Saving a Santorin Avant

[travis_w]

What are you using for vapor blasting?

Sent from my SM-S928U using Audizine Forum mobile app

[eurogz]

What are you using for vapor blasting?

Sent from my SM-S928U using Audizine Forum mobile app

Have a cabinet I can use at work. Similar to traditional media blasting but uses a slurry of glass beads, water, and pressure. Doesn’t have issues with dust and leaves a much more “factory” looking finish than any other media blasting I’ve used. That is how the majority of the parts on my block look so new:









Sent from my iPhone using Tapatalk

[jbain2]

Did you have to cut out the firewall to accommodate the turbos back there? Looks like they extend a bit more than traditional framed turbos. They do look very fun though!! Nice work!


Sent from my iPhone using Audizine

[eurogz]

Oh no doubt it’s gonna be tight but should fit. I am a bit concerned about heat but we’ll see how it goes


Sent from my iPhone using Audizine Forum

[travis_w]

I've been using a wire wheel to clean my stuff, but I'm thinking about buying a cabinet. I've always wanted one.

Sent from my SM-S928U using Audizine Forum mobile app

[Gunnarrrrr]

so what did you end up doing for pistons? did you stick to 81.5?


Sent from my iPhone using Audizine Forum

[eurogz]

so what did you end up doing for pistons? did you stick to 81.5?


Sent from my iPhone using Audizine Forum

Went with JE 82.5. Was considering a Wiseco option but I was in a time crunch and I wanted the displacement bump


Sent from my iPhone using Tapatalk

[Gunnarrrrr]

Went with JE 82.5. Was considering a Wiseco option but I was in a time crunch and I wanted the displacement bump


Sent from my iPhone using Tapatalk

ahh big boy bore. did you avoid 83 because you wanted to play it safe with an APB block instead of a BEL, or just to keep a little material to work with in case something goes wrong?


Sent from my iPhone using Audizine Forum

[eurogz]

Was trying to keep some meat in the block. In all honesty if this thing pops I’m fully expecting it to be violent enough that I would need a different block anyway haha. Counting the one that’s still in the car there is currently 4 blocks in my garage but one is being stored for a buddy until he’s ready to do an rs6 setup and one will probably be sold off. Also have a spare 01e that I was going to build but the one that is currently in the car has way less rust so I’ll probably just rebuild and reuse that one instead. Will slow me down in terms of time but I’m trying to keep this setup as clean as possible


Sent from my iPhone using Audizine Forum

[travis_w]

Deleted

Sent from my SM-S928U using Audizine Forum mobile app

[eurogz]

Picked this stuff up from the coater today, camera doesn’t do the color justice. Looks very blue in the pictures, looks very purple in real life. I was shooting for “blurple”, I’m happy with it.

Waiting on a power steering pump that I forgot to order, then there’s really nothing else I can use as an excuse to stall working on the turbo lines. Main concerns are coolant feeds as there is pretty much zero room behind the motor mount brackets, and oil drains as -10 fittings are substantially smaller than the oem drains


Sent from my iPhone using Tapatalk

[travis_w]

That looks good. What did they charge and did you take the baffles out?

Sent from my SM-S928U using Audizine Forum mobile app

[eurogz]

225 for both valve covers and the manifold with 2 stage powder. Baffles were not removed, I specifically asked about it and coater said he just masks them off and has never had issues. There is for sure some media inside the intake manifold however which I’m kinda pissed about but will just have to spend time cleaning I guess


Sent from my iPhone using Audizine Forum

[Silverex]

225 for both valve covers and the manifold with 2 stage powder. Baffles were not removed, I specifically asked about it and coater said he just masks them off and has never had issues. There is for sure some media inside the intake manifold however which I’m kinda pissed about but will just have to spend time cleaning I guess


Sent from my iPhone using Audizine Forum

Unless he used baking soda I’d spend a bunch of time cleaning it out. Sand/glass can get embedded and be a pain to remove completely. I’ve lost an engine after not cleaning it out well enough

[eurogz]

Yeah I’m gonna drill out the baffles and bolt them back in. Those are not dice I’m willing to roll. Manifold is easy at least since the plenum cover is removable


Sent from my iPhone using Audizine Forum

[eurogz]

Drilled out the baffle on a spare valve cover I have, there is definitely not enough meat to tap for bolts so that plan is out. Guess we’re just going to spend a lot of time rinsing and pray.

If anybody has any other ideas for removing and reinstalling the baffles I’m all ears.


Sent from my iPhone using Audizine Forum

[travis_w]

Did you make sure the inside of your oil pan was 100% free of the glass beads?

I just painted my valve covers, so I didn't have to mess around with taking the baffles out. I used etching primer but I still think it's going to flake.

Sent from my SM-S928U using Audizine Forum mobile app

[eurogz]

Upper pan was cleaned pretty thoroughly both after blasting and after machining, that I’m not super worried about. Lower pan is new


Sent from my iPhone using Audizine Forum

[travis_w]

Cool. The engine looks great. Going to be an awesome car.

