Stage 3 B5 RS4 build and beyond.

[Perth_RS4]

Hey guys,
I'm starting a thread to review the parts used in my build.
I have owned the car for 1 year and driven 15000kms so far, including a epic 3500km in 4 days across Australia from Melbourne to Perth.
I plan to build this car into my idea of what a daily rs4 can be. First step is to take it to Stage 3 on E85 and fix all the shifting issues.
Parts acquired so far are.

TheTurboEngineers:
TTE550 with Hotside ported out to 44mm to match manifolds. Zircotec Ceramic coated.

JHM Motorsport:
Full transmission rebuild kit with carbon syncros and updated 1-2 carrier,
Uprated shifter centring spring,
Short shifter trio,
Upgraded cross rod.

Advanced Automotion:
New Input shaft, New First and second gears. All with Cryogenic treatment and WPC treated.

Wagner Tuning:
RS4 intercoolers,
3in downpipes Zircotec ceramic coated.

034 Motorsports:
2.7 Spec twin carbon clutch and flywheel,
Billet differential carrier,
Motorsport 'Street' density motor mounts,
Snub mount and bracket,
Transmission mounts 'track' density,
Billet Diverter valves and silicone hoses,
Silicone Spider hose replacement,
Sway bar end links front and rear,
Subframe reinforcement kit
Rear 25.5mm sway bar.
Billet rear tie rods.
Adjustable upper control arms.
Motorsport density top Strut mounts.

AKmotorsport:
Billet Aluminium Rear subframe mounts.
Full rear suspension poly bushings street density upgrade.
Front subframe Poly Bushings.

Fluidampr harmonic dampner

THE-Tuner:
Exhaust manifolds - Zircotech ceramic coated,
SAI block off plates
95mm Maf
102mm THE-Y
63mm Fresh Air Pipes.

Hel Performance:
25 row oil cooler kit for RS4
Braided Steel Brake lines front and back.

Wavetrac rear LSD
Prospeed T3 torsen center differential upgrade for 01e

Fuel:
Walbro 450lph fuel pump '274'
MSD2351 Fuel pump voltage controller.
Radium Engineering Venturi Jet pump kit.
Fuel lines upgraded to 3/8 hard lines and 8AN Black braided stainless steel flex lines.
Bosch EV14 flow match 1150cc short injectors.

UPSmotorsports:
Metal clutch slave and braided steel line.

I will have 3 tunes on the ECU that can be swapped using the cruise control stalk.
tune 1 will be base tune simular to stock but so i can run the new hardware.
tune 2 is a stage 3 tune for 98RON fuel. Expecting around 550+chp
tune 3 is a stage 3 E85 tune. Expect around 620+chp
About to send the new manifolds and downpipes off for Zircotec Performance white treatment and when they return the build begins. I cant wait

[Mark00s4]

Sound like a good list of parts.I would love to see some photos of the the Tuner stuff and some info on price,and fitment.

[Yuppie]

Look forward to the build. What was the price on the manifolds from THE Tuner?

[Drehmoment]

What turbos are you going to use ?

I would skip the Spec and get a AMD /TTV

[audi-hammer]

What turbos are you going to use ?

I would skip the Spec and get a AMD /TTV

I would assume the oem k04's that the car comes with, RS4 + k04's + e85 is a good time. Agreed skip spec and get a south bend clutch

[Perth_RS4]

THE-Tuner manifolds were 1590€ plus shipping. Fitment is like standard.

Im going to be using the standard k04s for now.

Not much love for the spec clutches here!? This one is a twin disc, carbon on carbon. Build quality looks great. Excellent power holding, slip characteristics and great wear life.

[funkin]

^ that's the clutch I'm using- it is fantastic.

Can't wait to see more of your build!

[Mark00s4]

you got to post some pics !

[Perth_RS4]

[S4tech2]

Ohhhh I saw THE tuner post pics of your manifolds on Facebook. Very nice!

[Perth_RS4]

[jaychen]

have you confirmed whether the braided clutch line will actually reach the master on a RHD car?

[james 408]

couple things:
I've had problems with the 034 motor mounts. Not sure on the rest of the rest of the parts u listed from them.

manifolds: larger manifolds might not have any benefit for you on k04 turbos (most tunes cap their boost in high rpm anyway, on stock manifolds i could generate 25-30lbs of boost on k04s, well above the typical stage 3 boost levels). And assuming those are larger manifolds, that would likely delay spool.

otherwise build looks sweet. what suspension / spring rates u rockin? also didn't see adjustable upper control arms on the list?

[avant1987]

this should be fun to watch.

