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 Homemade T25 Garrett S4 View next topic
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Andy P
knowledgeable



Joined: 19 Oct 2011
Posts: 269


PostPosted: Wed Jul 09, 2014 12:58 pm  Reply with quoteBack to top

Thought I'd make a bit of a project thread for my car now that I've done a fair bit of work already.

I'll introduce you to the car -



A pretty high mileage (185k!) noggy S4, pretty standard aside from wheels, coilovers, revo map and also running LPG. I bought the car to be my daily motorway cruiser as I was doing 800 miles a week and with the LPG it was cheaper to run than a 2.0tdci Mondeo.

I've got another project S4 track car (noggy saloon) so this was destined to stay standard and eventually become the tow rig.

I've since changed jobs and I'm down to "just" 250 miles a week, and although the car was still to remain standard, fate had different ideas...

So, this brings me to a few months ago when this happened - DOH!


The OS turbo had started howling and whilst trying to baby it home a huge plume of blue and white smoke erupted behind the car creating a smoke screen Dick Dastardly would be proud of!

A little annoyed but i suspect the car is on its original turbos and clutch so they had a decent innings.

Once home I had a little think on what I was going to do. Decided that for the effort of pulling the motor out I didn't really want to put another k03 in and the cost of k04's didn't get me so excited either.

Turn's out I already had a few "spare" T25's in my workshop so thought why the hell not! Worth a punt.

So, out comes the engine (what a *%&$^*X?!!)






I checked the blown turbo...




Turns out the failure has been caused by a foriegn object - I found one of the airbox clips in the inlet pipe!!!

Here's a comparison of the k03 and T25 (19mm spanner for ref) -


To be continued..
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Jamo
Skilled


Car: B5 RS4
Power: 580+
Torque: 700+

Joined: 13 Jun 2009
Posts: 1361


PostPosted: Wed Jul 09, 2014 1:05 pm Reply with quoteBack to top

Ouch! question is how the hell did an airbox clip get into the intake system?
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Andy P
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Joined: 19 Oct 2011
Posts: 269


PostPosted: Wed Jul 09, 2014 1:12 pm Reply with quoteBack to top

So the plan is to cut and shut the stock manifolds with a T25 flange. Why? Reliability. I was going to get some tubulars but then I don't want the issue of potential cracks etc. Its not the best solution I know but everything here is being done on a budget - to see if it can be done!





Whilst I was at it, I changed the clutch with a LUK RS4 set. I've seen mixed reviews for these so will see how it goes.





Managed to spill plenty of gearbox oil when taking the engine out so drained and refilled (ignore the pikey bricks!)


Quick shot of my drive - wish I had a garage to work in!


And then started mocking things up with new inlets to suit the T25's. The keen eye'd will spot a mistake with these...




And then I mocked up a downpipe. Made from 2.5" stainless, will have a flex and Vband connection.






To be Continued...
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Andy P
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Joined: 19 Oct 2011
Posts: 269


PostPosted: Wed Jul 09, 2014 1:28 pm Reply with quoteBack to top

Now to sort out the lines to the turbo, I wanted to keep as much of this as stock as possible.

The oil drain lined up exactly and only needed a reflange


The rear coolant line and oil feed bolted up directly with no need for modification. (thought I had a pic of this, will edit if i remember to take one)

And going back to that "mistake" I mentioned earlier, the inlet pipe I mocked up fouled the engine mount so I had to make a slight S bend




And this is pretty much how its sat currently - all lines are done, I've re-used the K03 wastegates with modification to the T25 wg bracket. I've ordered a tight radius 90 to weld to the inlet and then this side is virtually complete.


I've forgotten to also mention all my rocker cover seals were pissing oil so all the top end seals have now been replaced with new. I know I've taken pics of this, I'll find and upload... OH, also replaced the timing belt and all pulleys / tensioners...

As my existing exhaust is full of oil, decided that I'd get a new one as they're cheap, and it'll make life easier to see if there are any issues on start up. I don't really want the exhaust bellowing blue smoke and hiding any engine / turbo issues...

XSpower exhaust -


Thought it was a decat... Beau had other ideas




Thats all for now...  

