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viperbl

666 BHP RS4 - The Beast!

Well, hopefully more 700, but 666 sounds better does it not??? †

OK, only a few days until I should be able to start building her back up!! Engine block should be with me tomorrow and all the internals are coming back from a successful balance on Thursday/Friday I hope...

In the meantime, here is the new workshop, a before and after pic, †cleaner, less dusty environment for engine building





Some head parts etc, mostly cleaned and ready for build ...



Some more parts that need cleaning ... I hate cleaning ...

MarkB

Puts my garage to shame I won't be posting any pictures of mine.

Good luck with the build and keep us posted
dace

Looking good and 666 sounds about right..
Simon

Looking good mate - matches mine. White walls and red floor is a good combo!

James

Well when you have done you car.....
Spanner Monkey

Should be good once done, viperbl.

Garage looks miles better, still have one major issue though...! The size!  

Guess you haven't told the forum about our efforts to find that lost valve spring & retainer and the efforts of getting headaches by cleaning parts through electrolosis? lol!
James

Any pics of the build?
viperbl

James wrote:
Any pics of the build?


Hopefully the build will start tonight!!! Pictures will come in thick and fast I hope!
Ghost

Have fun hope all goes well.
MarkB

Any updates yet Rich?

I've made the thread sticky as I'm sure it's going to be an excellent read...
viperbl

Cheers Mark ...

I have farmed the heads out to be ported/polished and valves put in etc, they should be finished soon. Also, turbo's should be here soon, but they have not given me a tracking number yet ... so ... who knows!

Current plan is take the parts to London in June, build the engine, put it back in the van, take it to the IOM, fit to the car and then drive back to the UK for mapping ...
s4woody

where abouts in london is the engine going too..mite meet you when you take it and say hi...
viperbl

So, last night I was on the phone all night demanding turbo's, I had even worked out flight prices across the pond to go and get them myself! But, finally, I was given a tracking number, that works and shows delivery for my goods as being wednesday!!! So, on the basis that might hopefully mean Friday after customs I am going to try and get on the boat this weekend and head for an engine build in London!

I am heading to watford for the engine build, I will let you all know and maybe meet up with some of you for beer or two ...
viperbl

Cancel that, I have just called FedEx and been told its a Dummy tracking number... WTF!!!!!!!!!!!!!!!!!

I really think I am gonna need to get a flight out there now, this is well over a month now that its been sitting waiting to be sent, keep getting fobbed off with loads of stories, now to give me a fake tracking number, I just can't believe some companies.
DavidT

viperbl wrote:
Cancel that, I have just called FedEx and been told its a Dummy tracking number... WTF!!!!!!!!!!!!!!!!!

I really think I am gonna need to get a flight out there now, this is well over a month now that its been sitting waiting to be sent, keep getting fobbed off with loads of stories, now to give me a fake tracking number, I just can't believe some companies.


Rich, if it was sitting there ready to be sent, they would have sent it & billed you, surely ?
viperbl

DavidT wrote:
Rich, if it was sitting there ready to be sent, they would have sent it & billed you, surely ?


Agreed, which leads me to believe they are not sitting there, or something else is up ... all my pestering last night has led them to (from what I can see) to get onto fedex, arrange a shipment and give me a tracking number to shut me up.

I called FedEx again, they confirm that they have all the paper work, but they have still not had a phone call to say the parcel is ready for collection, nothing will happen until this call is made.

Itís been a month now that they have been ready for shipping, I have had all excuses from busy to customs returning them because they did not fill a form in correctly.

Email system down (funny how my read receipts come back tho ) and not able to get tracking numbers...

I have been more than patient, but I think I need to get proper confirmation today that it has been sent or my money back, itís getting silly now.

But here is the thing, if they are having problems getting parts, just tell me!!! itís not like I donít understand getting parts can take time, but, maybe they sold my kit and just stalling me until they replace it? Who knows ... itís such a pain not being able to walk down there and speak to folk...
DavidT

Oh dear, a real tale of woe. The thing is, it happens quite often with US companies supplying to the UK. It's like they think we are in another world somehow.

Name & shame I say, or at least threaten to do so.

Do you have UK options to get what you need ?
dummi

thats bad news Rich completely out of order,, but don't be dis-heartened on the positive side you can still build the engine without the turbo's, they are only connected externally to the engine by pipework afterall...
viperbl

Yeah, I have resisted this long from the whole name and shame thing, but I am running out of options ... unless they come clean or give me a refund I will be looking at other avenues, but could really do without it!!!!!!!

