan, maybe not, but I pulled it anyway to clean and reseal with Dirko. I also replaced the oil rings for the oil return lines to the sump.



Sealed up and ready for the front. I replaced the plastic thermo housing with the aluminum unit as well.







I pulled the exhaust manifolds, so new gaskets were going in.



Back to the front and manifold installed.





Replaced all the seals and tensioner gaskets. Timing belt done and intake manifold installed.





Sealed up those damn rear cam seals. I got tired of them leaking on my older 2.7s



This time I am using the factory Touareg coil pack adapters with the newer coil packs.







At this point it was turbo time. I didn't want the stock K03s, and I didn't want anything super huge/expensive. I bought a set of mixed flow F21s from Frankenturbo but there was a decent backorder, so I can cancelled it. I was able to get a sweet deal on a new set K24s, with inlets and downpipes from SRM for about a $100 bucks more than the F21s.







Fitting the inlet pipes...



Testing out fitment with the Y-Pipe.





Finishing up on the engine...

[nefkntym]

Pulling it off the stand today.







TTV Billet Steel Single Mass flywheel



Still need to install the pilot bearing, but pretty cool that it is all one machined piece to include the ring gear and the tone ring.



I stopped today at the flywheel and went outside to hang out with my wife and daughter and start writing this up. Less work is more fun...



So far I have met all of my goals up to this point. I settled on and bought a Stage 3+ Allroad tune from Solomotorsports on Friday. That should show up this week. The only fab I will have to do is mating the downpipes to the existing exhaust and doing another harness. Since this is another 7.1.1. ecu, that should be fairly easy. Hopefully this goes fast from here.

[customa4]

Awesome work man. You make this stuff seem so effortless.

BTW, that Volvo is badass.

[elewsader]

Pulling it off the stand today.



.

That's "living it", I always look forward to seeing what's going on with the Stormtrooper.

[nefkntym]

Awesome work man. You make this stuff seem so effortless.

BTW, that Volvo is badass.

Thanks, I love my V60R!! I think the Volvo has been a great addition to our family. Being able to handle camping, roof boxes, hitch mounted cargo carriers, hitch mounted bike carriers and towing a trailer is definitely a value add. Doing it with 3.0L 325hp 354Ft Lb Twin Scroll Turbo I-6 six and AWD doesn't hurt either

That's "living it", I always look forward to seeing what's going on with the Stormtrooper.

Thanks! I really do want to do more of this!!

[nefkntym]

I was able to press in the pilot bearing to the flywheel this morning before taking my daughter to school and heading off to work. The clutch nor the flywheel came with pilot bearings, my old Southbend/Sachs 7A clutch for the VR6 came with a couple of extra pilot bearings. Good thing I held onto them instead of chucking them.

[MurkyRivers_A4]

I remember when my press was that clean. After 11 years of abuse she still works but is fugly!

[nefkntym]

I remember when my press was that clean. After 11 years of abuse she still works but is fugly!

Good to know that they last, mine is just over 2 years old.

[nefkntym]

I have been a slacker the past couple of days on this. I have been coming home, lounging around with the family and hanging out on the deck watching the sunsets trying to relax. Hard to believe that just a few weeks ago everything was covered in white.





Last night, I did go out to the garage the measure the flywheel bolts on a hunch. Glad I did, the stock flywheel is a bit thicker than the TTV flywheel. I have read that the stock bolts are fine and that they are too long. I measured them as having maybe around ~1.5mm of clearance.

With that in mind, before leaving for work this morning I decided I would use the stock washer to take up the slack.

Drilled out the retaining pins.



Then I drilled out those holes with a stepped drill bit to clean it up.



Then I marked an extra bolt with white out. The first set of three lines is the edge of the TTV flywheel, the outer set next to locktite is the stock flywheel.



With the washer on, I am 1 thread off the stock flywheel thickness.




This evening I put it back on the engine and torqued it down.





Hopefully tomorrow morning I can clean the flywheel and put on the clutch.

[nefkntym]

It is nice having extra time in the mornings.

