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big mac

my s4 build

this week i shall mostly be upgrading my s4 saloon



the car no longer wears the bentleys but now has a set of bbs ch 8.5x18 et 35

the planned spec is:

pj k04's
cx racing fmic
devils own water/meth injection with controller
034 motorsport street density engine mounts
xs power turbo back de cat exhaust system
630cc injectors
rs4 rear brake set up

already fitted
bilstein pps9
apr bi pipe
autobahn 88 silicone hoses
esp dts
cayenne front calipers and rs4 discs

before i start the build must say thank you to a few member and top fella i have met and have parted with some of these bits for my build in no particular order
virdee for rear brakes and suspension diamond fella
davs4 for brakes and some great advise
doms4 for the water injection and the awesome homebuild bracket
will1981 for the oil cooler and injectors also for some good advis e and a bit of banter
graham at camberley audi for sorting me out gaskets and a few other odds and ends very quickly top man
and lastly philws4 for the turbos and being a generally great bloke and friend
wish me luck guys all comments welcome and i will try to keep the thread updated over the next week

mods i relise this is probably the wrong section so please feel free to move  
philws4

Wishing you all the best Ian and look forward to following your build thread. Spec is fairly similar to mine so will be very interested in the all important numbers
Virdee

Ian - hope your well

Looking forward to this!

No worries on the help. If I can be of any help in the future, do let me know.

For now I'll grab the popcorn!
mikey-s

Good luck mate, don't forget to take lots of photos!
noodles

Good luck mate,hope to be doing that kind of build myself one day,look forward to some pics and ideas.
MathiasS

Good luck !!
ddidds

good luck and enjoy it !
big mac

mikey-s wrote:
Good luck mate, don't forget to take lots of photos!

Sorry mickey forgot you off the list
Mickey for the de downpipes and advise and watching his awesome rs going round the ring will hopefully keep the photos coming and updated if there is anyone else I forgot to thank please consider yourself thanked
mikey-s

Lol, that wasn't a hint mate, just wishing you a problem free build!
will1981

Good luck Ian, 460+ without a doubt  

Don't forget to paint it a decent colour too    
big mac

will1981 wrote:
Good luck Ian, 460+ without a doubt  

Don't forget to paint it a decent colour too  

 


Inter cooler pipes are being powder coated yellow lol as it adds 20 HP
Magic

I think you forgot to add me in your thanks - BITCH.

Thanks Magic for inspiring me to get more power after you thrashed my ass in your S4 will do...
big mac

Magic wrote:
I think you forgot to add me in your thanks - BITCH.

Thanks Magic for inspiring me to get more power after you thrashed my ass in your S4 will do...

Thanks to the gayest detailer in town for his donation of humour and for keeping halfords in business you are a legend and yellow is the way forward ;p and also employing me part time to fund my project x
calibra_se8

Should be a nice spec when you're finished, I'm in the middle of my build right now also, good luck
Rotta

as said by other members wishing your a gremlin free upgrade!!
MarkB

Re: my s4 build

big mac wrote:

mods i relise this is probably the wrong section so please feel free to move  


I assume you'd like this in the Projects and Builds forum? Consider it done and good luck  
davs4

Should be good Ian........... took your time though  
Gil

Hi b,m. Even though I'm watching you do this build I couldn't resist seeing what you wright up about it
Gil

Write even
big mac

ok so today my aim was to get the engine and box out of the car
big thanks to graham durbridge at camberley audi that did me a superb deal this morning on the gaskets and other odds and ends i'd ordered
also have to say a big thanks to my mate at infinit automotive in bracknell for the use of the workshop and helping hand big thanks gil  

so started about 10.30 this morning front end of disconnected the air con pas clutch coolant hoses and wiring loom then underneath for exhausts driveshafts and propshaft and by 5.30-6ish it was all out on the floor this was with a few interuption during the day and helping one of the other guys on the yard so i am well pleased as my goal was acheived with not to much hassle

tommorrow i will seperate the box to inspect the clutch and flywheel which is supposed to be an ally lightweight one have an luk rs4 clutch sat at the workshop if needed as one again was supposed to have been fitted just before i bought the car some 14000 miles ago









right lets see who got a good eye and can tell me what is different about gil's caddy pick up this is being built for our nurburg trip in september and is being fitted with a 20vt so whos got the keen eye????
will1981

Jesus, mine came out in 4hrs.....the gas axe is a quality tool  

Good work Ian, but the yellow IC pipes are very gay  

GTI-6 alloy on the rear, what's going on there?
big mac

will1981 wrote:
Jesus, mine came out in 4hrs.....the gas axe is a quality tool  

Good work Ian, but the yellow IC pipes are very gay  

GTI-6 alloy on the rear, what's going on there?


its only gay if you push back apparently will  

well spotted with the wheels we have got rid of the leaf springs and gil has fabbed a 205 gti rear beam in so we are hoping this will be one quick well handling caddy    
will1981

Or swallow......