Its so true Rez, would like to have done it in one go, but I suppose if I need to build it back up with my hybrids for now and source another garrett kit (I know of no one in the UK David, think its gonna have to be another US or such like company!) at a later stage ...
dummi

thats unfortunate the pipe work is difficult to do on that, maybe Raj would be up for the challenge
viperbl

dummi wrote:
thats unfortunate the pipe work is difficult to do on that, maybe Raj would be up for the challenge


I may even consider pipework that brings the turbo's up along the side of the engine, not out the bonnet, just in a easy to access place so I can change them without an engine pull!!!

But, just called the company, the guy I am dealing with is going to call me back in 1 hour when he gets into work, lets see what he has to say.
viperbl

Been hounding them all week, finally he said this other guy (who used to work as their welder there, and when he was working there communications was great!, but he has left and set up his own welding company) was helping him with it!!??   What, helping you call Fedex who have supposedly lost my kit??!?! WTF?! ďOh, err, do you want his numberĒ he said, ok, give me it ....

Call up this guy, and what a breath of fresh air, he explained to me that he had picked up the kit after they had called him, he is going to build the kit up to make sure everything fits as it should before shipping.

So, after weeks I finally get a straight answer ...

Anyway, here are some pics he sent me last night of the speed sensor in the Garrett housings, This will go back to two gauges that will show me the shaft speed, hopefully I should be able to see any over spooling and address it quickly...




James

Great news
viperbl

Couple of pics of the speed sensor kit ...

Gotta love gadgets  

Still can't get over the actual speed turbo's spin at!!! 160,000 RPM!!!!


MarkB

Looking good Rich. Where are you going to mount the gauges?
viperbl

MarkB wrote:
Looking good Rich. Where are you going to mount the gauges?


Cheers Mark.

I think I am gonna fit them down on my right hand side, down near the foot well for now ... reason being I don't want it to look like a scooby inside! lol

I am looking into options to channel everything through a laptop and onto my tv screen, this way its all hidden unless I turn the screen on, but also need to work out how to get warnings if they overspool, If I can't make it easy to turn the laptop on, I probably won't and then I won't know if its overspooling, which would make it pointless putting them in!

But also open to any ideas  

Other option is to maybe put them under the radio, since I am using a 1DIN one I have space underneath, so could mount them there, and maybe put some kind of over over the top so they are not in view all the time ...
GardinerG

Looking good Rich, glad to hear things are getting sorted.  Has he given you any idea as to when you will get the turbos?
viperbl

GardinerG wrote:
Looking good Rich, glad to hear things are getting sorted. †Has he given you any idea as to when you will get the turbos?


He did say today! LOL! and then said he would put it on a sat delivery, but I recon next week now, (gotta clear customs and all that first), which means I really should hold off coming over until the start of next month since I am coming over then anyways ...
ScottR

[quote="viperbl"]Still can't get over the actual speed turbo's spin at!!! 160,000 RPM!!!![quote]

Or over 200,000RPM if they overspin due to boost leaks according to Grant at AET!!!

dace

Great news Rich. Can't wait to see the end result.

Vmax when it's completed?
viperbl

dace wrote:
Vmax when it's completed?


Oh definatly! Although, I might have to fit my spare box with the shorter 6th gear to get that 200!! Not sure the long 6th gear will get me there in time!!!!!!!!!  
Doug

You'll need to do the narrow body conversion to catch me  
viperbl

Doug wrote:
You'll need to do the narrow body conversion to catch me †


hahahah, sooooooo true!! my big fat tyres are just not made for it!
quattrokid

would the gauge fit into onr of the centre cooling ducts in the dash?
viperbl

quattrokid wrote:
would the gauge fit into onr of the centre cooling ducts in the dash?


Aye, it probably would, but I am starting to mount up on gauges! I have my AFR one which is a rectangle one and also the meth injection one which again is a round 50mm one.

I guess I might have to sit down and think about this!
quattrokid

why 2 gauges? I mean wouldnt the turbos be rotating at the same speed as each other anyway? IF  1 spins faster than the other then wouldnt this mean a bank of cylinders is being fed more air?

the comment suggesting the display comes on the screen would be pretty cool... as you say you dont want to start looking like some Evo... or worst still from Back to The Future.

At the speed you want to go at YOU will be like Back to The Future LOL!!

Sounds like your gonna have one helll of an engine when your finished.
dummi

viperbl wrote:
MarkB wrote:
Looking good Rich. Where are you going to mount the gauges?


Cheers Mark.