..Flame away  
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Andy P
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Joined: 19 Oct 2011
Posts: 269


PostPosted: Wed Jul 09, 2014 1:29 pm Reply with quoteBack to top

Jamo wrote:
Ouch! question is how the hell did an airbox clip get into the intake system?


No idea! But it was in there!!!
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RACK
Knows a Bit


Car: S4

Joined: 18 Oct 2013
Posts: 198


PostPosted: Wed Jul 09, 2014 2:48 pm Reply with quoteBack to top

Loving the cat lol
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ScottR
Veteran


Car: B5 S4

Joined: 22 Apr 2008
Posts: 8457


PostPosted: Wed Jul 09, 2014 7:38 pm Reply with quoteBack to top

Brilliant to see something different and also DIY. Hats off to you. Was feeling smug as I knew it was the engine mount which was going to be the problem... but now I just feel sad as I've had to see my engine out so many times!

What sort of power will these be capable of?
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Jamo
Skilled


Car: B5 RS4
Power: 580+
Torque: 700+

Joined: 13 Jun 2009
Posts: 1361


PostPosted: Wed Jul 09, 2014 8:49 pm Reply with quoteBack to top

You are installing 2 X T25's right?
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Challice
Experienced


Car: S4 V8
Power: 340bhp
Torque: 301lbft

Joined: 05 Mar 2011
Posts: 3043

Location: Wiltshire

PostPosted: Wed Jul 09, 2014 9:09 pm Reply with quoteBack to top

Ace! Nice handy work, it's all coming together nice, ash hoses are pretty damn good for their price.

Would have tought the T25's are about K04 size and flow?
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Andy P
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Joined: 19 Oct 2011
Posts: 269


PostPosted: Wed Jul 09, 2014 9:17 pm Reply with quoteBack to top

ScottR wrote:
Brilliant to see something different and also DIY. Hats off to you. Was feeling smug as I knew it was the engine mount which was going to be the problem... but now I just feel sad as I've had to see my engine out so many times!

What sort of power will these be capable of?


Thanks for the positive comment. I've found with these cars that there aren't many home built cars and even fewer that aren't using BW turbos.

A few rudimentary calculations suggest these should be coming on song by 3k and pull hard to the redline. Difficult to pinpoint the power these will make... more than stock k04's?
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MichaelG
Skilled


Car: S4 B5
Power: standard
Torque: standard
Engine code: AGB

Joined: 27 Feb 2011
Posts: 1158

Location: Glasgow, Uddingston

PostPosted: Wed Jul 09, 2014 9:21 pm Reply with quoteBack to top

Nice wee project and a break from the tried and tested KO4 route. I'll be keeping an eye on this thread.

Keep up the good work
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Andy P
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Joined: 19 Oct 2011
Posts: 269


PostPosted: Wed Jul 09, 2014 9:39 pm Reply with quoteBack to top

Jamo wrote:
You are installing 2 X T25's right?


Haha, yeah, 2 of them! Half way there
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ian52
Skilled


Car: Misano B5 RS4
Power: 489
Torque: No idea

Joined: 31 Aug 2009
Posts: 1899

Location: Perth

PostPosted: Wed Jul 09, 2014 9:48 pm Reply with quoteBack to top

How about a T28 from a 200sx if these work ok. Think they are good for high 200's in them or the T28 from a GTI-R over 300. If this works good T28's could be good for big power cars maybe.
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Andy P
knowledgeable



Joined: 19 Oct 2011
Posts: 269


PostPosted: Wed Jul 09, 2014 9:49 pm Reply with quoteBack to top

Challice wrote:
Ace! Nice handy work, it's all coming together nice, ash hoses are pretty damn good for their price.

Would have tought the T25's are about K04 size and flow?


Yup, have used ash stuff for years now. Can't be beaten on quality at this price!  Cheers for the comment
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Andy P
knowledgeable



Joined: 19 Oct 2011
Posts: 269


PostPosted: Wed Jul 09, 2014 9:51 pm Reply with quoteBack to top

ian52 wrote:
How about a T28 from a 200sx if these work ok. Think they are good for high 200's in them or the T28 from a GTI-R over 300. If this works good T28's could be good for big power cars maybe.


Yup, it's half the reason why I'm going with turbo's i had lying round test the theory without spending out too much. If it works I can straight swap to any T2 flange turbo... GT2871R for example...
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