URS6 Avant 5.2

[jolio1994]

The RS6 powered Avant is no more... It treated me well for the past 7000 miles, but I'm determined to get this thing to 300,000 miles. So here.. we.. go!

received_798238210941640 by Joel Francisco
2020-11-01_07-15-06 by Joel Francisco


The engine fits with zero modification to the subframe or front end. Probably because the subframe was already notched for the 4.2 Turbo. Engine is bolted to the 5sp 01e transmission at this point, but only with 2 bolts.

20201102_141028 by Joel Francisco
20201102_141006 by Joel Francisco
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20201102_141309 by Joel Francisco

[pkt1213]

Wait what?

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[idotavant]

But what will you do for boost? Joking, but at this point, I know better than to think it will be n/a


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[arjun90]

What happened to your rocker panels?

[2.ohhh]

I knew you had this up your sleeve....I stumbled across the other thread by accident the other night while lurking around when you were asking about lift points for the V10...

As always, excited to see where this goes!

[Turbavanttro]

Can't wait to see your progress on this torque monster!

[V1nny]

Sorry, can't believe it is even doable.. Where would you put radiator?

[jolio1994]

There's 8" of room between the front most part of the engine and the front bumper.

With a 2" dual pass radiator and 3" shroud + fans, I'll still have plenty of room left over.

[idotavant]

Crank the rear bias on the center diff for that weighty schnoz!


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[JorisRS6]

Nice Joel! Itll be interesting to follow this project


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[Sul_Reed]

You’re wild


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[C_lebAR03]

Stumbled across your IG only a few hours ago and here we are! Nice work, can’t wait to see it running


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[jolio1994]

Alrighty, made some decent progress these past few days. Made a lift plate since the S6 5.2 didn't come with pick-up points for a hoist. Thing is sturdy as a rock and has a front crossbar to grab onto with a ratchet to change the pitch of the motor! Pretty sweet! I also changed the 5.2 timing cover for the BNS 4.2 and got 5 or 6 of the bellhousing bolts to line up. After that I just modified the 4.2t engine mounting brackets and the motor just slipped right in! I'll finalize engine placement this weekend and then I can start working on the 5-1 headers I think!

Be sure to follow my Instagram for the most up to date pics/videos of the build @rs6_jolio

20201112_154911 by Joel Francisco
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[Bordom]

This makes me want to a C4.

Makes me want to 5.2 swap my Allroad from the 4.2 I did too lol

[idotavant]

Yeah. I’m thinking I could sell the v3 kit I have, and buy a 5.2 for as much or less than keeping it all and doing the 4.2 chain job could be.

(Fantasy false logic, but it sounds fun)


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[jolio1994]

I'm not sure yet if 5.2 is the way to go.. but we will all find out by the end of the year haha.

Everything just seems to fit... it's beautiful. I have the dual pass radiator I used on the 4.2T in there, but with a twist. I've managed to trim enough of the C6 S6 shroud and big boy fans down so it fits! There's about another inch I will move the radiator assembly forward towards the bumper which leaves ~3" of room between the fans and the crank pulley! The reason I'm so happy is because:
A. I didn't have a shroud on the 4.2T and it sucked in the Summer.
B. I can use the factory C6 S6 fan control module instead of having to manually flip a switch (and possibly forgetting... haha).

Everything's great there... I ordered a bunch of parts from FCP Euro and ECS Tuning as well as a carbon cleaning kit from JHM Motorsports. Also ordered $900 worth of piping for the tubular manifolds. For the exhaust I plan on running 1 1/2" primaries to a 5-1 collector. 3" exhaust about 5' back where both sides will transition into a single 4" all the way out the back. It should be very loud and scream.. I have the file a great friend of mine drew up in CAD of the exhaust manifold flanges. If anybody knows anybody that can cut them out of 3/8" or 1/2" stainless please drop me a line.

I think this just leaves me with ordering a B7 RS4 Clutch Kit and starter as well as a new radiator (same dimensions, just different feed/return location's) off of Summit Racing, and I should be good to go.

20201113_201918 by Joel Francisco

[Revolv0]

Did you get the intake manifold spacer from JHM? Good luck with this build, the V10 noises will be so so worth it. Ill let mine sit between 3-4K RPM for the symphony it produces, and it never gets old.

