jonan's build thread

[jonan]

you should get those things clear braed.

had my e-codes cleared today and noticed that they are foggin up on the inside...lol have to do o-ring mod on a brand new set...should have done it before i mounted them but whatever...

jet hot called today on my drive back, asked for payment and they are shipping my manifold back to me today...should have it on tuesday...

[jonan]

lol, i just bought a second RNSe MKII for my RS4 from LINDW4LL, i told myself i wouldn't build to cars at the same time, but i guess that idea is out the door...

bringing the RS4 in on monday to get detailed, xpel coated and ceramic coated...

should have the rest of my motor parts for the B6 this week from IE...

[uzone02]

still going to big turbo B6?


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[jonan]

still going to big turbo B6?


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lol...i keep changing my mind between part out b6, move forward with build, or keep at k04...first world problems i guess...

[jonan]

just got the APR manifold back from JetHot, waiting for 034 to source my gt2860rs...then will send the hotside to JetHot for same treatment...



looks even better in person

[uzone02]

the purpose to get ceramic coating is to trap the heat inside the manifold?

btw I am also going the pretty much similar setup as you do.




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[jonan]

the purpose to get ceramic coating is to trap the heat inside the manifold?

btw I am also going the pretty much similar setup as you do.




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yep, keeps heat from radiating throughout the engine bay so you don't fry your wiring, plastic, and rubber hoses...hotter gas inside the manifold travels faster out of the exhaust...

[jonan]

THE BUILD CONTINUES!!!

after everything is put together the rs4 will be my weekend toy, till then gonna beat on it cause it never gets old...

got a TON of shit in the mail today...the gt2860rs turbo is fuking huge compared to the k03...



also, my fluid ampr pulley was back ordered and finally came in today with the rest of my IE parts...



not sure why they wrote "linked apart" on the oil pump chain, nor am i sure how to actually link the chain together...have tons of time to figure that out though...



if i didn't have so much life shit getting in the way i'd be covered in grease right now in my garage...have to leave for a business trip to atlanta sunday and won't be back till the end of next week...have to tidy up the garage before i leave because i have a shit ton of b6 parts lying around...thankfully, my fiancee doesn't care much as long as i keep everything hidden neatly away...otherwise she'll start throwing shit away...

when i get back i'm gonna take apart the turbo and send the hot side to jethot for the same titanium colored ceramic coating, debating whether or not to jet hot the hot and cold side of the turbo...thoughts?

i may be going overboard though, cause i'm ceramic coating the hot side AND covering it with a turbo blanket...can't wait till shit dies down towards the end of june and i can actually start tearing my motor out, looking forward to learning new skills since i've never built a motor before

[jonan]

had some time to take apart my turbo and test fit the PTP turbo blanket that came in the mail today...







i tried test clocking the turbo to the same orientation as the k04 and noticed that the waste gate arms are nowhere near each other...i've never actually clocked a turbo before so i have no idea if there is some sort of trick to clock the turbo to the correct orientation and still have the waste gate arms maintain contact...not too worried about it right now though since i have plenty of time to figure it out...



you can see what i mean better in this photo, arms on opposite sides...



this guy is lonely...



finally managed to get the housing off, i had to order a 1/2 inch wrench since my socket wrench wasn't low profile enough to get over one of the bolts holding the brackets which kept the exhaust housing on...



sending off the snail to jet hot tomorrow to get the same ceramic coating in titanium topcoat finish as the APR manifold

[All_Euro]

That blanket fits perfectly... I have a small Chinese blanket on my K04 in the GLI but it doesn’t fit right unfortunately.

I may be wrong but it looks like you can unbolt the wastegate and swap spots with the other bolts/bracket on the compressor housing...?

[jonan]

That blanket fits perfectly... I have a small Chinese blanket on my K04 in the GLI but it doesn’t fit right unfortunately.

I may be wrong but it looks like you can unbolt the wastegate and swap spots with the other bolts/bracket on the compressor housing...?

i tried that, but the spacing between the bolts is too wide for the wastegate bracket...i'll mess with it more when i get the housing back...i did a bit of googling and it looks like i need a different wastegate bracket...not 100% sure tho

[uzone02]

just wondering how do you connect the GT28RS outlet to the testpipe ?

