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audimad100

my Loba 530 conversion

well im going to get a head start this weekend, going to get the CX Racing FMIC fitted prior to my engine pull on Wednesday.

still a couple of minor bits to get but pretty much there, clutch release bearing, oil filter and im toying with the idea of a pair of Yamaha or Kawasaki radiator fans to help with cooling after loosing my front mounted electric fan.

me old mate reg is on stand by and has pre-booked the nice new shiny ramp in the car club for 4 days of S4 loving

most of you will have seen this little lot but i thought i would stick it up in this thread as it all starts here.




Reconditioned RS4 KO4 turbos upgraded to Loba's 530 spec
CX Racing FMIC Kit
Seimenns Deka 660cc injectors
Bosche 044 motorsport fuel pump in a modified RS4 Basket
XS KO4 Turbo pipes
650bhp/ 650lbsft rated padle clutch/ RS4 Pressure Plate
new cambelt kit
new water  pump and thermostat
front end lower steel water pipe
full set of Silicone hoses
genuine Audi turbo gasket/washer kit

will try to remember to take plenty of pictures of the build to try and help out anyone else thinking of going down this route
ScottR

Nice one. Us DIY'ers need to stick together!
audimad100

for sure, hows yours going Scott, your build has given me some real good pointers for things to look out for. plus its only about 5-6 weeks ago that we did Reg's so still fairly fresh in our minds. only thing is i have a 4 day window to complete else the Wife will be bending my ear for loosing her car
ScottR

Hoping to get my LWFW, clutch and cambelt done this weekend, along with fitting new engine and gearbox mounts if all goes to plan. As always, I'll be sure to highlight the problems and what I've done to get round them.
audimad100

  i know what you mean, im hoping that i dont find anything to drastic. the car pulls really strong and doesn't use any oil (1 litre in 5425miles) mechanically she is sound just a noisy rear wheel bearing which i will try to do while we have it on the ramp but if i dont get it done as time is short it will wait for the following weekend
MarkB

Moved to projects and builds.

Good luck, keep us updated
marc1

Looking forward to watching this project. Good luck with it all.
Rasss-4

Yep same here, keeping an eye on this build!  
mikey-s

Good luck with the build.  You want it done in four days eh?.. You're gonna be busy!
audimad100

cheers Mikey, yeah going to be full on for sure. but i reckon the Cornish will have it nailed    
Matt_D

I think a pair of rad fans are not needed as the main viscous fan copes ok
audimad100

cheers Matt
tomorrow will be day 1 really as im going to get the front mount fitted. now i may play with the pipework as i want to retain my side grills with the pipework tucked in out of the way.
will take some pics of how it goes
Rasss-4

9:03am - Your should be about half way now!!!
supersi

So how you got on today ?
audimad100

well been a good day,
pulled the bumper and made a start, i as many have done used the original fan bracket to mount the intercooler




i welded a couple of new brackets  on after i cleaned off the originals


bit of time messing about with setting the intercooler up


there  is a bit of cutting out in the front panel under the headlights to get the pipewok to sit right, you can also see where i have modded the airbox




going to get the bumper finished off tomorrow, would have been done today but friends turned up

supersi

Well its a start dave well done....Did you not get the water injection kit?
will1981

Well done Dave    Many pints well deserved!!!
audimad100

supersi wrote:
Well its a start dave well done....Did you not get the water injection kit?



No i havent got the WM kit yet but i will be
supersi

audimad100 wrote:
supersi wrote:
Well its a start dave well done....Did you not get the water injection kit?



No i havent got the WM kit yet but i will be


Mite be worth working out placement and  taping welding the injector points now ? Maybe
Matt_D

Looking good

Just a stupid question whats the black bag hanging in front of the rad ?
audimad100

its fairly easy to mount the injectors for the WM kit with everything in place, i have a nice spot lined up for the pump already

Matt the black bag was fitted by the previous owner, there is a washer jet nozzle fitted along side the number plate well just below which is piped up to this with a switch in the car, when you hit the switch you get 2 jets of water spraying forward of the car ideal at traffic lights      
pjbRs

audimad100 wrote:
its fairly easy to mount the injectors for the WM kit with everything in place, i have a nice spot lined up for the pump already

Matt the black bag was fitted by the previous owner, there is a washer jet nozzle fitted along side the number plate well just below which is piped up to this with a switch in the car, when you hit the switch you get 2 jets of water spraying forward of the car ideal at traffic lights



