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Thread: My first AR

  1. #481
    Veteran Member Four Rings ShelbyM3's Avatar
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    My first AR

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    Brain storming some ideas for the intercoolers and transmission cooler.
    034 lower pipe for this side?

    Mocked it up on the bench and threw a rough cut line on it.

    Nope. Not close enough for my comfort. The angles are way off.

    Try again. Different 034 pipe. Pipe for driver’s side tweaked, backwards…this looks promising.

    Cut on the black using the lower radiator pipe as a point of reference here.

    Better. I think this could work. I bet I could force my way in there and then create something to prevent abrasions. The hardlines can move a little and maybe I make a little step-down bracket like I did for the driver’s side downpipe bracket to the transmission. Could work. I also want and need to bring this intercooler in closer to the A/C dryer and frame rails. We shall see when the family is not sleeping…

    Edit: stayed up way too late playing around with this driver’s side 034 hose and I think I’m gonna settle on this orientation moving forward. It gives me the best access to the transmission cooler lines and I think I can make it work by, unfortunately, adding another joint into the mix.



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    Last edited by ShelbyM3; 12-20-2024 at 12:40 AM.

  2. #482
    Veteran Member Four Rings Audibot's Avatar
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    If you are worried about abrasions, you can also consider 1. Expandable Braided Sleeving, 2. Silicone Multi Purpose Repair Tape, and/or 3. a larger diameter hose piece snipped slid on top.
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  3. #483
    Veteran Member Four Rings ShelbyM3's Avatar
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    My first AR

    I decided I’d use my sawzall tonight to cut my pipe because I was tired of waiting. It worked well.




    I cut about 3” off either side.
    Test fit, I cut a few inches off this end of the silicone 034 hose.



    I got this little bead roller off Amazon. It doesn’t have the most reassuring reviews, but I decided to give it a shot over using the pliers method.


    I lubed it up with some silicone grease on the dyes and went slow and steady.


    My masterpiece

    Test fit with the driver’s side intercooler, which will essentially emulate where I plan on cutting the passenger’s intercooler at and the coupler I’ll use to reduce and connect the two pipes.



    Overall I’m pretty happy with this solution. I’m hesitant to cut the intercooler, but now after the test fit I’m feeling much more confident.



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    Last edited by ShelbyM3; 12-20-2024 at 09:06 AM.

  4. #484
    Senior Member Three Rings danspach's Avatar
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    That piece looks great. Have zero experience with a bead roller but that is a super cool skill to have in the arsenal. Mmmm, specialty tools.


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  5. #485
    Veteran Member Four Rings Audibot's Avatar
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    Agree! When you had those marks before cutting, I was wondering how you were going to create that bead. Nice work!
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  6. #486
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    Thanks guys! I’m hoping it’ll give me the clearance needed. I’m going to test fit the lock carrier one more time before I make the cut.

    What are anyone’s opinion on me using the weld already on the intercooler as the bead for my coupler? I’m working with some tight quarters and I honestly don’t think my bead roller can roll this piping, aside from the awkward shape and weight of the intercooler trying to support it and roll it at the same time.


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  7. #487
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    I’d be very curious to hear other people’s opinion, but if the bead is somewhat uniform, I don’t see why you couldn’t use that. Isn’t the point of the bead to add some structural rigidity but also give the clamp a surface to seat against? Seems like it would work. Especially if it’s easier the grief and aggravation of trying to roll the bead right after the weld.

    Plenty of room for the clamp, right? And the hose would fit over the weld?

    Just my thoughts.


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  8. #488
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    quick and dirty alternative to bead, is to score end of the pipe with the rough (~100 grit) sandpaper in circular motion, to prevent silicone hoses "walking" under boost. I also heard hair spray could be used for similar purpose.

  9. #489
    Veteran Member Four Rings ShelbyM3's Avatar
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    My first AR

    Test fit the lock carrier and it should work with a little trimming and persuasion.


    Well I’m committed 🫣


    Aggghhhhhh!

    The coupler that I planned on using wouldn’t deep throat the pipe enough so I couldn’t use the weld as a bead. Womp. I tried to use exhaust pipe expanders and some heat, but the silicone won’t hold the shape. Double womp.



    I’m hesitant to cut off too much more and shoot myself in the foot so I tried to bead roll. I started with the intercooler on the floor and slowly worked the roller around the top of the pipe pressing toward the floor and getting a small groove. Then I transitioned to the vice upright and got a good bead.



