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

  1. #121
    olethalb's Avatar
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    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













    little clean up


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  3. #122
    olethalb's Avatar
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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





    fitted new clutch and fly



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







    the hybrid strapped on with proper k04 lines



    new plastic water way as the original broke up on removal



    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




  4. #123
    olethalb's Avatar
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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





    and heat wrapped it



    new position, you can see issue where the blank is



    also got another fmic core to modify to fit





    new pipes made to be welded



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


  5. #124
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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





    lower boost pipe



    tb boost pipe



    turbo intake pipe





    fitted the TB boost pipe and DV etc



    popped off the old cam cover and looks like new





    fitted the new cam cover



    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


  6. #125
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    Hi olethalb

    Ive got the same sprint blue DTM 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

  7. #126
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    Nice work ,if you get bored when yours is finished i'll leave mine with you for a month .lol.
    06 A4 AVANT QUATTRO 2.0T S-LINE SE,GARNET RED, RS4 REAR ARB,SPACERS ALLROUND,H & R SPRINGS,B5 PERCHES,A6 V8 RIMS.PORSCHE CAYENNE TURBO S SIX POTS .REVO MAP ,STATIS CATBACK EXHAUST,PANEL FILTER.

  8. #127
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    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
    06 A4 AVANT QUATTRO 2.0T S-LINE SE,GARNET RED, RS4 REAR ARB,SPACERS ALLROUND,H & R SPRINGS,B5 PERCHES,A6 V8 RIMS.PORSCHE CAYENNE TURBO S SIX POTS .REVO MAP ,STATIS CATBACK EXHAUST,PANEL FILTER.

  9. #128
    Golfedd's Avatar
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    Nicely done Olly, that VHT stuff gave a good finish! mmmm the painful memories of wrinkle haha.

    Looks good!

    Phantom A4 Build Thread

  10. #129
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    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!

    Phantom A4 Build Thread

  11. #130
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    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














  12. #131
    olethalb's Avatar
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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

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



    stock SE grill



    frame removed and measured up against the RS6 item



    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





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





    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





    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


  13. #132
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    Saw the pics of FB earlier Oli, love your work, looking forward to seeing it in the flesh, and you of course


    "Will these wheel fit my car PM's will not be replied to, do you research & use the SEARCH button"

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  14. #133
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    Looks great.
    2000 AMK S3, Revo'd, forge 007p, B8's, H&R's, tarox g88's, ferrodo ds2500's, and in the fastest colour



  15. #134
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    hi mate looks good did you bake it all to get the wrinkle

  16. #135
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    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





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

    [IMG]http://i276.photobucket.com/albums/kk32/ollethalb/dtm/FC063C54-C902-4325-9F97-02FA9839402D-6967-
    0000065CF5EFC923_zpsbd2a264d.jpg[/IMG]





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



    and removed the old one

    [IMG]http://i276.photobucket.com/albums/kk32/ollethalb/dtm/7EF24F53-E34F-4121-A2AC-6121A957AA01-6967-
    0000065CFD54EED5_zps60d0e513.jpg[/IMG]

    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





    mounting brackets fabricated




  17. #136
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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.

    Phantom A4 Build Thread

  18. #137
    olethalb's Avatar
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    me too Eddwin


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



    dropped the bumper off



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



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





    test fitted the bar





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







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







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







    popped some paint on



    fitted the 'new' grill in the bumper



    and test fitted the bumper





    that was it for now 'crash bar' has been painted but need to get the pipes rewelded and my welder is away this weekend

  19. #138
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    Looks great, what was the original front mount from?

  20. #139
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    hey mate i think a gloss black grill will look alot better, Classifieds: A4 (Non Sline gloss black Grill)

  21. #140
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    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







    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



    with bumper fitted



    all back together


  22. #141
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    The one you removed. Cheers.

  23. #142
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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

  24. #143
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    Cheers looked great.

  25. #144
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    will be on ebay this week

    gave it a wash


  26. #145
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    On eBay? You selling up dude?

  27. #146
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    Is that a 2" core? Bit thin for your turbo spec isn't it?!
    Audi A4 (B7) 2.0TDi S-Line Avant Quattro - Steve Edition in Lava Grey
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  28. #147
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    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

  29. #148
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    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




    Ready to go



    Driver door comparison



    Rear Quarter comparison



    Mirror- light buff as it's a soft clear coat on these



    had to be a bit gentle around the arches, they are a tad - frail



    Bonnet after stage 2 pass






    Boot done final stage (no protection)









    Exhaust tips got a quick whip over






    Finished up







    Phantom A4 Build Thread

  30. #149
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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

  31. #150
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    Fairy Liquid, is that not the devil for detailing cars.
    2005 B7 A4 2.0T in Moro Blue

    Interior, Number Plate & Sidelight LED's from T8ups, 18" 9 Spoke TT Wheels.
    BGB Engine Code.


  32. #151
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    Should never use fairy washing up liquid anywhere near quality paintwork, It's full of salt and will ruin a good shine.

    Audi S4 quattro in Dolphin Grey Metallic, Silver leather, carbon inlays, RNS-E, 6 speed manual, electrically adjustable & heated seats, xenon headlights with power wash, cruise control, storage pack, 18" OEM RS4 wheels, RS4 ARB, LED lighting upgrade, FASH plus every bill since new.




  33. #152
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    Quote Originally Posted by mancdan View Post
    Fairy Liquid, is that not the devil for detailing cars.
    Quote Originally Posted by GeoffDunk View Post
    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

    Phantom A4 Build Thread

  34. #153
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    Phew, thats good then
    2005 B7 A4 2.0T in Moro Blue

    Interior, Number Plate & Sidelight LED's from T8ups, 18" 9 Spoke TT Wheels.
    BGB Engine Code.


  35. #154
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  36. #155
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    there is 2 new pic's for my desktop wallpaper

    there my only be 213 of them left but this surely is the best one of them all,
    “If everything seems under control, you're just not going fast enough."

  37. #156
    olethalb's Avatar
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    Wow, thanks for compliment bud

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


  38. #157
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    does that say 363 BHp?
    “If everything seems under control, you're just not going fast enough."

  39. #158
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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.

  40. #159
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    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



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





    hoping this is going to be new turbo week

  41. #160
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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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