[jonan]

just wondering how do you connect the GT28RS outlet to the testpipe ?

i ordered a five bolt to v-band connector from ATP, i'll post a photo of it when it comes back from jethot since i'm coating that portion of the turbo as well...

i'm just gonna wrap the testpipe instead of coating it...

[uzone02]

i ordered a five bolt to v-band connector from ATP, i'll post a photo of it when it comes back from jethot since i'm coating that portion of the turbo as well...

i'm just gonna wrap the testpipe instead of coating it...

then how about the v band to 3bolt testpipe ?

I got stuck at this point...


or just 5bolt (GT turbo) to 3bolt (OEM testpipe) ?

[jonan]

then how about the v band to 3bolt testpipe ?

I got stuck at this point...


or just 5bolt (GT turbo) to 3bolt (OEM testpipe) ?

my test pipe is 3 bolt, so i bought a stainless v-band flange for the testpipe from ATP. i'll need a machine shop to cut one end of the testpipe off and weld the v-band flange on in its place...

[jonan]

breakfast is served! started to take inventory of all of my parts since i'm going to begin pulling the motor next weekend...



i spoke with jethot, they will be shipping back the hotside tomorrow so i should receive it towards the end of the week...i still need to call APR to get new manifold bolts so i don't have to reuse the old ones...

does anyone have any recommendations as to which brand of cherry picker and motor stand i should buy? also, are the cheapo feeler gauges on amazon good enough or do i need to pony up for some good ones? i also need a ring gap tool but not sure which style or brand to buy...

other than feeler gauges, are there any other types of gauges that i should pick up? the only gauge type of tool i currently have is a cheap autozone spark plug gapper...lol...

despite the clusterfuk of parts on my dining table, i noticed i missing an entire box full of shit which has my injectors and various timing components in it...i'll be listing the k04, tt-injectors and forge TIP for sale once i have them free from the motor

also, thinking of porting the exhaust manifold to match the exhaust gaskets...not sure if it is worth it tho given i'm going with the gt2860rs and i'm not trying to spend much more money on this build...

[jonan]

to port, or not to port?



there is a wee bit of material that could probably be shaved off of the manifold; however, i do not want to ruin the structural integrity of the manifold since i spent a bit on the manifold itself and getting it ceramic coated...i've never actually had anything ported before so my fears could be completely irrational...

also, if i have the manifold ported, do i need to have the head ported as well? would a ported exhaust manifold and unported head negate each other?

[Ephry73]

breakfast is served! started to take inventory of all of my parts since i'm going to begin pulling the motor next weekend...



i spoke with jethot, they will be shipping back the hotside tomorrow so i should receive it towards the end of the week...i still need to call APR to get new manifold bolts so i don't have to reuse the old ones...

does anyone have any recommendations as to which brand of cherry picker and motor stand i should buy? also, are the cheapo feeler gauges on amazon good enough or do i need to pony up for some good ones? i also need a ring gap tool but not sure which style or brand to buy...

other than feeler gauges, are there any other types of gauges that i should pick up? the only gauge type of tool i currently have is a cheap autozone spark plug gapper...lol...

despite the clusterfuk of parts on my dining table, i noticed i missing an entire box full of shit which has my injectors and various timing components in it...i'll be listing the k04, tt-injectors and forge TIP for sale once i have them free from the motor

also, thinking of porting the exhaust manifold to match the exhaust gaskets...not sure if it is worth it tho given i'm going with the gt2860rs and i'm not trying to spend much more money on this build...

I would take a trip to harbor freight. They have a lot of great tools for really really good prices. Any porting you do has good benefits


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[jonan]

I would take a trip to harbor freight. They have a lot of great tools for really really good prices. Any porting you do has good benefits


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would i give up bottom end for top end, or top end for bottom end by porting the manifold?? or would it be an overall increase throughout the powerband??

[Ephry73]

would i give up bottom end for top end, or top end for bottom end by porting the manifold?? or would it be an overall increase throughout the powerband??

Hard to say but it’s all flow and how well you can meet the parts. Ages ago working on aircooled type 4 motors the gains were vast and no bottom end lost. Just better overall response. With the heads you have and good tuning I don’t see why you would loose anything down below at all. Plus it’s not like you’re reshaping ports and enraging. You’re just port marching and blending which will make things better.