Might even cock its rear wheel...........
philws4

Good first day Ian,well done

Well worth checking the metal water pipe that goes across the front of the engine behind the snub mount while your at it Ian as mine was all but rusted through

It's not that bad a job really is it
audimad100

great start Ian good to see another car getting the personal touch.
has your mate gone for the Peugeot torsion bar suspension for the slammed look
big mac

audimad100 wrote:
great start Ian good to see another car getting the personal touch.
has your mate gone for the Peugeot torsion bar suspension for the slammed look

Not really for looks he wants it to handle will have around 250 HP and is going to the ring in September he ran a red top nova last year and put in14 laps all around 9.30-9.40 but like the challenge souls be good we all know how well a apt handles
big mac

philws4 wrote:
Good first day Ian,well done

Well worth checking the metal water pipe that goes across the front of the engine behind the snub mount while your at it Ian as mine was all but rusted through

It's not that bad a job really is it

Cheers Phil no issues today and I will check that pipe more updates tommorrow but it all looks good from what we have seen today
big mac

Re: my s4 build

MarkB wrote:
big mac wrote:

mods i relise this is probably the wrong section so please feel free to move  


I assume you'd like this in the Projects and Builds forum? Consider it done and good luck  

Cheers mark top man
Magic

And make sure you clean that engine bay up you grease monkey....lol
Gil

Magic wrote:
And make sure you clean that engine bay up you grease monkey....lol


maybe you could come and do it for him.....he's looking a little stressed out today
big mac

today i have removed the gearbox clutch and flywheel from the engine for inspection everything looks good gona fitt an rs4 clutch old one is also rs4 and doesnt look to be that worn but while i'm there just as well along with new flywheel bolts
removed the n/s turbo today and manifold and replaced with a new k04also replaced waterpump cambelt and all tensioners got a couple more bits on order for the morning and it will be all systems go again
both k03's had servere end float so where due to be replaced surprized they hadnt done the seals to be fair more tommorrow!!













Magic

Great job so far mate.

See you tomorrow.
Grim Reaper

Nice project you've got going there. Pretty much identical to my spec although i'm still on RS4 intercoolers as been too lazy to fit my fmic
big mac

Grim Reaper wrote:
Nice project you've got going there. Pretty much identical to my spec although i'm still on RS4 intercoolers as been too lazy to fit my fmic


if my figuares are anywhere near yours i will be a very happy man
big mac

both turbos fitted and piped up today flywheel sorted and refitted clutch fitted good clean up tommorrow refit gearbox and downpipes then its back in the car hope to be able to fire it up tommorrow see how far i get getting excited now about hearing it run again
big mac

sorry got a bit behind with this thread here are some more pictures from the build these pictures show the intercooler being fitted and the engine going back in the car


bay all cleaned



engine all cleaned up




back in its rightful place


front panel all on and sorting the fmic and oil cooler locations

nearly finished just some bumper mods!!!lol

so car has been back on the road for around 2 weeks now fired up on the button and runs perfect no real issues either a couple of small boost leaks were found when leak tested but i did have an issue with the amount of boost the car was developing even with the n75 disconnected i was getting a bar of boost!!!!! changed the diverter valves to no avail had a chat with rich and he said try the n75 as it maybe fault and not closing correctly there fore bleeding boost off makes sense really so today i have bypassed the n75 and bingo got .6 bar (wastegate pressure) next on my list is 044 fuel pump and injectors once the ecu arrives from rich and if i can get the water /meth finished off before mapping at jjb on the 30th will try and update as i go and sorry for the delay but work has been manic and my spare time is being spent on the car checking and double checking everthing
Gil

you forgot to mention the exhaust sounds like theyre splitting atoms as it comes on boost.... best sounding car ive heard for along time
big mac

boost leak tested the car again today and had a hissing from the drivers side turbo area so an hour or so later engine mount removed and intake pipe removed found the cause a small tear in the boost control hose to the actuator so left the car at gils workshop and need to order a new pipe tommorrow as there is not enough rubber to cut it back but this looks like it could have been the problem all along ...lol and it would have to be the one thats a sod to get to and has about an inch of rubber on the end of the metal moulded pipe!!!!aaaaaaaaaarrrrrrrrrr also received an ecu from rich today that has a base mapfor the 630 injectors so can get them in the car now along with a banjo for my 044 so tommorrow nite i will be fitting this lot
mikey-s

Use an air saw to cut off the crimped part off the pipe, then you're left with a mirror image of the actuator connector. see my build thread, I've just had to do this to mine.
pjbRs

Is this back on the road now Ian?

Nice build thread btw, car looks mint.
big mac

pjbs wrote:
Is this back on the road now Ian?