The manual component will be even more glorious.

Will the headers your planning fit in a C6 s6 as well? I would love a set! I asked JHM V10 to get on the list, but they were so wishie washie about cost and commitment.

[V1nny]

Amazing tight fit. Not sure if NA engine would benefit from such low restriction exhaust, as it needs some backpressure. Also depending of how much torque your setup will produce, B7 RS4 Clutch may not last that long, so I would consider Southbend Stage 2 endurance instead.

[jolio1994]

So, due to space and packaging, I don't think the headers I'll be making will fit the C6 S6. The 01e is a lot narrower, and I'll be butted up pretty close to them to avoid the firewall, frame rails, and trans tunnel.

As for the clutch, it's a B7 RS4 "setup". I will be on a Ringer Racing Stage 4 good +850hp.

The engine mount brackets were finalized today and I fitted the HPFP's on as well to make sure everything clears the hood... Millimeter's guys... lol

20201116_154421 by Joel Francisco
20201116_154441 by Joel Francisco

[jolio1994]

Engine and transmission came out today, this thing is just caked in grease. Gave it a really good cleaning and will get it back on to start making the exhaust relatively soon. In the meantime, it's time to start cleaning some valves. Here's 1 pass on cylinder #1, already a night and day difference!

20201122_155238 by Joel Francisco
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[diabolical1]

great project!

the ports and valves came out looking great!

how many of the tranny bolts lined up?

[neilpaku]

Nice! I have a regular C4 Avant and it's such a good looking body. I'm on 255k miles with no work on the driveline from the cooling fan to the diffs. Engine still starts same as ever - no power of course but the 26 mpg is hard to go past for a daily drive. My local Euro shop likes taking care of it so it's all good. Rust starting to get into the a-pillar but otherwise pretty sound which is impressive because it's been in the salty NE since 1995...

[jolio1994]

great project!

the ports and valves came out looking great!

how many of the tranny bolts lined up?

Thanks dude! Currently only 5 line up, but once torqued, should be fine... I have the additional bottom 3 that "can" line up if I drill through the lower oil pan. It's just webbing part though, wouldn't be going into the internals with it, so I may do one or two!

Got er bolted back up. Almost ready for some exhaust!
20201128_210422 by Joel Francisco

[TQdriver]

Watching this thread like a Netflix series, popcorn n all!

What’s ur thoughts on the carbon cleaning, any advise for someone about to do the same on their 5.2?

[jolio1994]

Watching this thread like a Netflix series, popcorn n all!

What’s ur thoughts on the carbon cleaning, any advise for someone about to do the same on their 5.2?

Thanks man! Carbon cleaning isn't that bad. 7 of the 10 cylinders can be done with #1 at TDC. Then just have to move the crank to get the rest... IIRC #4, #8, and #9. I got the $25 brush and pick kit from JHM that attaches to an electric driver and went to town with some fuel cleaner I picked up from Autozone

I put in a solid 4 hours on it today getting the longtube headers made. It's a shame some 5-1 collectors aren't going to fit between the engine and the front axle. I have to pull cylinder 6 in from the side right at the base of the collector if I have any hope of it working. First thing tomorrow though I need to get the engine in the car to see where cylinder 6 can/can't go due to space constraints on the frame rails and maybe this weekend I'll have them welded.

I know the 4-1 isn't ideal so roast away

20201203_183142 by Joel Francisco
20201203_184151 by Joel Francisco, on Flickr

[idotavant]

I would roast you but I don’t see how to do it well either. If it’s that tight going down, how the hell are you going to get it back up to the turbos


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[2.ohhh]

I would roast you but I don’t see how to do it well either. If it’s that tight going down, how the hell are you going to get it back up to the turbos


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No turbo issues...IIRC, this is a NA build. I'm sure that Joel will correct if I'm wrong though.

Joel, nice looking work, especially since you just learned to weld at home on your last project...very impressive!

[LakeTahoeQuattr]

Wait wtf! How did you get an 01e mated to the back of the 5.2? I was told this was not possible?!! If this is the case why wouldnt I do it with my c6!! If I put the actual lambo engine that revs to 8250 + a built 01E I could get 610+ HP out of my C6. I'd be down!

