my DTM 'build' - story so far, hybrid K04 - custom FMIC

right....

now i had the clutch and knee is a little better (not much) i decided i'd start the swap

i've had the new engine for a while and other parts were slowly coming together

well first (easy part) was to strip out the old engine

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little clean up

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now i had the lump out i could start building up the new one

90% of ancillaries are different from tranverse to in line

swapped;

alternator bracket

alternator

p/s pump

a/c pump

all water ways and hoses

sump

cambelt cover

cam cover

also A4 mounts bolted up

the A4 uses a spigot bearing in the end of the crank so fitted one of them

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fitted new clutch and fly

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the dowels were longer on the A4 too so they had to be swapped out

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the hybrid strapped on with proper k04 lines

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new plastic water way as the original broke up on removal

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now it was al fitted up with s3 injectors, new inlet mani, painted TB, new pump with original auto tech internals i wiped it over and
sat it back in the bay

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few other bits needed attending to while i was at it

the decat pipe i got from the states pushed the lambda up against the heatshield, so i welded a new boss in

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and heat wrapped it

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new position, you can see issue where the blank is

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also got another fmic core to modify to fit

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new pipes made to be welded

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new custom crash bar mocking up with 30mm 3mm wall tube

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i also wanted to smarten things up, i never painted the lower boost hose and the throttle body one had been sanded for WMI injector and chipped. was also not happy with the cam cover

so i braved the VHT wrinkle finish and set to work

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lower boost pipe

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tb boost pipe

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turbo intake pipe

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fitted the TB boost pipe and DV etc

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popped off the old cam cover and looks like new :)

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fitted the new cam cover

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unfortunately thats as far as i've got it's been raining heavy all day, i'm going to run the old FMIC while the new one is welded and i
can properly fit and paint the crash bar

also got this to modify on somehow, it's from a mondeo to replace my existing p/s cooler

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Hi olethalb

Ive got the same sprint blue DTM :beerchug:I want to upgrade to s4 discs 345mm what will I need to adapt this Mod ive seen something before about changing the caliper bracket

Cheers
 
Which flywheel did you get ? ,steel single mass or alloy with steel insert?,this is my next job,i was thinking of getting a clutch off drake on audizine he does modified rs4 clutch kit,i'm just not sure which flywheel.I need to get them ordered as mine is getting a bit worn.cheers Andy
 
Nicely done Olly, that VHT stuff gave a good finish! mmmm the painful memories of wrinkle haha.

Looks good!
 
imagine, how epic it would be... to have like, some kind of RS4 style start button, that would flip up in the cigarette lighter?

#BITTER!
 
cheers chaps, will reply when i get a little more timewell the engine was fitted idled perfectly, took it out for a spin and got a misfire on boost on cylinder 3 swapped loads of parts including 4 new gen plugs and coilpacks.
yesterday i took out the injectors (PITA job) and swapped cylinder 3 injector to #4, took it out and misfire on #4 so seems one of my 3k old S3 injectors are dead, looked it up on ETKA and they're £150 each. also been getting 'low fuel pressure' code so looks like intank pump is dying - another £300 :( - ah well pics of the progress anyway

fitted pics and painted parts

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next i plucked up the courage to hack two grils apart to make one...

removed the frame and trimmed the edges off the RS6 grill

http://i276.photobucket.com/albums/kk32/ollethalb/dtm/CFC79E6C-8FD6-48B4-B0C9-400E0A43C2D7-957-
000001059CFCBF76_zps896bf83b.jpg

12B860E4-C702-4B59-9C9B-60B137E57E1C-957-00000105A1D27299_zps0be15355.jpg


stock SE grill

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frame removed and measured up against the RS6 item

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i decided i'd trim the outer edge off of the SE grill as i did with the RS6 grill and glue them together as the witdth and angles were pretty close

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once i'd trimmed the RS6 to size i secured it with cable ties then glued it

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after leaving it to set for a week with the cable ties holding it in position i removed the ties and painted the surround wrinkle black

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also did this, not sure if i like it yet will need to use it some more



also ordered a lot of bolts / clips and a new drivers vent, i'd noticed a few rusty looking bolts mainly on the front panel and a few damaged plastic loom clips when i swapped out the engine

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hi mate looks good did you bake it all to get the wrinkle
 
Nate - thanks bud, DC was last time i saw you. i was with Dele and the hamster :D

Rav thanks

harvey - no i just heated it up carefully though as it's mainly plastic

yesterday i went and picked up a new injector and RS4 in tank pump, unfortunately the fuel filter was out of stock