    I think I can now cut down a 034 coupler that’s intended to go on the top of a stock intercooler and flip it so the bi-pipe flare mounts to the intercooler.


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  10. #490
    Veteran Member Four Rings Audibot's Avatar
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    Nice attempts and improvision. Getting closer
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  11. #491
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    Said coupler for the upper stock intercooler hose.

    Mock up and then I cut it down, but left some meat to protect this section from the lock carrier.

    It all together on the bench.



    Mocked up on Dana.






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  12. #492
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    Grabbed my spare lock carrier for mock up now because the rad pack and stuff is heavy.

    It’s quick release

    Passenger’s side mock up. I need to trim about 5cm toward the front of the vehicle and 8cm shy of the radiator section.

    Transferred over my cut line to the good carrier. I’ll measure out the driver’s side my next time allotment so I can do all the cutting at once.



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    Quote Originally Posted by danspach View Post
    I’d be very curious to hear other people’s opinion, but if the bead is somewhat uniform, I don’t see why you couldn’t use that. Isn’t the point of the bead to add some structural rigidity but also give the clamp a surface to seat against? Seems like it would work. Especially if it’s easier the grief and aggravation of trying to roll the bead right after the weld.

    Plenty of room for the clamp, right? And the hose would fit over the weld?

    Just my thoughts.


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    I think it would have held, well enough. Unfortunately the hose didn’t fit over the weld. It got right up to it and the reduction on the hose itself prevented it from sliding on further. But, my bead turned out really nicely and I left just enough room for the hose clamp to fit between the weld and the bead I rolled.


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  14. #494
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    Quote Originally Posted by V1nny View Post
    quick and dirty alternative to bead, is to score end of the pipe with the rough (~100 grit) sandpaper in circular motion, to prevent silicone hoses "walking" under boost. I also heard hair spray could be used for similar purpose.
    Thank you!


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  15. #495
    Veteran Member Four Rings ShelbyM3's Avatar
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    Quote Originally Posted by Audibot View Post
    Nice attempts and improvision. Getting closer
    Thank you! I need to now tackle the driver’s side which will be much easier than the passenger’s side, I’m hoping. I went for the bigger job first.


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  16. #496
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    Life threw us a curveball this weekend and my wife needed to take my parents to the airport. I volunteered to stay home due to seating constraints and took out some anger cutting my lock carrier.
    Passenger’s side:






    Driver’s side:





    Hurry up and wait for parts.




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  17. #497
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    My first AR

    Got said parts and did some more hacking.
    Third times the charm…


    I had to find and run a 6” length reducer coupler.

    Time for a test fit.


    There’s a lot less tension now with a longer coupler

    Time for the lock carrier test fit



    The driver’s side was hitting in the top outter corner so I initially cut this L shape out from the under side of the headlight support area.



    Wasn’t enough. So I cut out a big long strip and it’s now a snug fit.




    The passenger’s side had lots of room up front, but is really close to the big hardline coming off the A/C dryer. I’ll need to make sure I have good clearance there once final install is done. It was close to the belly pan mount on the lower coupler I made, but I think it’ll all just find its place once I tighten the carrier down. I’ll watch it closely.



    I think this may be a job well done. I’m gonna wait to bolt it all up because I’ve got someone 3D printing new bi-pipe brackets for the timing covers. Once that’s sorted out I can tidy things up, I hope 🪵


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    Last edited by ShelbyM3; 12-30-2024 at 11:34 AM.

  18. #498
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    Some excellent work going on here. You make me want a 2.7T AR again

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  19. #499
    Veteran Member Four Rings Audibot's Avatar
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    Great work as always!
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  20. #500
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    Quote Originally Posted by Bordom View Post
    Some excellent work going on here. You make me want a 2.7T AR again

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    Do it!

    Thanks guys!


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  21. #501
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    I got a new aftermarket fan blade and cleaned things up. Thanks EuropaParts!







    I wrapped the A/C Dryer hardline with some foam and zip tied it in place, and then slapped a slab of foam on the dryer itself to protect the passenger’s side intercooler.

    I almost forgot to blow this intercooler out after I cut it. Of course I remembered as I literally tightened the last hose clamp, but thank goodness I remembered! Yeow! That could have been bad! Had to disassemble it all, which is a damn puzzle, clean out the passenger’s intercooler from my cut and bead, then reinstall.


    Sending it!

