Archive for AudiSRS.com The place for Performance Audi
 


       AudiSRS.com Forum Index -> Projects and Builds
mikey-s

Old Faithful - Project Revamp

Time to revamp a car that I hold a real soft spot for, a 98 Nogaro Blue S4 saloon, my first S4. †I had it for a while, loved it, abused it, did a ring trip in it, then regretfully sold it to a mate (Liam). †He used it like I did, then sold it to another mate, Keith (Jrmillie on the forum). †Between us we've owned it for around 5-1/2 years and it really does feel like part of the family.




From my ring trip, with a mate throwing up over the armco..



The car has been very relaible in all this time, but recently Keith has been itching to sort a couple of little niggles, namely an appetite for water and a couple of small oil leaks. †He's also succumbed to the tuning bug (probably due to passenger rides in my car), so the decision was made to pull the engine and do a few mods. † † † I've been working away so the engine pull got delayed more and more, so Keith took it upon himself to get the ball rolling, firstly by sorting the brakes, then by pulling the motor on his drive (respect)!


B7 fronts



Trigs brackets / B6 rears



Engine pull



As soon as it was out we got cracking. †The build spec seems to be changing all the time, and Keith must hate me by now for spending all his money, but the current spec we're aiming for is: †

IE conrods
Straight RS6 turbos
Ported exhaust manifolds
3" DP's
2.8 large port heads
2.8 inlet cams
RS inlet manifold
RS Y-pipe
RS throttle body
RS charge pipes
RS intercoolers
RS MAF / Airbox
LOBA OEM + 15% clutch
Seimens injectors

Big thanks to Grizz @ Unit 20, †Si @ Loba, and Jimbo for doing us a good price on parts, I'm sure we'll be needing more. †

We got the engine in the garage and started to pull it apart



XS DP's after 5 years of abuse



Found the source of the water leak



Considering the age & mileage, the condition and cleanliness of the internals was fantastic



Before you know it the block was bare, and then painted



This was where the fun began. †We found out that the single use main bearing bolts were on back order, no ideas when they will turn up! †Then while assembling the new rods / rings onto the pistons we discovered that the ARP conrod bolts were the wrong thread.. †FFS. †Ahh well, we made use of the time, made some turbo jigs and modified the RS6 turbos to fit the S4. I'm off to the states on Friday, so I'll pick up a cheap tapered ring compressor and rod bolt stretch gauge - they seem expensive and hard to get hold of in the UK.






So to today. †Still no sign of the bolts we need to dtart putting the bottom end together, so we decided to go to a breakers yard in Bury to remove a complete 2.8 engine, just for the heads. †After finding the car on top of another, and finding it was an auto quattro, we decided to remove the heads in situ which was way easier.



That's all for now. †Will update as and when.. †
calibra_se8

Great work, should be a nice spec when finished
mikey-s

The aim is to make it oil/water tight with a hugely expensive full gasket set,  reliable,  and to at least double the power output.  Yes, it should be sweet when it's done.
will1981

Nice project Mike, is Rich mapping it when complete?
HHH

loving the pic at the Ring, quality !!  
S4BiT

Did you use XS downpipes without flexis to have a result like this?
mikey-s

I'm not sure Will,  that's up to Keith.

That photo was taken by a professional photographer called Richard Shepy, he was a front seat passenger in a car that was passing us,  perfect timing!

Regarding the downpipes,  these were run without flexis bus I honestly don't think it would have made any difference,  at the break the 'stainless'  really is Piss thin.
Challice

Nice work  
Brent

i'll be watching this, great work

Love that ring pic too
pjbRs

mikey-s wrote:
I'm not sure Will, †that's up to Keith.

That photo was taken by a professional photographer called Richard Shepy, he was a front seat passenger in a car that was passing us, †perfect timing!

Regarding the downpipes, †these were run without flexis bus I honestly don't think it would have made any difference, †at the break the 'stainless' †really is Piss thin.



Nice parts list.

So it's ok to fit without flexis? I'm having trouble finding anyone local who can fit them.
mikey-s

I wouldn't personally fit them without flexis (although I did fit these to this car ).  For the cost, I'd seriously look at getting flexis fitted.
pjbRs

mikey-s wrote:
I wouldn't personally fit them without flexis (although I did fit these to this car ). †For the cost, I'd seriously look at getting flexis fitted.


So I've been told, but if mine last 5 years?  I thought it would be easy to find someone to fit flexis.
mikey-s

pjbRs wrote:
mikey-s wrote:
I wouldn't personally fit them without flexis (although I did fit these to this car ). †For the cost, I'd seriously look at getting flexis fitted.


So I've been told, but if mine last 5 years? †I thought it would be easy to find someone to fit flexis.


These have had a blow for a long time, we put it down to the poor quality doughnut type connectors but it must have been this crack all along, so don't bank on it lasting 5 years - it may last, it may not..
pjbRs

mikey-s wrote:
pjbRs wrote:
mikey-s wrote:
I wouldn't personally fit them without flexis (although I did fit these to this car ). †For the cost, I'd seriously look at getting flexis fitted.


So I've been told, but if mine last 5 years? †I thought it would be easy to find someone to fit flexis.


These have had a blow for a long time, we put it down to the poor quality doughnut type connectors but it must have been this crack all along, so don't bank on it lasting 5 years - it may last, it may not..



Ok mate thanks.  

Looking forward to seeing how you get on.
F12KYB

GREAT PROJECT LOOKING FORWARD TO THE FINISHED RESULT
Stigter

Lol - you guys said at the pub that the car in the breakers yard would be at the top of a stack!!

