Chris's double build thread... Silver n Blue Bullet

[csobel]

Dear Audizine,

A few years back my stage 2 Allroad was rear ended by a guy going 50mph while at a stop. 10 grand later it got back on the road, but a few months later my wife was also rear ended, this time by an F250. It spelled the end for our first Audi, which I was very attached to because most of the mods had been done for free by Techtonics tuning when I lent them my car for 3 months prior to going to Afghanistan back in 2010. I lay low and drove a Subaru wagon since the two accidents, waiting to release the kraken when the time was right...

The time came unexpectedly. I got a hankering to rebuild an engine with my son and got a 2.7t from a recycling yard out of an Allroad with 100k for $500. After browsing Craigslist for some time I found a 2001 Santorin blue S4 that had been listed a few hours prior for $1600 sold 'as-is' with some engine problems. "Hey I should impulse buy this bad boy and stick my rebuilt engine in it." My original intention was just to get a hurting S4 back on the road and enjoy it for a while. Somehow that plan went south real fast.

Once I had the drivetrain out of Blue B (this was my first time pulling an engine from a car... wowie), I was like "there is no way this is going back in there with the original turbos. First I talked myself into doing a mild stage 3, shopped around, then I bought the Garrett Gt25r's with manifolds etc off Audi-hammer. Now I'm in deep, no going back. Realize the tiptronic the car came with is going to be shredded by this setup especially if I talk myself into Meth or E85. Then I decide to do a B7 6 speed swap... thanks JH motorsports for the parts list. Wow that was like 25 parts but I got them all as of today thanks in part to various AZ memebrs: Audi-hammer and vdubbin. I was able to get everything together for $2200 including the tranny from a B7 S4 with about 140k on it and all the axles, driveshaft, adapters, etc.

Then I get in even deeper and buy the 2001 Silver S4 shell that vdubbin parted out, scooped it up with my trailer and now I have two S4's getting built up. I just dropped the block and heads off at my local performance machinist to get hot tanked and he's going to balance the crank for Silver B with some RPM rods, coated bearings and a main stud kit. Hoping to reuse the pistons with new rings as they only have a light 100k on them but we'll see what he finds as far as tolerances.

So here's pictures of this double build thread and a brief overview of the plans for each car! I will probably sell Blue B in order to fully fund Silver B, but my wife really wants to drive the triptronic so maybe we can just sell the subaru and keep the S4's.... hmmmm....

Silver B
Garrett Gt25's
WMI kit
Semi-Built block
Tubular mani's
Downpipes into full 3" dual exhaust
B7 S4 6 speed
Supporting stuff--BBK, coilovers etc
Custom tune planned by Addict motorsport near Seattle

Blue B
Hybrid K03/K04 turbos rebuilt by a local guy who is really well regarded
Tiptronic with RevMax TC
Fully rebuilt engine
VAST piggy pipes into an ABD 2.5" exhaust
BBK with stock suspension, control arms all replaced
Custom tune by Addict

I'm waiting to get my block and heads back so I can reassemble everything but I kind of have helmet fire trying to figure out which one to work on right now... I have pretty much everything for silver B but I'm missing the turbos for blue B and have run out of money for the time being. That's ok, lots of work to do meanwhile. If you see something jacked up just let me know, I'm not a professional when it comes to cars and I'll probably have a bunch of questions!

Attachment 61653Attachment 61654Attachment 61656Attachment 61657Attachment 61658Attachment 61659Attachment 61660Attachment 61661

[Robsa6]

Go for it! Sounds like you bit off a chunk

Sent from my SM-G930V using Audizine mobile app

[SoundEfx]

Good luck pimp.
Normally one B5 build is too much for an average person, but you being a super hero, will conquer TWO B5's at the same time.

You're my hero.....

[csobel]

Picked up a lightly used set of RS6 turbos that a guy welded up to fit the B5. These are gonna go on the blue one; probably going fairly light on the tune due to the tip. I had intended to get the original K03’s upgraded but this opportunity came up while I was picking up the clutch and flywheel for silver B and I caved into the temptation. At $800 in good condition it was cheaper than getting the K03’s upgraded was my thought??!!

[csobel]

Attachment 61743

[redline380]

my wife was also rear ended, this time by an F250.

LOL, your wife got rear ended. My wife got rear ended once. 9 months later....

A few years back my stage 2 Allroad was rear ended by a guy going 50mph while at a stop.

[csobel]

Hey the math worked out in my head... maybe I should have used a calculator.

“While I was at a stop I got rear ended by a guy going 50. Audi still drove home!”