    Passenger’s side fitment along the lock carrier is 100% touching the metal part of the carrier. Meh, there’s lots of silicone and it can all flex. I’ll monitor this and probably tweak it more as time goes on. I think I can probably suck the whole pipe here up a little making it shorter and bring the intercooler closer to the engine and turbo giving me a little more space by the lock carrier.

    A/C Dryer clearance is tight!

    Driver’s side. Not much to mention here. Good fitment. It’s held in rock solid by the lock carrier in the corner and snug against the windshield washer reservoir.



    Got everything on and torqued down. Next will be the transmission cooler lines.


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  22. #502
    Veteran Member Four Rings Audibot's Avatar
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    Does the drier touch the intercooler? Wondering how much that affects airflow and hence charge cooling.
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  23. #503
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    Absolutely love this thread. Very well done with the teardown and writeup!
    Bought an a6 allroad -04 few weeks ago with some random errors i'm battling atm.

  24. #504
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    Quote Originally Posted by MrTigros View Post
    Absolutely love this thread. Very well done with the teardown and writeup!
    Bought an a6 allroad -04 few weeks ago with some random errors i'm battling atm.
    Time to check all the drains, reseal the cabin filter carrier and look under the carpet? xD

  25. #505
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    Quote Originally Posted by Audibot View Post
    Does the drier touch the intercooler? Wondering how much that affects airflow and hence charge cooling.
    It does not, but it can. There’s maybe 1/4”-1/2” of clearance. I put a zip tie around the intercooler outlet pipe pulling it toward the lock carrier to add a little tension and prevent it from bonking, on top of the foam padding.
    I don’t think it’ll affect charge cooling too much. There’s is plenty of airspace around the A/C components. These intercooler are massive compared to stock and I think the biggest limitations they’ll have is overall airflow being obstructed by the bumper cover.


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    Quote Originally Posted by MrTigros View Post
    Absolutely love this thread. Very well done with the teardown and writeup!
    Bought an a6 allroad -04 few weeks ago with some random errors i'm battling atm.
    Glad you enjoy it! I do, too! While it’s not ground breaking I hope it helps people in the future.

    Congratulations! I hope you know what you’re in for (Just saw your post, you’re getting a big taste of it right out the gates )


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  27. #507
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    My first AR

    Quote Originally Posted by Avantly View Post
    Time to check all the drains, reseal the cabin filter carrier and look under the carpet? xD
    When it rains it pours…

    Quote Originally Posted by MrTigros View Post
    Absolutely love this thread. Very well done with the teardown and writeup!
    Bought an a6 allroad -04 few weeks ago with some random errors i'm battling atm.
    Check out my “My Second AR” thread for the cabin air filter box solution I came up with, as it’s prone to leaking, too. My seal had torn and my box was cracked allowing the seal to lift and let water in.


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    Last edited by ShelbyM3; 01-06-2025 at 04:49 PM.

  28. #508
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    Quote Originally Posted by ShelbyM3 View Post

    Check out my “My Second AR” thread for the cabin air filter box solution I came up with, as it’s prone to leaking, too. My seal had torn and my box was cracked allowing the seal to lift and let water in.


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    Yeah i did look at that! Smart solution. i eyed my box just quickly and felt around it the other day when it was raining and it felt dry on the inside. But i'm gonna remove the whole box and reseal it to be absolutely sure it's good!
    Probably gonna do the same with the ECU box, abit more to remove but possible, Also on that side i can fix the hole where wire comes up since previous owner tried to seal it with something that looks like papermache or smth,. most likely that's where i got so much water in from!

  29. #509
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    Quote Originally Posted by Avantly View Post
    Time to check all the drains, reseal the cabin filter carrier and look under the carpet? xD
    done and done! xD
    I had swimming pools on both sides, malfunctioning gearbox and central locking that's dead. Now gearbox works as intended, all dried up, and working on finding where my central locks error is, Hopefully with a wiring scheme i can test all wires and see what goes where!

  30. #510
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    Managed to hook up the transmission cooler lines, just barely. It was like wrestling a greased up hog trying to get them aligned just right with the hardlines and not cross thread, but I was able to with much persistence.





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  31. #511
    Veteran Member Four Rings Audibot's Avatar
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    So tight! Happy to see you continue the work!
    2016 A6 TDI Prestige - Malone Stage 2, DPF Delete, EGR blockoff, S6 F&R brakes, 034 RSB, RSNav S4, P3 v3 TDI gauge
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  32. #512
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    My first AR

    Managed to swing the A/C condenser up and into place after bending and manipulating the mounting brackets and hardlines. It was close so I just persuaded it home after a bit. It was a pain to get the lower passenger’s side on because the rubber hose was mashing into the intercooler. It’s such a tight fit. I tweaked it just under the bumper bolt here and it gave me a lot more breathing room between the intercooler.