I think I am gonna fit them down on my right hand side, down near the foot well for now ... reason being I don't want it to look like a scooby inside! lol

I am looking into options to channel everything through a laptop and onto my tv screen, this way its all hidden unless I turn the screen on, but also need to work out how to get warnings if they overspool, If I can't make it easy to turn the laptop on, I probably won't and then I won't know if its overspooling, which would make it pointless putting them in!

But also open to any ideas  

Other option is to maybe put them under the radio, since I am using a 1DIN one I have space underneath, so could mount them there, and maybe put some kind of over over the top so they are not in view all the time ...


Rich, Quattronutter has everything wired into his head unit screen from a small pc, talk to him about it
viperbl

dummi wrote:
Rich, Quattronutter has everything wired into his head unit screen from a small pc, talk to him about it


Really? I will send him a PM, might be the way forward ... cheers
viperbl

quattrokid wrote:
why 2 gauges? I mean wouldnt the turbos be rotating at the same speed as each other anyway? IF †1 spins faster than the other then wouldnt this mean a bank of cylinders is being fed more air?

the comment suggesting the display comes on the screen would be pretty cool... as you say you dont want to start looking like some Evo... or worst still from Back to The Future.

At the speed you want to go at YOU will be like Back to The Future LOL!!

Sounds like your gonna have one helll of an engine when your finished.


All the air consolidates at the plenum, so one turbo could spin faster than the other I believe, but this is more so I can see what is going on and if one (or both) spin too fast ... I can hopefully see after mapping if the turbo's are working within their spec. The more I know the better I think!

Haha, I was watching Back to the future at the weekend there! well, a little of it, just enough to think, I wonder if I could use a flux capacitor?  
ScottR

Now a gauge with two needles - one for each turbo...  that would be fancy gadget!
viperbl

I had a look at these http://www.plxdevices.com/

Really cool gauges!! BUT, you need to use their senders, so no good to me Pity they could not just recieve a 5v input from any device and deal with it ...
viperbl

Right, been talking to the welder who has the kit at his place now, he is putting it together on a test B5 engine to make sure it all builds ok...

I have confirmation from him that it will be back with the company before the end of the shipping day, today. SO, MAYBE, it will be shipped today!!!
James

Great news
quattrokid

quote Viperbl>>>Haha, I was watching Back to the future at the weekend there! well, a little of it, just enough to think, I wonder if I could use a flux capacitor? †[/quote]

sounds like you already have one.

thanks for the explanation by the way
Spanner Monkey

Slowly but surely.

Summer's nearly gone, Viperbl!
viperbl

Spanner Monkey wrote:
Summer's nearly gone, Viperbl!


Yep, and guess what, no tracking number last night ...

... and nearly another week past again  
Cornishmoocher

Just reading about the turbo speeds posted earlier,  I had †a turbo chuck a blade on a ships engine, that only span up at 40k rpm and it was like someone had stuffed the thing full of semtex and set it off, mind you, the diameter of the the turbo housing was 1.8 meters........

sounds like a great project taking place.

cheers Alex
dummi

Cornishmoocher wrote:
Just reading about the turbo speeds posted earlier, †I had †a turbo chuck a blade on a ships engine, that only span up at 40k rpm and it was like someone had stuffed the thing full of semtex and set it off, mind you, the diameter of the the turbo housing was 1.8 meters........

sounds like a great project taking place.

cheers Alex



eh are you suprised??
Cornishmoocher

Actually I was surprised, i was litterally reduced to scraping the bits up, and found a part of the housing on the walkway entrance to the engineroom, 25 feet verticaly above the engine. A 3/8 steel checkerplate deck plate looked like a cheesegrater!
I think shocked was a better discription, we were all just happy that no one was in the engineroom at the time.
dummi

sounds terrifying , sorry viperbl we'll stop now
viperbl

That sounds pretty extreme!!!!!!!!!

And no worries guys, just talk amongst yourselves , not much going on with this build right now!!!! Again, I was told it would be shipped yesterday, guess what, no tracking number so can only assume it was not...
dummi

Shame you don't have a contact over there who could go find out whats actually happening if anything
viperbl

dummi wrote:
Shame you don't have a contact over there who could go find out whats actually happening if anything


That would be good, better still if they work in the underworld  

Well, the welder emailed me at 5am (middnight their time) to let me know that he had finished the kit and was dropping it back off with the company tomorrow morning first thing for shipping ...

What could possibly hold it up now?!?!?!