[csobel]

Nothing too fancy tonight, just wiping off valve components after soaking in cleaner for a few days. Lots of little bits from 2 sets of heads... phew!

Attachment 62031

[csobel]

Tonight I picked up my valve covers from having a friend powder coat them; one black and one red. The heads are back from the machine shop hot tank and I’m going to think about what I should replace or not replace. Heads 1 is from a 100k allroad and overall in very good condition. Head 2 is from my 180k Santorin S4 but they were fully rebuilt around 150k.

I’m planning to get them both flow tested after reassembly. What are your guys thoughts on what to replace or not? I’m definitely doing the seals and probably the sleeves on the 100k set but was thinking of just doing the seals and cleaning on the 180 since they were redone recently. I have no sure way to confirm this other than when I took the heads apart they were significantly fresher than the 100k set so I’m inclined to believe it.

Edit: I'm going to measure all the valve stems tonight and check against the factory spec.

Attachment 62579Attachment 62580Attachment 62581Attachment 62582Attachment 62583

[csobel]

So I went down a pretty deep rabbit hole of measuring the valve components. My conclusion is that the one going into B.B. is great, but the other one is trashed. I found out Ferrea does a huge military discount so I’m going to get a whole set of ferrea springs, valves and retainers for Silver B. I’ve also decided to do a fully built block on Silver B and throw in some JE 81.5 pistons. I guess my thought on everything is like, I’m so close to having everything to pull off these builds... why not wait a little bit and spend the money to go all the way on the higher HP car? It’s not everyday you have your block stripped to pieces.

I also spoke with an Audi transmission place in Bend about doing a performance rebuild on the tip. I had a really good feeling after the conversation that they were both capable and interested in taking it on. I need to source a rebuild kit, valve body and TC and bring it down. So far I’ve emailed IPT about a kit but no answer yet. I’ve heard so many mixed things about IPT and level ten. The 303 place was supposed to be the heat for a while but the main guy doing the tip rebuilds left some time ago. Any suggestions or pointers?

Thanks,

Chris

[csobel]

The JE pistons have arrived, which was the last thing I needed to get the assembly balanced!

Attachment 66112

[JustManson]

Toooooo dam pretty!

Wow the covers came out amazing. Hopefully the clearances work out.


Sent from my iPhone using Audizine

[csobel]

Toooooo dam pretty!

Wow the covers came out amazing. Hopefully the clearances work out.


Sent from my iPhone using Audizine

Thanks! I ended up making a small contraption with some precision gauges I use for my real work and got some good readings. The clearances on the intake valves were very good—less than 50% of the max recommended and they cleaned up great so I’ll keep those. The exhaust valves were much closer to being out of tolerance; .6mm (.8mm is the max) and even after scrubbing and soaking in nasty solvent they are full of carbon. So I’m gonna replace those with new ferrea valves and it should be good.

Chris

[csobel]

Here is a pic of measuring the valve lateral deflection. Kind of technical but I really wanted to learn how to measure the tolerances myself. The mitutoyo gage measures to a decent resolution (it can go to .0001 inches) and is held in place with a very stiff locking arm while the valve is deflected sideways in the guide. I read tonight that the actual play is whatever you measure side to side divided by two... so these valves are all within really good specs and for this particular head I don’t think anything else is needed besides replacing the seals and checking the deck flatness.

Attachment 66334

[csobel]

I picked up a Nogaro full interior for Silver B while I was out of state and drove it back this last weekend. I always liked that interior a lot but I wasn't totally sure how it would look. I threw in a couple parts yesterday and I think I like the silver/blue combo!
Attachment 69843

[csobel]

Got a turbo kit today courtesy of AudiHammer... The GT25r's are externally wastegated which is nice, and the kit comes with some nice custom TIG welded downpipes, dump tubes, and tubular exhaust manifolds. I'm thinking of having the higher flow 60mm billet compressor wheel from the GTX series fitted and balanced but otherwise everything looks good. I'm still waiting on my block to come back as I decided to get head studs and delayed the whole process, but it should be done next week and I'll be able to start the re-assembly!

Attachment 71612

[csobel]

Here are a couple pics for fun comparing the stock K03 to an RS6 K04 to a GT2554r. The RS6 and GT are a similar size although the compressor wheel on the RS6 is 1.5mm's or so larger whereas the turbine on the GT is 3mm larger. The GT has the advantage of being dual ball bearing and the compressor wheel looks a lot cooler which surely adds butt dyno power.

K03 vs RS6 K04:
Attachment 71613

RS6 K04 vs GT25r:
Attachment 71614