[idotavant]

No turbo issues...IIRC, this is a NA build. I'm sure that Joel will correct if I'm wrong though.

Joel, nice looking work, especially since you just learned to weld at home on your last project...very impressive!

Totally trolling him. Wanted to see if he’d bite


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[TQdriver]

Do you have firewall clearance to run the exhaust tubes over the front axle then turn down to the collector?
Have look at these headers fab’d for the larger auto trans, they run up over the axle.
https://www.audizine.com/forum/showt...GHLY-MODIFIED)

Where did u find the R8 intake, do they have flaps or no?

[LakeTahoeQuattr]

Run 5 exhaust pipes out the side of the front fender like an airplane :)

[2.ohhh]

Totally trolling him. Wanted to see if he’d bite


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LOL, that's what I get for looking at forums at 6 a.m., but with Joel, you never know what he has up his sleeve!

[jolio1994]

I would roast you but I don’t see how to do it well either. If it’s that tight going down, how the hell are you going to get it back up to the turbos

Haha, no! No turbos! As I said I need a nice reliable 500hp N/A build! NO BOOST!

Wait wtf! How did you get an 01e mated to the back of the 5.2? I was told this was not possible?!! If this is the case why wouldn't I do it with my c6!! If I put the actual lambo engine that revs to 8250 + a built 01E I could get 610+ HP out of my C6. I'd be down!

Getting the 01e / 0a3 to mate up to the S6/S8 5.2 is super easy. The only thing required is a B7 RS4 style clutch kit, D3 A8 starter, D3 A8 rear timing cover, and C6 A6 3.2 5mm transmission spacer! The 5.2 found in the R8 / Lamborghini is a bit different on the rear timing cover, as it uses a dry sump upper and lower oil pan. Not sure how that'd play out, but it'd be tits to see!

Do you have firewall clearance to run the exhaust tubes over the front axle then turn down to the collector?
Have look at these headers fab’d for the larger auto trans, they run up over the axle.
https://www.audizine.com/forum/showt...GHLY-MODIFIED)

Where did u find the R8 intake, do they have flaps or no?

So with the auto trans if look closely Audi designed the front axle shaft to be butted up as close to the bellhousing as close as possible. The was so they could run the exhaust over it and still clear the transmission tunnel.

The 01e and 0a3 have the cups for the front axles about 6-8 inches behind the bellhousing which makes it almost impossible to get the exhaust to run over it. 5 pieces of tube would be too wide to use with the trans brackets. A cross member would have to be used on the bottom of the transmisision if there was any hope of doing it, and the C4 chassis doesn't currently have any provisions for one to bolt to.

Can it be done, yes.. but it's more effort than I'm willing to place on something that'll still be super difficult.

Good friend down in GA spotted the intake manifold posted locally for a stupid price so I snagged it. They don't have flaps on the upper section, still sourcing the lowers and I'm not sure yet.

I started the other side and it's a lot "easier". Man, if I started making these for the B6 / B7 S4 I'd make a killing... I'm trying to do the first 4 (have them welded) and then add the final cylinders 1 and 6 after because stainless loves to move and warp while welding. Test fit for the driverside went better than I expected for not having a jig.

20201205_184650 by Joel Francisco

[idotavant]

500hp na. That’s what I like to hear. I was kidding anyway, but I wouldn’t have been shocked!

Good luck with those headers. Excellent effort so far. The balance of “practicality” is always tough


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[jolio1994]

Thanks dude! Did a test fit and all seems good with room for 1 more on each side! I'll have them welded this week once I get some purging gas and then finish the last runner; hopefully by the weekend.

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[diabolical1]

great score on the R8 intake! i'm stoked for you. :)

also, as with anyone that does their own welding (and fab), i always have to give props.

[Wompie]

my hero.

[magnatron]

This is truly amazing work, I can't wait to buy a house with a garage, and start doing this myself man, amazing work really!

[jolio1994]

Haha thanks guys! I almost got the fabrication side of things done... almost! I welded the primaries up last Wednesday and Friday I had a baby girl so I probably won't be able to work on it for a bit. I'm thinking maybe this weekend I can finish it, but maybe it's just wishful thinking on my part haha.

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[S/RConcepts]

Awesome news man, congrats! This is going to be one hell of a family hauler lol.