Nice build thread btw, car looks mint.


just had this boost problem tonite phil so off the road again till i sort it tommorrow

@mikey yes mate cut it off tonite but didnt have a hose to fit it might try again tommorrow as im sure i got some in the shed
philws4

Glad you found the problem Ian,well done
big mac

sorted it to night no boost leaks now and new n75 valve that does'nt leak!!! happy days and bang on .5 bar boost
davs4

Nice thread Ian now bring on the power  
lucky

Great look yellow tubes
big mac

[quote="davs4:328615"]Nice thread Ian now bring on the power  [/quote
]
Cheers Dave fuel pump and injectors to fit the weekend and finish off the water/method can't wait to drive it properly again fmic keeps air temp right down and oil cooler is great too
big mac

lucky wrote:
Great look yellow tubes


Thanks mate wasn't to sure when I first fitted but like it a lot now will try and get some pics up with the bumper fitted
big mac

right got the 630cc injectors fitted and the 044 fuel pump in the s4 basket this weekend and fitted the ecu rich sent down with a base map to run the injectors also started to fit the water meth nearly there with that all pipe work run though and wiring done just need to remove bi pipe and fit the injectors i will try and add some pics of the bits i've done and the superb bracket that dom(bluebrake) made for the water/meth tank tommorrow now just cant wait for the roadtrip to jjb saturday this week is dragging already!!!!lol
ScottR

Why do you need to remove the bipipe?
big mac

To fit the water/meth injectors
ScottR

I'd read your previous post as you needing to fit the fuel injectors.

I did all the plumbing of mine before reassembly of the front end. Just got the electrics to wire up now.

Thumbs up for your work so far. Looks like you've flown through it. Jealous!!
deans4bird

looks great why did u take the bentley wheels off they set the car off nicely
have you got any pics with the ch's on. im in the process of moding my s4 b5 too just have rs4 brake up grade kw suspention miltek pipes and a k04 upgrade. im on the hunt for some wheels i was thinking about mercedes monoblocks. have you sold the bentley wheels? and are u doing any meets? dean bird
big mac

Bentleys are still available for sale bud they look the nuts but not really suitable for what I use the car for if interested chuck us a pm
S4mi

Where are the final results of this build? I guess it's done by now..  
Did you use S4 MAF or RS4? Did you have any problems with engine temps with the FMIC in the summer? Curious 'cos I've started collecting parts for a similar build..  
big mac

S4mi wrote:
Where are the final results of this build? I guess it's done by now..  
Did you use S4 MAF or RS4? Did you have any problems with engine temps with the FMIC in the summer? Curious 'cos I've started collecting parts for a similar build..  


Sorry only just seen this been on holiday I used the s4 maf the intake temp after a hard lap of the ring in 28 degree plus heat were around 42-45 degrees with coolant temp around 100 this was running water meth tho not had chance to have it on the dyno yet as 1st-2nd synchronize Shit its self best 0-60 so far is 4.4 and I have left a 430. + EVO for dust and a 450+e92 m3 on the autobahn by about 3 car lengths if you need any advise pm me more than happy to help
big mac

not updated this for a while so thought it was about time    

car made 458.4 bhp 492 lb/ft on the dyno running water meth
my gearbox was fubarred damage on a fair few gears and first to second selector hub fubarred got a box from mikey s again a forum member digs me out the shit big thanks mikey    stripped to check it and it was in fine order so because parts were on back order throw it in till i could source parts and build a bullet proof box needless to say second gear synchro has now shit its self on this box and i am still waiting for parts on back order so with a track day at bedford looming tommorrows jobs are

1 change gearbox oilfor mt 90 redline stuff hopefully this will help the box a bit till the parts arrive
2 fit the neuspeed rear arb and uprated drop links
3 boost leak and vac check
4 bloody good clean as it is hanging

i am tempted to go the next stage with the car but it is so reliable at this level i cant make the desision!!!! arrrr i hate these cars and love them all at the same time    

will post some pics tommorrow of the progress
lynchy

Just stick with the power you have Ian
StumpyRS4

Hard darts Mac.
The RARB and drop links (RS2 ?) will make a massive difference to the way the car behaves - great upgrade.

What's the next level you're contemplating?
big mac

Lo600's and rods with kkd manifolds dont want silly power if i could get to 550 and a tad more torque on s4 heads woul be nice
StumpyRS4

Roger that...

LOBA seem to offer the best 'next step' and the LO600 is definitely the choice I would be opting for.  Seems to give great results on every car that gets them.

Big bucks, but big results too.

I have 2.4NA heads if you're interested (big port), and RS4 rods and pistons which I was going to fit, but I don't think there's much point on my car.  They would get you over 550ft lbs...
big mac

Will have a chat with you at bedford carl
big mac

Would like a passenger ride in yours with the rs6 turbos just to give me an idea
StumpyRS4

Cool.

The map has the boost turned down though.  So you may not get the feel you're after.  Only running c21 psi.

With the weight reduction, it will still feel quicker than your car is now, but power/torque is probably somewhere around the same as your car is now.

A word of warning for anyone wanting a pax ride (for which they're welcome to) my pax seat is very 'snug' !
arotished

love the color
big mac

arotished wrote:
love the color


Thank you bud its a love it or hate it thing got the arb fitted today what a tranformation car feels so much more nimbal and pics tommorrow : D
Alps

big mac, stick to the power for now. Then when you get really bored, UP IT. You can save up in the mean time too for even more power.
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