Sent from my SM-S928U using Audizine Forum mobile app

[Tightmopedman9]

Is that a oxygen sensor bung on your manifold? Apologies if you already know this, but if you plan on mounting a wideband in your manifold be aware that without pressure compensation the lambda reading won't be accurate. The absolute deviation in accuracy spans 80%, so the inaccuracy isn't insignificant. In order to account for the inaccuracy you need a controller which can compensate lp (pump current) based on pressure.

You can see a graph for the amount of inaccuracy in Bosch's datasheet for the ADV LSU: https://www.bosch-motorsport.com/con..._pre_Turbo.pdf

[eurogz]

Good info!

Those are EGT sensor ports, the front o2 sensors will be in the downpipes (which I haven’t showed off yet but they are beautiful!)
and wideband will be further back. Downpipes back haven’t been mocked up yet but will probably be full 304 stainless, 3 1/2” single to dual outlet with either a single muffler or single resonator (again haven’t even really thought about how I want to lay this out yet)

Stock EGT sensors are pretty much useless so I have been kicking around the idea of wiring an aftermarket set of EGT sensors into an FIS Control to monitor, but with e85 and no cats I’m not really concerned about EGT’s being an issue, may just plug them and code them out


Sent from my iPhone using Audizine Forum

[replica_rs4]

Looks great. Who made manifolds and what are specs for turbos?


Sent from my SM-A715F using Audizine Forum mobile app

[Tightmopedman9]

Based on the location I assumed it was for an EGT sensor, but the bung looked quite large for an EGT sensor. It's probably just the shadows playing tricks...

I agree, on E85 you shouldn't ever have to worry about EGTs. With that said, having the additional information wouldn't hurt. Definitely don't bother with the factory EGTs - the minimum temperature they can report is 945ºC, which I doubt you'll ever hit on E85.

[eurogz]

Looks great. Who made manifolds and what are specs for turbos?


Sent from my SM-A715F using Audizine Forum mobile app

James Young made the manifolds, downpipes / wastegate pipes, inlets and charge piping. As far as I am aware he is the only person offering a kit for the G series turbos on the 2.7t currently, he’s sold a bunch of kits but don’t think many cars are on the road yet. There was another kit that used to be available in Europe I don’t see being advertised anymore. I know White Dog Racing built at least one car while they were still around, and I know a guy local to me that built his own setup in a swapped B6. Several running cars in Europe I’m only aware of a couple in the states.

Turbos are G25-660, flow is supposed to be comparable to the gen 2 GTX3071R with better efficiency and a smaller size.

https://www.garrettmotion.com/racing...eries-g25-660/

Based on the location I assumed it was for an EGT sensor, but the bung looked quite large for an EGT sensor. It's probably just the shadows playing tricks...

I agree, on E85 you shouldn't ever have to worry about EGTs. With that said, having the additional information wouldn't hurt. Definitely don't bother with the factory EGTs - the minimum temperature they can report is 945ºC, which I doubt you'll ever hit on E85.

The RS6 EGT sensors read from -40C to 1110C and would be the “ideal” solution which I’m still entertaining. I do agree more data is always a good thing. I was offered the option of individual EGT bungs per runner which I may have done if I didn’t hate the idea of a standalone setup vs stock ECU. My buddy is building a car with a FuelTech setup and I’m super jealous of the functionality but it’s not very “street car” and I love the idea of a wolf in sheep’s clothing


Sent from my iPhone using Audizine Forum

[Silverex]

Pretty sure Ignitron allows extra inputs via Can-Bus. So if you got a EGT controller that can send the messages via can you’d be able to log them also…all in a mostly PnP ECU.

[AudiWhatee]

Picked this stuff up from the coater today, camera doesn’t do the color justice. Looks very blue in the pictures, looks very purple in real life. I was shooting for “blurple”, I’m happy with it.

Waiting on a power steering pump that I forgot to order, then there’s really nothing else I can use as an excuse to stall working on the turbo lines. Main concerns are coolant feeds as there is pretty much zero room behind the motor mount brackets, and oil drains as -10 fittings are substantially smaller than the oem drains


Sent from my iPhone using Tapatalk

STUNNING!

Love this thread and thank you for the continuous updates!

[CELison]

Looking good. Nice headlights

[RMode]

Looking good. Nice headlights

Headlights with good lineage too


Sent from my iPhone using Tapatalk

[Tightmopedman9]

The RS6 EGT sensors read from -40C to 1110C and would be the “ideal” solution which I’m still entertaining. I do agree more data is always a good thing. I was offered the option of individual EGT bungs per runner which I may have done if I didn’t hate the idea of a standalone setup vs stock ECU. My buddy is building a car with a FuelTech setup and I’m super jealous of the functionality but it’s not very “street car” and I love the idea of a wolf in sheep’s clothing

Yeah, but RS6 EGT probes are minimum $399... You can just get a K type thermocouple for $20 and an Auber Instruments 1/16" DIN gauge for $50. Shoot, I have a spare gauge I'd just give you if you paid for shipping. Based on the rest of this build I guess cost isn't much of a consideration.