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[teckjoel1320]

What would you want for the k04 and TIP? I’m in the market for both? My B6 is my daily, my M5 is my toy, and I need a little bit more power out of the daily. Thankfully I have a few backup vehicles so I’m ok with downtime on mine. Once my 1.8t goes I’ll be going 2.7/3.0t and just wind up Daiying one of my TDis.

Let me know on the k04 and tip. Don’t need injectors as I’m already on 550s.

[itsmatt33]

would i give up bottom end for top end, or top end for bottom end by porting the manifold?? or would it be an overall increase throughout the powerband??

more likely to lose something down low but this is exhaust so might actually lose nothing at all.

[jonan]

What would you want for the k04 and TIP? I’m in the market for both? My B6 is my daily, my M5 is my toy, and I need a little bit more power out of the daily. Thankfully I have a few backup vehicles so I’m ok with downtime on mine. Once my 1.8t goes I’ll be going 2.7/3.0t and just wind up Daiying one of my TDis.

Let me know on the k04 and tip. Don’t need injectors as I’m already on 550s.

YGPM

[V70R]

would i give up bottom end for top end, or top end for bottom end by porting the manifold?? or would it be an overall increase throughout the powerband??

If you are removing any material, I would port-match the manifold for a smooth transition of airflow from cylinder head to exhaust mani. Doing such should not sacrifice any bottom-end power in favor for top-end, as you are simply removing a minute amount of material to increase the efficiency of air exiting the combustion chamber.

Let me know your Jet-hot opinion and cost if you care to share! I have a VR6 manifold and T66 turbine housing we ready to be sent out, just not sure where to send things.

[jonan]

If you are removing any material, I would port-match the manifold for a smooth transition of airflow from cylinder head to exhaust mani. Doing such should not sacrifice any bottom-end power in favor for top-end, as you are simply removing a minute amount of material to increase the efficiency of air exiting the combustion chamber.

Let me know your Jet-hot opinion and cost if you care to share! I have a VR6 manifold and T66 turbine housing we ready to be sent out, just not sure where to send things.

the coating seems to be of excellent quality...we'll see how the color holds up under multiple heat cycles though...

[jonan]

got my snail back from jethot today!

[jonan]

so i decided to have the shop that did a bunch of work on my rs4 do my motor build...they finally got the head off and should have the rest of the motor sent to the machine shop by tomorrow...

there was a bit of build up in the head, but that was because i drove <5 miles each way to train station during my commute to NYC every morning for the past decade...the motor never really got up to operating temps...probably made worse when i drove during the winter and the coolant temp gauge never even made it to the middle...thank god i live in TX now



i inspected the cylinders while i was there and they still had some crosshatching on the walls despite having 170k+ miles on the clock...



i didn't think of it but i should have pulled the k04 and took the injectors home so i could sell them...gonna have to go back there later this week to pick up the parts i'm selling off...

the valve cover will be sent to be powder coated wrinkle red like the rs4 valve covers

[Nzila8]

got my snail back from jethot today!

What a lovely sight

[Ephry73]

I have o-rings if you need them. i can put them in an envelope. Just need to get your own tube of graphite grease. Lovely find brother!! enjoy it and drive it in good health. But the 1.8 back together as stock with the timing belt done and let her go :)

[jonan]

This was the first car i bought with my own two hands after i graduated from college...so i dont think id ever sell it after more than a decade of ownership 😁

[Ephry73]

This was the first car i bought with my own two hands after i graduated from college...so i dont think id ever sell it after more than a decade of ownership

Hahaha I hear you.