Ringer Racing Stage 4 clutch





'

I couldn't find my pressure plate bolts. Ordered new ones today from VW, they are supposed to be here tomorrow.

[Pr1ce]

So crispy and clean and awesome. Always enjoyed your work... Keep it up please

[ShogunR32]

Keep up the good work. Im having fun with my white avant even though it is a money pit.

[BBinA4]

Great build!

Makes me miss my B6.

[nefkntym]

So crispy and clean and awesome. Always enjoyed your work... Keep it up please

Thanks, I try to keep it clean.

Keep up the good work. Im having fun with my white avant even though it is a money pit.

Avant twins, my white Avant is a money pit as well!!

Great build!

Makes me miss my B6.

Thanks, I have thought about giving up the B6 numerous times over the years. I just can't bring myself to do it. A lot of cars have come and gone, but the B6 Avant always makes the cut.

[nefkntym]

I was hoping to further along by now, like the engine and trans in the car and I am working on exhaust further.

Over the weekend I was able to get the trans on.





Once that was done, I pulled the down pipes out of the box for the first time since I was ready to install them and shove this thing back in the car. The downpipes I was sent were the transitioning 3" -> 2.5" units, I sent them back to SRM on Tuesday so they can be swapped for the full 3" units. I haven't even touched anything since Sunday. While I am waiting, I will just work on other stuff in the garage to include cleaning it.

I need to get into the habit opening stuff right away and checking it.

[customa4]

I had the same thought the other day. I ordered 034 motor mounts about a year ago and went to install them the other day only to realize I never even opened the box. I wasn't sure what to expect once I opened them but luckily the right mounts were in there.

[nefkntym]

I had the same thought the other day. I ordered 034 motor mounts about a year ago and went to install them the other day only to realize I never even opened the box. I wasn't sure what to expect once I opened them but luckily the right mounts were in there.

Lucky and good deal, 034 has had some issues with order fulfillment in the past. Speaking of mounts, your post just reminded me of the Apikol rear diff mount that I bought about ~2.5 years ago that I never got around to installing. I still have so much stuff that I still need to do.

[customa4]

I think the worst part was I bought them from a forum member. I do have the Apikol rear diff mount installed too. Nice upgrade

[nefkntym]

Getting back to this. The downpipes finally showed up on Monday. I pulled them out of the box and did a quick test fit that evening and I think I finally bolted them down Tuesday evening.





Wednesday, I pulled the CCT solenoid off an extra set of heads that I have and bolted it up the passenger side. Next up was the fuel rail and the injectors and I finished off the night with getting the harness started.



I did some more work on installing and mainly cleaning the harness tonight. For the most part done with the main engine part other than the oil pan sensors and the starter/alternator connections. I will probably just hook those up when I get it back into the air. I dug out the old 02 sensors from the last APB engine and got those hooked up. Unfortunately the harness side connectors are wrong, but I checked the old V6 harness and it has the right connectors. I need to bust out the de-pin kit and swap them out.

Saturday the plan is to get the car in the air so I can bolt in the 2.7 power steering line to the rack and then put in the engine and trans. I am hoping all goes well.

[Bische]

Look great my man!

Do you have a buyer for the VR?

[nefkntym]

Look great my man!

Do you have a buyer for the VR?

Hey, thanks buddy!!

No, not yet. I am not in a hurry to sale it, so I don't feel the need to "give it away". I have sold everything except the longblock, intake manny and the starter.

[nefkntym]

Got a chance to work on it today. Swapped the 02 plugs and got the power steering lines done.



Left it like this for the evening, a friend came over for dinner. Got to eat and watch some movies.



Will finish getting it in tomorrow.

[ADCS]

You suck lol.
I am still waiting on turbos to be in stock.

I am impressed that you can use the cherry picker on the race deck. I had originally discounted it because it always seems like most people that have it don't actually do work in their garage. I was moving towards the porcelain/ceramic tile route but now I am going to have to reconsider.

[nefkntym]

You suck lol.
I am still waiting on turbos to be in stock.