Nice mod very James bond. Squirting numptys with hot water

Fair play to you for doing all this yourself.  
audimad100

the big part kicks off on Thursday with the engine pull, already spied a problem, some leaky joints (rusty old jubilee clips) on the power steering pipes
audimad100

quick update,
got the bumper trimmed out, i have taken quite a few pics for anyone wanting to do this, there is a fair bit of cutting out on the crash bar. then you have the trial fit trim a bit more fit again oh trim that bit off      



















bumper will have to stay like this until i have a bit more time to tweak the pipework
supersi

You been out for a test drive?
Matt_D

pjbs wrote:
audimad100 wrote:
its fairly easy to mount the injectors for the WM kit with everything in place, i have a nice spot lined up for the pump already

Matt the black bag was fitted by the previous owner, there is a washer jet nozzle fitted along side the number plate well just below which is piped up to this with a switch in the car, when you hit the switch you get 2 jets of water spraying forward of the car ideal at traffic lights



Nice mod very James bond. Squirting numptys with hot water


WTF thats weird, i can understand spraying water on the SMIC's but not at some random person walking in front of the car
think_or_thwim

Nice one mucker!!!
audimad100

think_or_thwim wrote:
Nice one mucker!!!


Cheers Reg, we still on for thursday, if you can come to my place and drive Ethel over the car club i can bring the van across
think_or_thwim

no snags, time?
audimad100

best have an early start, got lots to do        how does 8.30 at my place sound, i will sort a McDonalds on the way got to have a cuppa before we start
audimad100

supersi wrote:
You been out for a test drive?


yes running nice, had a slight bit of hesitation first going away. i filled up with fuel and when i started up the car again the hesitation had gone, i think the ECU has learnt that i have more cooler air now. does feel stronger and pulls better on my local runway. cant wait now to get the turbos fitted and get the map sorted
s4balljoint

ScottR wrote:
Nice one. Us DIY'ers need to stick together!

too right    
DavidT

This is shaping up to be a super build thread Dave. Keep the posts and pics coming
audimad100

will do, the pull will be on thursday morning. Reg and Si are primmed and ready for action
think_or_thwim

Been in today. Swept, mopped and tidied. All ready to go. Need to resupply the yorkshire tea and chock bics and were off. Failed bleeding brakes today. Shite tool that air sucking gun thingy. Trad method i think will do it. New pipes on redy... Thurs it is then
supersi

ill bring my bleeding kit reg
audimad100

i'll get mine on the ramp and make a start, you get the brakes sorted. i will re-stock the tea and biccies. do you boys want me to do a curry for lunch
supersi

audimad100 wrote:
i'll get mine on the ramp and make a start, you get the brakes sorted. i will re-stock the tea and biccies. do you boys want me to do a curry for lunch


curry sounds good  
audimad100

will cook a big pot of Chicken curry to fuel the workers tomorrow night
audimad100

right day one has finished.
got my A team along for the ride Reggie the jibba jabba, and Si is that my phone hang on lets get a pic

if anyone is going to pull there own engine make sure that you pull out the drive shafts, we managed to get Reg's engine out with them in situ but mine werent having any of it which cost us a few hours of try this try that, and swear at the Blue Bitch
1st off drop the fluids from the car, we did the rad, engine oil, gearbox oil and diff oil.


followed by removing the front panel, you need to undo the wiring plugs next to the power steering tank, i would mark all of your bolts that hold the front panel in place with a pen so to aid lining up the panel later. leave the lights and rad in place just remove the hose's on the rad


next you need to sort the wiring, you need to remove the ECU and unplug all the wiring from inside the box. this is the complete wiring harness for the engine and this will come out when you pull the motor.


you need to remove the 2 wiring mounts on the bulkhead and disconnect the Lambda sensor plugs. you will also need to remove the earth straps and wiring harness that runs across the drivers side chassis leg, part of this is a main battery lead. just remove the rubber gromit in the bulkhead and this will pull through




when you think you have everything undone, check as there is the heater hoses on the rear of the block and the clutch slave cylinder to sort, i ditched the gas out of my AC system as its easier that pulling the pump off the engine, just be careful when you pull the engine out as the fridge pipes from the pump are very close to the chassis leg. you need a spline set for the inner CV joints on the gearbox and a set of allen key style sockets for the prop shaft.
have a trolley jack under the rear of the gearbox to help control the angle when you start to pull the engine forward.

i told Reg i had dropped 10p and he was in there like a terrier down a rabbit hole

im sure i have forgotten loads but hay ho.


once we had the motor out it was pull off the turbos to find them in really good nick, only thing is a very small hairline crack next to each waste gate plug.