Quality project and good to meet Keith - hope all the waiting for bolts and bits doesn't hold you up as once its done its going to be a very very quick s4.
mikey-s

Stigter wrote:
Lol - you guys said at the pub that the car in the breakers yard would be at the top of a stack!!

Quality project and good to meet Keith - hope all the waiting for bolts and bits doesn't hold you up as once its done its going to be a very very quick s4.


Haha, yes we did!  It turned out well in the end, we managed to bag the heads for around £100 less than he was asking for the engine.  There's another 2.8 there, I may go and buy those heads just to keep on stock!
mikey-s

Time for a slight update. †Firstly I must say a huge thanks to Mathias, we've bought a load of parts off him and he's been a true gent bending over backwards to get them to us. †Much appreciated

So after a proper maching shop honing and full monty steam clean this is how the block looked..




New rings having the gaps checked and adjusted..




Then fitted to pistons..




Crank in, with new bearings. †Started fitting the Integrated Engineering rods & pistons..




Tightening the ARP conrod bolts the correct way..




Three more to go..




Turns over a treat, so the upper sump & oil pump are fitted..




As it stands now until I can get my hands on it again!!





Until next time!
ScottR

Could eat my dinner off that.
mikey-s

ScottR wrote:
Could eat my dinner off that.


I wouldn't go that far, but we did scoop a few beers off it..  
DavidT

Looks too nice to have fires in!

Can I move it to the 'Projects & Builds# Forum Mike?
mikey-s

DavidT wrote:
Looks too nice to have fires in!

Can I move it to the 'Projects & Builds# Forum Mike?


If you would Sir!  
mikey-s

Lots to add to this thread,  will do when I get some time.   All I can say is the car is finished & mapped,  and it's an absolute flyer.    Went out as a passenger the other day and I can honestly say it's one of the fastest cars I've been in for quite a while.
Nez

Great project any idea what sort power it's pushing?
mikey-s

Nez wrote:
Great project any idea what sort power it's pushing?


No ideas Nez as it never went on a dyno,  but apparently Rick seems to think mid 500's according to his ass dyno.  Tuners ass dynos can be fairly accurate!  It really does struggle to put the power down.  
mikey-s

It's a bit late in coming now that the car is finished, and you've all probably seen these engines in bits lots of times but time for a quick update anyway:  

On went the heads:






Removing flanges from 3" DP's for the RS6 flanges to be welded on:



Engine bay cleaned ready for the lump:


Only strapped this way to get the lump out of the garage!




And how she stands now.  


It was a pleasure building this motor, the car certainly deserved it because it has had such a hard life during my ownership, then Liams and Keiths!  

Happy driving Keith!    
ScottR

Lovely stuff! He's popping round here for some parts in a couple of weeks and promised to take me for a spin.
jjrmillie

I agree Mike it was a pleasure! and throughly enjoyable! and now having just as much fun from driving it!!   (although I have to admit it scares me a little   ) spot on mate! thanks for all your help,  speak soon
mikey-s

The spec we aimed for was changed during the build,  but here's the final spec:

Straight RS6 turbos
RS4 intake manifold + throttle body
RS4 Y pipe & accordian
RS4 MAF & airbox
RS4 intercoolers
Bosch EV14 injectors
Bosch 044 fuel pump
Compression dropping gaskets
2.8 large port cylinder heads
Facelift ported exhaust manifolds
034 engine mounts
034 poly snub mount
Intergrated Engineering rods
Loba OEM+15% clutch
RS4 oil cooler (heat exchanger deleted)
3' DP's with RS6 flanges
N249 delete
Unicorn custom remap with FS & LC

As well as:
Full gasket and seal set   @ the cost!
New crank bearings
New piston rings
Waterpump & thermostat
Timing belt kit
Boost gauge
After run pump
Alternator refurb
Redline gearbox oil
Cupra lip spoiler

Have I missed anything??
jjrmillie

the only other thing I can think of Mike is all new stretch bolts throughout, head, mains, big ends etc. oh and a new shinny water bottle!!
Noggymike

Top Job Mike

Great attention to detail throughout especially the gasket set!!!


I may be in contact when the Noggy gets a engine pull!!!!!

M
mikey-s

Noggymike wrote:
Top Job Mike

Great attention to detail throughout especially the gasket set!!!


I may be in contact when the Noggy gets a engine pull!!!!!

M


Careful, they'll be asking for sponsorship money with talk like that!  
F12KYB

great project now its timr for the fun
Noggymike

mikey-s wrote:
Noggymike wrote:
Top Job Mike

Great attention to detail throughout especially the gasket set!!!


I may be in contact when the Noggy gets a engine pull!!!!!

M


Careful, they'll be asking for sponsorship money with talk like that! †



     


Your'e from up North

so I know how tight you are          
Graham

Nice write up Mike.
mikey-s

Graham wrote:
Nice write up Mike.


Really?   Thought it was a p8ss poor attempt myself!  It could have done with more detailed pics, and text,  but I'm really struggling for time to do anything at the mo.   Anyway, Keith's happy and the car is a flyer!  So I'm happy to.  
Graham

I am sure you could have added a lot more, but we all have time constraints so it is understood. I particularly liked the pics of the engine or engine parts being worked on. We don't see that often.
Nez

mikey-s wrote:
Nez wrote:
Great project any idea what sort power it's pushing?


No ideas Nez as it never went on a dyno, †but apparently Rick seems to think mid 500's according to his ass dyno. †Tuners ass dynos can be fairly accurate! †It really does struggle to put the power down. †


Lol ok  
       AudiSRS.com Forum Index -> Projects and Builds
Page 1 of 1