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[jonan]

some progress pics, motor came back from machine shop a last week and my shop started assembling the motor, they finally had a chance to drop it in the car today...



















ran into a few roadblocks though, the wastegate and bracket that came with the gt2860rs won't allow the turbo to clock correctly so i'm trying to source the wastegate and bracket that is used on the APR turbo...

also, still need to source a set of stud and bolts for the APR exhaust manifold...APR literally quoted me $198.50 for replacement hardware...



the chain for the oil pump that IE sent me came with a link missing, guy at my shop said that seemed funky so he order a new one from audi as he didn't want to risk using an oil pump chain that looked to be broken, i'll have to sort that out with IE once i get everything back from them...

the stock oil and coolant lines won't work with the gt2860rs either apparently so they have to source and build a set of braided lines for me...if all goes smoothly in terms of sourcing parts and shipping i should have the car back in my possession late next week...

once everything is buttoned up, i'll essentially have a brand new motor...every gasket, seal, critical fastener, and mechanically moving part has either been replaced or upgraded...also powder coated the valve cover to match the VC in my rs4, i think it turned out nicely

once i have the time and motivation to drop in the 01e i picked up awhile ago and have the b6 paint corrected and wrapped it will be a finished product IMO...i'm actually excited to see how much power this thing puts down when i get it back (butt dyno relative to the rs4)...

i'll be leaving my rs4 with them when i pick up the b6 to do a compression/leakdown test...the work i had them do greatly reduced oil consumption but i'm still losing about ~1QT per 1,000 miles...before it was around a quart lost per 200 miles which was really alarming...

i'd love to hear some opinions about breaking the motor in...i've read everything from drive it like you stole it from mile 0 to doing a moderately aggressive break in over time and hitting certain RPM levels at certain mileage milestones...this is my first fully built motor so i'm not sure which approach is best...

i'll be conducting a blackstone UOA at every oil change to make sure the motor is breaking in properly...

[jonan]

here is the aforementioned oil pump chain that my mechanic refused to use, he's never seen one delivered with a missing link like this before...

[jonan]

Oh yea, def a cracked head. in my complete HONEST opinion, I think the GTRS was the best setup for the car. it is the most OEM + in terms of power. people say the k04 is how the car should have come from the factory but the torque spike on it is not practical for daily driving. The gtrs is the most well rounded setup for daily driving and it wont kill you financially. i dont think you need to do valvetrain but everything else looks on point for a solid gtrs build.

for the record, machine shop checked head and it was fine, the head gasket itself was actually toast...but all things considered i was APR stage 1 since 13k miles and the gasket made it all the way to 175k miles...not bad...

[jonan]

finally got the car running! i'm about 17 miles into the break-in period...changed oil last night after drive home

gonna change oil again at 100 miles, 500 miles and then switch to synthetic at 1,000 miles...rev to around 3.5k without entering boost and just let engine break to create vacuum...

the motor itself doesn't sound much louder than the stock valvetrain...i was a bit worried that the ferrea valves would clatter a lot more...

also, the JHM LWF RS4 clutch is actually nicer than the clutch in my RS4...eager to see how everything runs once broken in...

[Wet0willy01]

Nice progress

[itsmatt33]

finally got the car running! i'm about 17 miles into the break-in period...changed oil last night after drive home

gonna change oil again at 100 miles, 500 miles and then switch to synthetic at 1,000 miles...rev to around 3.5k without entering boost and just let engine break to create vacuum...

the motor itself doesn't sound much louder than the stock valvetrain...i was a bit worried that the ferrea valves would clatter a lot more...

also, the JHM LWF RS4 clutch is actually nicer than the clutch in my RS4...eager to see how everything runs once broken in...

lets get some dyno number asap!

[jonan]

lets get some dyno number asap!

there is a local dyno meet this coming saturday, but i'm not sure i'll have motor broken in by then sadly...



ceramic coating makes a HUGE difference in engine bay temps...totally worth it...



all cleaned up best i could, only thing left to do now is paint correction, respray, xpel then ceramic coat (also need to install the 01E that i have sitting in my garage...but i'm not too eager to tackle that project any time soon, maybe next year)...or just leave paint as is so i can't not give a fuk where i park in parking lots...



been a long and worthwhile journey with this car

[jonan]

also, the only thing i was a bit upset about was the turbo blanket install...shop totally got it wrong, i guess they didn't put it on before mounting turbo and testpipe...



i took it off because it looked like shit installed like this, i'm guessing to install it correctly i need to remove the downpipe? there is very little room to manuever the turbo blanket and i have no idea if it is even possible to install without removing shit...

[SleeperAvant]

I've always loved the APR inconel exhaust manifolds.