then it was gearbox off ready for tomorrow and starting to put it back together.



thanks for you help today guys and i hope the Curry did the job
supersi

curry was spot on dave was a good day, ive just got in...ill be back tomorrow 9-10am
s4marsh

Awesome work, Is this going to be in the running for quickest turbo swap?
Rasss-4

Love the pic of the front end on its own...looks sad and lonely waiting to be attatched to this fast becoming Beast again  

This is all happening pretty sharpish hey  
audimad100

was good Si, yours and Reg's help has been invaluable today.
im not trying to beat anyone with a turbo swap, but i am limited to 4 days of ramp time and i have a couple of other jobs to complete as well so it is fairly fast moving    
ScottR

Well done boys.  It's took me 3 months to get that far!
audimad100

ScottR wrote:
Well done boys. †It's took me 3 months to get that far!


       we are getting good as this now after doing Reg's a month or so ago
S4Player

Don't jinx it commentators curse and all that
audimad100

    you are dead right
supersi



get the zorst off was first job
















draining the fuilds






cracking the drive shafts from the gearbox








mad dangerous dave




working on a ford  
















audimad100

great pics Si, i think i need to get my hair cut    
supersi

audimad100 wrote:
great pics Si, i think i need to get my hair cut



ive got hundreds mate ill copy them all for you
audimad100

ideal, have you put that belt in your van yet
is there news from Darius, i reckon a couple of months with the work load i have
supersi

ill leave a note for my self to remember the belt   not managed to talk to D yet  


i got a few shots of your  turbos here









audimad100

will look even better tomorrow
Cornishmoocher

fantastic Dave!!
Hope to catch up with all you boys soon.
think_or_thwim

"I just make the tea, me!!"

Was a great day, plenty of hurdles to overcome, snapped tools and head scratching.  Got there in the end.  Ready for day 2!

Rule No 1, "Take the frigging shafts out".  How we got Suzi out without it must have been luck, but Ethel was having none of it!

quite a few Guys turned up and asked, "Whats up with it then?".
"Nowt mate, running like a dream" "we just love doing stuff on Audis and its been a few weeks now since we pulled an engine"

Fcuking nutters was the collective response i think!!  True though!

Lets crack on then!!!!!
mikey-s

think_or_thwim wrote:
quite a few Guys turned up and asked, "Whats up with it then?".
"Nowt mate, running like a dream" "we just love doing stuff on Audis and its been a few weeks now since we pulled an engine"

Fcuking nutters was the collective response i think!! †True though!


I've had that response many a time!  
philws4

Well done guy's a good first day
Does the gearbox oil have to be emptied when pulling the engine? I am guessing that it looses it's oil when the driveshafts are removed!
think_or_thwim

Loose a little Transmission fluid when disconnecting the Oil Cooler at the front. When splitting the gearbox, few more pipes need disconnecting, so again, more fluid loss.
Lots more come to come when dropping the gearbox drain plug so worth replacing it.
Drive shafts are dry connected to the gearbox, inc the rear propshaft (apart from grease on the joint)
audimad100

Cornishmoocher wrote:
fantastic Dave!!
Hope to catch up with all you boys soon.


think i will need a touch of the old mooch refrigeration fluid to top up my system so the wife can stay cold as hell    
audimad100

ok day 2  had a real topsy tervey theme.
got the go ahead from some real good guys in hamburg to fit there down pipes. now i have seen plenty of stuff up on the forum regarding the state of the welds, oh thats a massive lip inside but im telling you what i saw i wanted straight away. the Loba downpipes are fecking first class.
now these would be fitted to the engine ready to slot in place tomorrow, but then ethel had a change of heart, she didnt want to give up her Lambda sensors and that mixed with a fooked EGT and a WA*ked Aux belt tensioner put the mockers on me reaching the 500 club. got to say a big thank you to Darius and Micheal for you help today and sorry for having to pull out at the last minute.






right i have to apologise as i have been really slack on the pics today.
we cracked on first thing me and me old mates, got the clutch fitted, turbos bolted on with all the pipework. noticed we had an issue with an EGT so ordered one up for tomorrow although we have Gaz on board tomorrow and if he cant fix it it aint worth fecking about with
as said my DP's were not going to give up the Lambdas so the original DP's had to go back on.





so its cam belt, water pump and thermostat tomorrow after we drop the engine back in place.
a very good friend of mine said he had a cam belt locking bar that i could have that fitted the Audi V6 range. this fitted the 2.6 and 2.8 engines. if you look you can see how much bigger the 2.7 motor is.




i had to get this welded up before Darts tonight so this is ready for first use tomorrow.
if you are in the cornwall area and need the use of the cam locking tool for the 2.7 V6 let me know

will try to take a few more pics tomorrow
Dave
mikey-s

That tool will be for the earlier non-30v motors 2.6 & 2.8.