[eurogz]

Making sporadic progress. Made all my turbo lines, buttoned everything else up about 90%. Considering engine “complete” at this point. Once I pull the old engine I’ll finish up vacuum lines / wastegate lines / coolant hoses etc. There’s a local B5 meet in a few weeks I want to drive the car to, after that it’ll get parked on the lift and I’ll start working on the big stuff: trans rebuild, tubular subframes, fuel system etc. Still not 100% positive this motor will fit in the bay without some serious massaging.

Side note several B5’s have been on my lift since I put it in but mine never has lol.

In the mean time I’ve been jamming out some small stuff that’s been on the back burner while building the motor. Parts pile was getting to look like more of a parts mountain so happy to get some of it on the car:

Replaced cracked hazard trim and dash cupholder
Replaced exterior ambient temp sensor
Replaced temp sensor in the center hvac duct
Replaced cruise control stalk (shout out to Adam, but now my wiper stalk looks old and faded!)
Installed the FIS Control
Fixed a peeling door card
Replaced all 4 door handle springs
Replaced all 4 door speakers
Replaced rear passenger window regulator
New hood strut and hood latch
Verified climate control unit was not causing my blower issues, guess I need a blower motor / resistor.

Now working on rebuilding 6 calipers for my 18Z setup, hoping to get them mounted and bled this weekend. Fronts should be easy rears may be interesting.





Posting pictures on this forum is such a pain in the ass from mobile or I would update more, Facebook / Instagram sees this build more frequently


Sent from my iPhone using Tapatalk

[alpine4]

Awesome build! You replaced all 4 speakers, what did you replace them with? My speakers are blown and need replaced.

[eurogz]

They were just some 2 ohm replacements from PowerBass, 5.25” fronts and 6.75” rears with 3D printed adapters to mount them in the door cards. Nothing special but sound much better than the 25 year old blown factory speakers.

Brakes are coming along, need to finish up one e brake caliper and get them bled. Probably going to roll the front fenders and put spacers up front. No clearance issues with the v710 / 18z combo but I don’t like how much the fronts tuck. Rears are perfect with the 10mm spacers I’ve been running but the fronts rub on corners with no spacer would probably rip the fender off if I added them now. Hoping I don’t hurt the paint but already have some paint work I need to do eventually anyway.







Sent from my iPhone using Tapatalk

[eurogz]

Committed now. Other than breaking the line from the vacuum reservoir to the n249 everything came out smooth. 01E rebuild is the next milestone.


Sent from my iPhone using Audizine Forum

[eurogz]

Disassembly is always much more enjoyable than reassembly


Sent from my iPhone using Audizine Forum

[Tec_Nine]

Making great progress, really enjoy seeing others bringing these cars back to life and putting in the hours. I remember rebuilding my 01e with the JHM kit over a decade ago.

[zatch_303]

Garage and lift envy! Thanks for the updates and pics, love following along every update.

[ShelbyM3]

Disassembly is always may more enjoyable than reassembly


Sent from my iPhone using Audizine Forum

Is it that bad? How’d you get the nerve to open it up? I’ve got an extra 01E in my garage and I’ve always wanted to get into it, but I’m too chicken.

Great progress!


Sent from my iPhone using Audizine Forum

[eurogz]

Just gears and bearings in a manual transmission no black magic! JHM video makes it pretty easy to follow along. I’ve done plenty of bike transmissions but this is my first time inside an automotive transmission. If you have a press and are handy it’s tedious but not “hard”. Worst part is getting the tail housing apart without the Audi tool, I used a bearing splitter and some nuts/bolts and popped it right off.

Lift was the best purchase ever. Only thing the garage needs now is heat and insulation so I can actually stand working out there as it gets colder


Sent from my iPhone using Audizine Forum

[travis_w]

Did you have to cutout and pour deeper concrete for the lift?

Sent from my SM-S928U using Audizine Forum mobile app

[ShelbyM3]

Just gears and bearings in a manual transmission no black magic! JHM video makes it pretty easy to follow along. I’ve done plenty of bike transmissions but this is my first time inside an automotive transmission. If you have a press and are handy it’s tedious but not “hard”. Worst part is getting the tail housing apart without the Audi tool, I used a bearing splitter and some nuts/bolts and popped it right off.
Sent from my iPhone using Audizine Forum

I think I’m qualified. I’ve got a 12 ton press, a lift, a heater , just not the balls, hahaha. I’ve watch the JHM videos briefly. Once I get my engine install done and some breathing room, maybe I’ll take the plunge. Thanks!


Sent from my iPhone using Audizine Forum