    Had to tweak and rotate this mounting bracket out and up keeping the line alongside the intercooler.

    And still just enough room with the A/C dryer.

    Passenger’s side I forgot to bring the power steering cooler through before I hooked up the intercooler. So rather than undoing the whole puzzle of charge piping and the lock carrier, I had a sacrificial power steering fluid letting. Between that and the gear oil during the transmission cooler lines, I’m over it today.


    No more coolers hanging!

    I can almost feel it, now… I hope my bumper fits…



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    Last edited by ShelbyM3; 01-11-2025 at 06:46 PM.

  33. #513
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    Quote Originally Posted by Audibot View Post
    So tight! Happy to see you continue the work!
    Slowly but surely


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  34. #514
    Veteran Member Four Rings ShelbyM3's Avatar
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    Couple more items off the list.

    Prop shaft shield


    Find oil leaks…. Check


    Install CV axles



    These CV axle shields can go to hell. I hate installing them. I’ve found the right tool now, I just hate them.






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  35. #515
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    My first AR

    Attempted to fit up my factory exhaust. It didn’t work. More parts and waiting. I used my transmission floor jack, floor jack, some jack stands, and managed not to throw my back out last night




    System is hanging down about 6” so when I press them up into place the pipes are maybe 2” apart.


    I ordered up some 2.25”-2” reducers to bridge the gap and mate up the pipes. Hopefully they’ll be long enough and this will be a relatively easy solution. Then I can have a shop make it a little more permanent.


    Add: I lifted everything up into place based on the center rubber hangers, and I’m about 1.5” short on the passenger’s side and 3” short on the driver’s side.




    So I ordered this ugly adapter and we’ll see what I can jimmy up.



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    Last edited by ShelbyM3; 01-13-2025 at 02:18 PM.

  36. #516
    Veteran Member Four Rings Bordom's Avatar
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    I feel you on the exhaust. I dropped it myself and put it back up on my own on jack stands. God damn does it suck with a lighter aftermarket exhaust.

    I can't imagine doing it with the stock one lol

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  37. #517
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    Dude! Just ditch the exhaust. Run open pipes from the down pipes. Really let her breathe!


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  38. #518
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    Quote Originally Posted by Bordom View Post
    I feel you on the exhaust. I dropped it myself and put it back up on my own on jack stands. God damn does it suck with a lighter aftermarket exhaust.

    I can't imagine doing it with the stock one lol

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    My B8 S4 I put a Stasis kit on and that was a walk in the park compared to this monstrosity.


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  39. #519
    Veteran Member Four Rings ShelbyM3's Avatar
    Join Date
    Feb 05 2007
    AZ Member #
    15417
    Location
    Portland, OR

    My first AR

    Quote Originally Posted by jbain2 View Post
    Dude! Just ditch the exhaust. Run open pipes from the down pipes. Really let her breathe!


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    Don’t tempt me with a good time! It sounds SO good! A healthy mix of tractor vibes tossed in there.

    Although, if I lived about 7 miles further West I’d be in a non-DEQ zone of Oregon. We also have laws around unmuffled engine braking. Now, do I care, no, but I do want to be a relatively courteous neighbor My B8 S4 had test pipes and I hated me. The neighbor boy just put a fart can on his Accord and now I know why I hated me, even more


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    Last edited by ShelbyM3; 01-15-2025 at 12:02 AM.

  40. #520
    Established Member Three Rings Avantly's Avatar
    Join Date
    Oct 02 2023
    AZ Member #
    959953
    My Garage
    Squirrels, Chickens, and then there's the mice :/
    Location
    "Pure Michigan"

    Quote Originally Posted by ShelbyM3 View Post
    Don’t tempt me with a good time! It sounds SO good! A healthy mix or a tractor vibes tossed in there.

    Although, if I lived about 7 miles further West I’d be in a non-DEQ zone of Oregon. We also have laws around unmuffled engine braking. Now, do I care, no, but I do want to be a relatively courteous neighbor My B8 S4 had test pipes and I hated me. The neighbor boy just put a fart can on his Accord and now I know why I hated me, even more


    Sent from my iPhone using Audizine Forum
    Nothing beats the no muffler 2000's Ford V10's that drive past my house... At night I wake up thinking it's godzilla on meth trying to come through my window xD

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