The 30v tool fits all 2.4, 2.7 & 2.8 engines.

Nice piece of improvisation!  
Alps

Mate I'm loving reading this thread

Almost to the finish line?
supersi

few pics from day two






new clutch fitted




Reg fitting new oil pipe





Unwrapping the upgraded and refurbed KO4 ( lo530 )















reg had to modify †the home made fuel pump fitting tool







its a tad short, †so daves turn on the cutter














---------------------------------------------------------------------------------


A Few dave didnt want shown † State of this cabin filter 10 years old






nothing hear too see










taps it out and places backs in.... and says good for another 10 year, tight these cornish lot
davs4

Coming on well    

Is that XG 279 in the tin I see  
think_or_thwim

XG276 I think. !!!  Dont know what thats doing there, think we used the tin for adding some weight to hold some stuff together that was being glued, err, err or something like that lol!!

Think some XG250 (Silicone grease) may be spotted as well.  Its Not flipping KY either but kept turning up all the time!!!
audimad100

      bunch of P*ss takers, and everytime there is a spanner that needs picking up Reg is right there with the silicone grease    

Right day 3 is over and here is progress today.
we started off by stripping all the front of the engine down to replace the Water pump, cambelt and Thermostat.

we then replaced all the vital bits that needed doing, this included a new Aux belt tensioner as the bearing on mine sounded as though it was full of gravel






it was then time for a bit of good fortune we had a knackered thread on one of the EGT sensors which was going to cost me a couple of hundred quid but Reg and Gaz the Legend came to the rescue
ok we are ready lets get the motor back in, im glad it went in easier than it came out


the Trolley Jack under the gearbox is a must for getting it in over the subframe etc


then up in the air to get the Zorst back in place, connect the prop shaft back up and tighten up all the mounts. while we had her up in the air we re-filled the gearbox and diff oils



time to start putting the front end back together, i know i have red hoses before i get any stick, they are much thicker than the OEM ones and they were very kindly donated to the Build by Alecs



once all the pipework was on it was time for a pressure test    Whats that Bang noise i keep hearing and why is Reg jumping 6ft in the air    



all in all another good day, all the fluids are in and just a matter of getting over the issue of the 044 pump in the RS basket not fitting in the tank as its 1" taller than the S4 pump. time for a touch more Cornish magic failing that a big Hammer. Reg wrote i woz ere on the cover of Ethels tank she took this to heart and spat fuel all over him not once but 4 times    

oh yeah besides making a fine cup of Tea Reg has demonstrated his cleaning prowess, would make someone a bloody good wife me thinks
 


last day tomorrow  
think_or_thwim

" I just make the tea me!"

Is that FMIC skew wiff or is it just that the ramp is not true!  

Battery is on charge and cant wait for the key to be turned again! Hope nothing untoward is revealed on the Vagcom either.

May get to sort Suzis brakes out finally and the Noggys will be back on the Cornish roads!

Another great day and love working on S4's
audimad100

it was a good day for sure Reg, will be good to get them back on the road together again. think we need to be ready for the meet end of May.

you and Gaz the legend saved my bacon this morning so will have to sort out a night where we can drink Rogers EGT money
think_or_thwim

Just remembered, need to get some Salmon Pink paint from B&Q sometime, lol!!!!

Had some top banter last couple of days. Difficult to switch off when I get home and get grief from the Mrs for taking the p**s all the time!! Doh!!
davs4

Ye those XG tins come in rather handy for ballast  

Last day will be worth it  
pjbRs

Big up the cornish massive

Great team work guys.
audimad100

yeah it has been a big team effort, we all try to help each other out down here and its all down to SRS as i would'nt have met these guys unless i had my S4 and joined the forum.

we have a great bunch of guys down here running these cars and if someone has a problem or is going to tackle a big job then we all rally round, Supersi travelled down from Bude to Helston (must be 60-70 each way) 2 days on the trot    fortunately Reg's brother-in-law Gaz the Legend is there to help out and if he cant fix it then it is fooked
Rasss-4

I salute you guys, looks like you make a cracking team!
I can see it now,Mclarens very own future Cornish pit men...  
1 more day hey....buzzing!!!!
audimad100

nerve racking start as we have to fire the old girl up  also got a problem with the fuel pump not slotting into the tank so will have a play with that first thing.
its amazing what the Cornish will do if you say theres a horse and jockey pastie for lunch
gizmo