In any case, I am going to be in London on the week commencing of the 31st of June to build the engine regardless. I will not be spending Mon night in London but tue/wed/thu if anyone fancies a pint (although, I dare say I might be working some late nights!)
S4

What company are you using.....cant be someone like vast?  I hope they give you a little discount....or some freebies.



Darren
viperbl

S4 wrote:
What company are you using.....cant be someone like vast? †I hope they give you a little discount....or some freebies.
Darren


Its not VAST, i've delt with Prince and Mike, helpful guys...

Not going to name and shame, but anyone looking back through my posts could probably work it out ...

or just PM me
viperbl

Turbo's are in the air crossing the pond as we speak!! I may miss them since I am leaving here tomorrow, but FedEx said they would reroute them to London if they don't get here in time, so, all going well, I should have them to build a complete engine next week
Adam

Finmgers crossed then Rich!
GardinerG

Good luck Rich, hope it all works out!  G
viperbl

Thanks Guys!

Couple of pics as I load up the 306!

Who needs lowering springs when you have an RS4 engine to put in the boot!



dace

Do you want me to exchange those rusty discs for you.....
viperbl

dace wrote:
Do you want me to exchange those rusty discs for you.....


No thanks, mine are still round  
Spanner Monkey

0-60 in six months. One of the slowest cars i know!
Spanner Monkey

"The Stig stands no chance!"
viperbl

Got down to London, after battling with the traffic!

Not much completed today, chewed the fat a little and then set about setting the piston rings to the correct spacing...

Not going to make it in tomorrow, but Wednesdays job is lined up to start with plastigage the main bearings. Will get some pics up on Wednesday as the build continues.
s4woody

rick where abouts in london are you..be good to meet up...
viperbl

s4woody wrote:
rick where abouts in london are you..be good to meet up...


Over at a garage in watford ... are you local? Not sure I am gonna have much spare time, maybe thu evening, but, you could always pop over to the garage, sure it won't be a prob ...
s4woody

im in sarf london..bit of a slap but if i get the chance i,ll let you know...
viperbl

s4woody wrote:
im in sarf london..bit of a slap but if i get the chance i,ll let you know...


Yeah, just a little, considering there is no de restricted mountain road between south and north London  
Spanner Monkey

viperbl wrote:
Got down to London, after battling with the traffic!

Not much completed today, chewed the fat a little and then set about setting the piston rings to the correct spacing...

Not going to make it in tomorrow, but Wednesdays job is lined up to start with plastigage the main bearings. Will get some pics up on Wednesday as the build continues.


Sounds of though you've got all technical overnight! Guess someone actually gave your a brief as to what you've got to do? lol
dummi

Spanner Monkey wrote:
viperbl wrote:
Got down to London, after battling with the traffic!

Not much completed today, chewed the fat a little and then set about setting the piston rings to the correct spacing...

Not going to make it in tomorrow, but Wednesdays job is lined up to start with plastigage the main bearings. Will get some pics up on Wednesday as the build continues.


Sounds of though you've got all technical overnight! Guess someone actually gave your a brief as to what you've got to do? lol


haha they got him there, he's got to take it in or he'll never leave with his engine!
viperbl

Spanner Monkey wrote:
Sounds of though you've got all technical overnight! Guess someone actually gave your a brief as to what you've got to do? lol


dummi wrote:
haha they got him there, he's got to take it in or he'll never leave with his engine!


He told me I will know every nut and bolt in this engine before I leave, and he did not smile when he told me this, I think he is serious  
dummi

don't doubt it mate , all 1000 of them )
GardinerG

...there will be a test before you are allowed to leave.
viperbl

GardinerG wrote:
...there will be a test before you are allowed to leave.


No worries, I know all about brew making now - the guys at work will be pleased to hear when I get back
S4

ahhhhhh plastigage, back in the day I saw someone, whack it in the mains and turn it over.... it wan nice.


should have read this http://www.amazon.co.uk/Engine-Bu...Handbook-Tim-Monroe/dp/1557882452





Darren
viperbl

So, I am back from London!

Unfortunately, I do not have a finished engine, time got the better of us, and I ended up forgetting a couple of parts! DOH!

But, I have learnt how to plastigage, and we have built the whole bottom end and checked all limits and tolerances, everything came back right in the middle of the Audi recommended tolerances so I am happy that so far everything is perfect, just as it should be!

Some pictures then?

Pauter rods before connecting to Pistons



All connected up and ready to be inserted, and piston rings are not easy to put on! lol


After plastergauging the main bearings (Who can tell me what is missing in this picture then! The parts I forgot are missing from the pic ...



Crank and rods all in place ...