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took out the old pump and the gauze was floating around in the bottom of the tank

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while i was at it i dropped the tank to fit the RS4 pump controller

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and removed the old one

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got a call from audi to say my filter and new brake light switch were in stock, while i was collecting them the welder called to say the FMIC was ready for collection

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mounting brackets fabricated

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not seen the detail on that new IC - looks good man! looking forward to this being on the road, ripping up the road.
 
me too Eddwin


well thought i'd set about getting this front end sorted today

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dropped the bumper off

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removed the old fmic and started mocking up the new crash bar

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welded 16mm thick wall tube to the crash bar mounting points

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test fitted the bar

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then offered up the FMIC - unfortunately there had been a miscommunication in measurements so i had to mod the pipes

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then trimmed the mounting brackets, added some rivnuts to the bar and bolted it up

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once that was in place i needed to mount the horns so i welded the brackets to the crash bar mount

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popped some paint on

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fitted the 'new' grill in the bumper

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and test fitted the bumper

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that was it for now 'crash bar' has been painted but need to get the pipes rewelded and my welder is away this weekend :(
 
weekenny - the one i removed or the new one?

Jay - i'm happy with the wa mine's turned out

magic happend today, i called my welder, not only did he answer the phone on his day off he agreed to run a couple of welds for me :)

got to work and dropped some paint on the cooler pipes, as soon as was touch dry set about fitting it up with the painted crashbar

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next i had to address the power steering cooler - not many pics as it was snowing on and off so no time for pics. mounted the
mondeo cooler

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with bumper fitted

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all back together

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it was from a B6 1.8T kit, i only needed the core so ditched the pipes and welded my own ally pipes on to give clearance for the bumper
 
Is that a 2" core? Bit thin for your turbo spec isn't it?!
 
the old FMIC will be on ebay bud :)

ran some logs earlier to measure intake temps and normal driving was around 22* with ambient of 9.5* and spirited driving with WMI was seeing as low as 2* so seems to be performing well, no noticeable lag over old item :)
 
Took a trip over to see the scruffy DTM. It was in much need of a day's worth of Detailing up, paint was faded and dull and the sprint blue certainly can shine.

With the up coming show at Elemental it was time to sort it out...

Products:

Two Bucket wash: Fairy liquid
Cleaned off: Tardis all round
Clayed with: Elite Fine Grade
Rinse and Dry
Taped up and prep for rotary
Stage 1 all over: Lake Country Pads - S3 Gold class
Stage 2 on some areas: Lack country Pads - S17
Stage 3 all over: Lake country finish pad - S40

Rinsed down and gentle dry
Dodo Juice Acrylic Spritz sealant
Dodo Juice and Smartwax finish



The Photos
General dull paint

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Ready to go
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Driver door comparison
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Rear Quarter comparison
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Mirror- light buff as it's a soft clear coat on these
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had to be a bit gentle around the arches, they are a tad - frail
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Bonnet after stage 2 pass
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Boot done final stage (no protection)
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Exhaust tips got a quick whip over
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Finished up
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Oh Edd she's so shiny and clean :)

thanks bud, was good to catch up with you and the lads saturday
 
Fairy Liquid, is that not the devil for detailing cars.

Should never use fairy washing up liquid anywhere near quality paintwork, It's full of salt and will ruin a good shine.

haha yup, you're both right. I didn't use Fairy - Used meguiars Gold wash, then a rinse down with Auto-Glym Shampoo etc etc etc
 
there is 2 new pic's for my desktop wallpaper :respekt:

there my only be 213 of them left but this surely is the best one of them all, :applaus:
 
Wow, thanks for compliment bud

spent the day at MRC today and i got a good service and a fair amount of tweaking

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Amazing build, just been engrossed in it for an hour reading every post, what an amazing car also thanks for all the useful information in your thread.
 
craic - indeed it does, was hoping for more to be honest

Chris - thanks for taking the time to read :)

didn't do much at the weekend but it was nice weather so could take my time on the long over due rear brakes

when i bought the car it had just had new rear pads so plan was to get a bit of like out of them before doing anything with them, recently been getting a very annoying brake squeal so enough was enough.

i bought a pair of drilled and grooved discs to match the front, rears on DTM are 288mm but unfortunately solid

anyway, a pic of the nasty nasty rear set up

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after a good clean up, regrease, blue paint, new discs, mintex pads and repainted splash shield

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hoping this is going to be new turbo week :)
 
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alot of good work going on here

but out of curiosity, why didnt you just go ahead and buy yourself an rs4 for the money you spent on this?
 

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