It took me six months to do what you've done over the last few days!!  Top work, should get some great results.
audimad100

right day 4
yep this wont take long we thought, drop in the pump, top up the fluids double check everything and turn the key.
how wrong we were, the pump was a nightmare to fit, but we stuck with it and finally ready to go.
left the ignition amplifiers disconnected so we could wind the engine over and get the oil pressure up before starting her.
once we had done this we connected back up and turned the key, NOTHING she wasnt having any of it.
checked back through everything and finally realized the pump wasn't working, we have had to put in the S4 pump and she is running. we got her up to temperature and all was good, well that was until she spat the bottom hose off the rad and ditched all the water, no biggy just open the bonnet and sort it out. DID ANYONE RE_FIT THE BONNET CABLE ahhhhhhhh S*it another 45mins fecking about with her before we got it sorted
im still on the S4 injectors at the moment until Rich can get a safe map to me or i can geta date for the mapping and then change them over then.
got to say with the S4 pump and injectors and on my original map the car pulls extremely well, i have not given it a real hard WOT run but i can tell the car is much better.
we now need the Viper touch to finish off all our hard work.

massive thanks to Reg, Gaz and Si for all your help over the last 4 days, it has been a laugh. plenty of P*ss taking normally at my expense but i couldn't have done it without your help guys †
pjbRs

Good work guys.
think_or_thwim

They think its all over, it is now!

Unbelievable, the workshop doesnt have an Audi part in sight, even after two Loba 530 conversions.

Enjoyed every minute. top engineering, mean feats and difficult situations to overcome but we got there and saved £1000's.

Thanks SRS for the chance to meet fellow enthusiasts and to undertake some quality Audi ownership moments... †Oh and Gaz proved a couple of times what a legend he is!

Piss take phot required!


Next meet in May, which I wont be missing for the world. †Hope to see all the old faces and maybe some new faces as we will be quite far East (Liskeard area).

Big thumbs up from me
mikey-s

What pump was it??  I had a polarity problem on a Walbro I used a while back.  Switched the polarity and it worked fine.
audimad100

Reg that is a class shot of Gaz in his pulling machine and yes he is a legend.

Mikey the pump is an 044 motorsport and we tried it both ways across the battery and there was no go
addyboult

hell of a job there like dave, wont be at the may meet to see the results, any figures to go on?
audimad100

not at the Moment but we (Reg and Me) are trying to arrange a mapping session with Rich ( Viper) early May up at Unit 20 then a stint on the rollers. we will then have some numbers to show. mean while i got to get her Mot'd and get the cat bypass pipes made up with new flexi's as mine are a little tender from being dragged over speed bumps
think_or_thwim

Sisters!


Subtle differences but the same setup!
pjbRs

I may move down to Cornwall

k04'S please chaps.  
think_or_thwim

LOBA 530's, them there K04s are old hat now, we going for the future (Garlic bread).

As we always say, always on for an impromptu meet like today!!!

Went to Truro for a code read on my Stereo (Lost the fcuker) and thought I'd do a quick tour of Cornwall!!  Via St Ives &, Penzance!

Plenty of room for more R & S's down here!!
pjbRs

I'll change that order to Lobas then. A very nice pair of Avants there, well done lads.
davs4

Looking good I will be down this weekend if your near Fraddon?
think_or_thwim

Me and Dave are fitting my Turbo gauge and doing some boost checking but reckon we could blast up to Starbucks @ Chiverton Cross for a minimeet!! What time?
davs4

Whenever, need an excuse to get away from the outlaws  
audimad100

if we have an early start on your gauge Reg i might be able to sneak away for a quick cup of TEA mmmmmmmmmmmmm
cant be long as the wife is feeling like she is coming second best to these cars, i did say and your point is  
thats when i got the Look, you know THAT LOOK
audimad100

right been up North to visit the Guys at Unit 20 and the dark lord Rich from Viper Tuning.
had some issues with blowing a fuel pump, rescued by Grizz on the flatbed truck
a little while later we were on the rollers for some finishing touches to the new map

Link


second run was the best but i have some high pressure issues that need sorting before Rich can finish the map, boost spikes which Rich was unable to correct. boost was strong to 1.2bar but no control and was spiking to 1.8bar
the graphs below are all wheel horse power and torque







Rich dailed back the boost to keep the car safe, i can still feel the power and the potentual just need to do a bit more work before she is sorted
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