Bit of a pain, but the raceware hi tensile steel bolts did not fit correct, we had to machine the sump block down at some points to make it fit, then, realised that the oil pump was not going to fit at all, so had to take those bolts out and get an engineering firm (next door to us!) to grind them down for us ...



and now, for some pics of my nice shiney ported and polished 2.4 head










So, next week I hope to start the engine from a fresh again in my garage and go for full build ... I need a water pump gasket tho, anyone got one? I bet audi have them on back order!!

Oh, and turbo's? well, FedEx have lost them!! lol! but I have every confidence they will find them  
dummi

good job Rich your almost there

lol @ fedex - your turbo's being delivered are becoming the longest running joke on audisrs hope they get them to you soon
Doug

i had a set of wheels lost from the US in january - they are still waiting to "find" or get the insurance from them.
viperbl

And the job begins!!!

Here is a nice pic of the block on my engine stand...



Get the bearings greased up  


Inserting the pistons...


and some time later ... we have 6 pistons and rods in and all torque up to the crank




Then, the first problem, I was missing an O ring for the oil pipes that connect the oil pump, and, I also managed to nik the o ring that connect the oil pump to the crank ...




Also decided I should replace the rear oil seal as it was not looking brand new and I was not sure if there is meant to be a spring in the seal, as this one does not have it, maybe it has dropped off at some point ???


So, stop stop stop, again, until I get the rest of the stuff!!

I might try and put the heads on tomorrow...
buzzard

keep the faith rich!!!
its looking fantastic now its coming together.
it will be all worth it.
viperbl

I HAVE TURBOS!!!!!!!!!!!!

Turbo's are disassembled tho, so looks like I have my work cut out to assemble these as well!!! I will get some pics later ...
dummi

haha are you kidding, if you got them in pieces you need to send them off to be balanced make sure they haven't been fcked up
viperbl

dummi wrote:
haha are you kidding, if you got them in pieces you need to send them off to be balanced make sure they haven't been fcked up


ARGGGGGGG FFSSSSSSSSSSSSSSSSSSSS!

Any recommendations ??
S4

Really nice clear pictures, keep up the good work.

Darren
viperbl

S4 wrote:
Really nice clear pictures, keep up the good work


Cheers.

My brother is over soon, he is a photographer, so look out for some really cool pics!!!!
S4

you are Joking about the Turbos being in bits?  this cant be right,  I bet you paid the going rate to.

What are there comments on this?   why would they do it?


credit card/paypal claw back time I would say. goods not as described.



Darren
dummi

i always got a local place in our area to do it, 'the turbo centre' very good all the shops in the surrounding counties send the turbo's to them... but since you have to send them out maybe somewhere else is better?  they have really done a duff job doing the kit,  under normal circumstances I'd say send it back get your money back but we don't need  666 epic turbo journey part 2,3,4... lol... sorry it is awful service by a country that pride themselves on customer service... get some pics up so we can see what they sent you, maybe it isn't as bad as it looks!
ScottR

There must be plenty of Garrett specialists in the UK.  

Who is that's built the monster Garrett turbo for Project Satanschild?  Was it Turbo Technics?  Perhaps a good place to start.  

Can't understand why they were sent disassembled though, defo worth a partial refund.
viperbl

Now I am pi$$ed ...

The bloody compressors where not packed well, some of the sides where right next to the cardboard wall, others next to the housing etc ... See all the bent and chipped fins ...







Doug

thats not good rich.
viperbl

Do you recon these are repairable or is it a new unit??????
grizz

Gutted for u bud.
grizz

Don't think you'll need a new core but would need new compressor wheels .
Doug

send them back.
grizz

Who did you get them off rich ??
viperbl

I guess I will speak to AET tomorrow and get advice ... problem is sending them back to Canada (Vag motorsport) is that it took 4 months to get them in the first place!!!!
dace

That is a total disgrace. So sorry to see those pics Rich, after such a long wait.

Hope you get it sorted!
kies4

c**ts all the time making them then pack em so badly, u'd expect separate boxes at least............ idiots

turbo technics may be able to help with wheels, build and balancing. They worked on garrets I had in the past could save you a further hold ups but not bank balance
davs4

That is seriously bad engineering.. you could try these guys out dealt with them before and they are serious turbo nutters. They work up the road from me and are really helpfull. http://owendevelopments.co.uk/turbos/garrett-performance-centre.asp
dummi

unbelievable

Rich if i were you, keep the pipework and send the turbo's back and get some others from a reliable source, lucky your garrett are not one off's and easy to get off the shelf
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