I am impressed that you can use the cherry picker on the race deck. I had originally discounted it because it always seems like most people that have it don't actually do work in their garage. I was moving towards the porcelain/ceramic tile route but now I am going to have to reconsider.

Thanks! I know the stuff looks nice, but I first and foremost I want everything to be functional. The lift is bolted to the floor through the racedeck as well. Every time I put the car up, all the weight is just on a couple of Racedeck tiles.

From today, all in. Shifter in, driveshaft bolted up and axles bolted up to the cups as well.



Time to work on the exhaust and the wiring harness now.

[B5_t]

Great thread so far and amazing work ! Maybe I missed it but why give up the VR ? Just looking for a new project or wanted the twins back ?

[nefkntym]

Great thread so far and amazing work ! Maybe I missed it but why give up the VR ? Just looking for a new project or wanted the twins back ?

Thanks! All the VR stuff is in a different thread. Long story short, I wanted my money and my life back.

[Willënskraft]

Will there be lightsabers involved?

[nefkntym]

Will there be lightsabers involved?

ummm....not the droids you are looking for.

[nefkntym]

Got to work on the exhaust a bit today.

Going from this:





Back to this:







The work environment, Shark Week Baby!!! The 2nd most wonderful time of the year!



Still working on this, little steps for now because of Shark Week!

On a different note, I chose not to use the foot pedal and use the thumb controls on the TIG torch instead. I remembered hating them, I really liked using it yesterday.

[nefkntym]

I have been making progress again now that Shark Week is over

Started on the exhaust over the the long weekend, but with everything over the 4th, work and family, I didn't finish welding it up till last night.

Today was the install. Completely done with that and hooked up.





While I had the car in the air, I figured it was time for a little test. I pulled down one of my old OZ wheels from the S4 and S3 to test fit. With 12mm of spacer, they just barely clear the front calipers. Trying to decide if the juice is worth the squeeze since I would have to pick up a complete set of either 12.5mm or 15mm spacers from ECS along with longer bolts. I think I like it a lot more.

Enkei RPF1 or OZ Leggera HLT? About a 1/2 lb difference between the 2 wheels.







Once I was done with that test fit, I hooked the rest of the slave line, put back in the lower half of the battery box and started looking at the harness. I will start working on that tomorrow.

[heywier427]

Gotta put the front clip on to make a fair assessment, but Im liking the chunkiness of the enkie's :)

Keep it up!

[customa4]

I like both. I think it's a win, win either way.

[Bische]

Great job Aaron!

Enkei's win in my book by far, the OZ's look like a cheap replica wheel in comparation(I know they are'nt replicas :).

[heywier427]

Rock'em both big baller.

oz on the left. enkies on the right.

oh snap!

[teg2audi]

Im just jealous of that garage set up, nice!

[DownhillA4]

The build is cool, I guess. ;) All I care about is that gorgeous garage set-up, 3 bays and a lift, yes!

[b1337]

plus the flatscreen!

[nefkntym]

Im just jealous of that garage set up, nice!

The build is cool, I guess. ;) All I care about is that gorgeous garage set-up, 3 bays and a lift, yes!

plus the flatscreen!

Thanks everyone. The garage has kind of been an ongoing build since we moved into this house a year ago. I want it to be functional and comfortable. I am in the garage at the barstool drinking coffee and watching DirecTV as I am typing this.

[nefkntym]

Did a couple of things...



Let go of the V60 R Design and picked up a 2017 Q7 Prestige

Had to off the immobilizer this morning on the ecu in boot mode with a bench harness I made yesterday evening. Worked like a champ on the first try once I made the bench harness.



I also just did this about 20 minutes ago. Doesn't sound to great right now. I don't have any of the emissions stuff hooked up including rear 02s, and this a stock 2.7t file with 550cc injectors installed. Going to start finishing it up now and try kick off the Solo Motorsports flash file. Got everything verified, good to go. Only faults I have are for the stuff mentioned above.



I got the car running in one page, not bad.

[ADCS]

Nice job man! Awesome. I'm jealous. I'm still waiting on the F21s to be in stock...

Any trouble with the wiring aside from the initial boot mode glitch?