[MacDaddy]

couple things:
I've had problems with the 034 motor mounts. Not sure on the rest of the rest of the parts u listed from them.

manifolds: larger manifolds might not have any benefit for you on k04 turbos (most tunes cap their boost in high rpm anyway, on stock manifolds i could generate 25-30lbs of boost on k04s, well above the typical stage 3 boost levels). And assuming those are larger manifolds, that would likely delay spool.

otherwise build looks sweet. what suspension / spring rates u rockin? also didn't see adjustable upper control arms on the list?

Quite possibly, i know (its in the RS4 training guide) the exhaust ports in the RS4 heads are smaller than in the S4 to increase exhaust gas velocity, high flow manifolds may counter this.

[dannyn424]

It certainly would move the curve to right but

[dannyn424]

after tuning would increase peak hp as well

[Perth_RS4]

[Perth_RS4]

have you confirmed whether the braided clutch line will actually reach the master on a RHD car?

I have been told it will just fit.

[jaychen]

I have been told it will just fit.

Nice!

[Perth_RS4]

Gasket matched my intake runners and smoothed the throttle body inlet out. Intake manifold ceramic coated to help stabilise intake temps. I am using New south performance power gaskets to help the intake temps too.

[jaychen]

If new south gaskets are similar to phenolic spacers, they dont do anything for performance. Jeff tested them, results are on his website.

Looks good though.

[Dmitriygjr]

That suspension looks amazing...
Great job on ceramic coating as well

[Perth_RS4]

Finally some turbos for this build! TTE550s are going in. Huge hold up on getting a new mainshaft for my gearbox rebuild. Once some parts arrive there should be pics of the build taking place. Aiming for 600hp+ at the crank on e85. This is how my car has sat for this whole time. https://imgur.com/gallery/Sg9Eo

[Perth_RS4]

Decided to add some special sauce to my TTE550's I got off here. exhaust housings have been ported right out and the ceramic coated in Zircotec performance white.

[Perth_RS4]

Rear of the car is coming back together nicely. I re-prepared the entire underside.

[Perth_RS4]

Do you guys think I have missed anything except for Brakes and suspension? Those havent been missed. Those are big $$ items I will get later.

[sxC]

Wow, that is hands down the cleanest b5 suspension I think I've ever seen...

Good luck with the build! Looking forward to the progress

[zatch_303]

Keep up the progress! Sounds like you know what you're doing. Can't wait for the final result.

[jaychen]

you're probably going to wish you went with rubber bushings

[Cysco abt S4]

I love my solid subframe mounts and Polly joints even on the street . I want to do spherical lowers too

[Perth_RS4]

you're probably going to wish you went with rubber bushings

If thats the case.. My regret will be I didn't get a Mercedes c63s haha

[jaychen]

If thats the case.. My regret will be I didn't get a Mercedes c63s haha

they need to be greased all that time otherwise the squeak like all fuck. it gets extremely annoying. plus they don't last as long..

[Cysco abt S4]

Silicon one time on install equals no squeak plus they last way longer than rubber ones
Just drive my jetta once and you'll see , I installed them in 1998 and it's in the million miles club 1,481,+++.++ with over a million and a quarter on poly joints

[jaychen]

Silicon one time on install equals no squeak plus they last way longer than rubber ones
Just drive my jetta once and you'll see , I installed them in 1998 and it's in the million miles club 1,481,+++.++ with over a million and a quarter on poly joints

we have had the opposite experience it seems.

[Cysco abt S4]

we have had the opposite experience it seems.

Yes we must have
All information is welcome on this site (I think) I've never had bad experiences with quality parts where some have had nightmares with there's

[Perth_RS4]

Silicon one time on install equals no squeak plus they last way longer than rubber ones
Just drive my jetta once and you'll see , I installed them in 1998 and it's in the million miles club 1,481,+++.++ with over a million and a quarter on poly joints

A million Miles! That is damn impressive!

[S4UCE]

Lovely build. The ceramic coatings look sweet as does the suspension setup. Following along for sure - best of luck as you progress.

Silicon one time on install equals no squeak plus they last way longer than rubber ones
Just drive my jetta once and you'll see , I installed them in 1998 and it's in the million miles club 1,481,+++.++ with over a million and a quarter on poly joints

Sir, that's over 1000 miles a week for 19 years. This jetta must be a tank

[Cysco abt S4]

A million Miles! That is damn impressive!

Diesel 1991
1.6 na
Was driving back and forth from Ohio to ca twice a month for 10+ years

[jaychen]

AKmotorsport bushings?