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

olethalb

Registered User
Joined
Aug 29, 2012
Messages
356
Reaction score
87
Points
28
Location
NULL
when i joined i said i wasn't going to make a 'build' thread as not a lot was going to be done to this one, unlike my old bora.

this is still the case but i had a little thread on uk-audis as a record of what has been done, but they've recently upated the site and i cannot get on with it at all so i'll transfer what i have done so far.

spec - A4 TFSI permanent quattro DTM LTD edition made in 2006 to celebrate audis success in DTM racing

as i bought it - 220bhp k03 turbo recaro half leathers and DTM specific carbon extras

borabitsforsale15712015.jpg

borabitsforsale15712019.jpg

borabitsforsale15712014.jpg

borabitsforsale15712013.jpg

borabitsforsale15712016.jpg


first things first - new fuel pump tappet and cam chain and tensioner to keep things sweet

A4DTM16712006.jpg

A4DTM16712008.jpg

A4DTM21b712008.jpg


and after the work spruce the bay up a little

A4DTM21712005.jpg
 
Last edited:
after the engine had been treated it was time for wheels, these came up fairly cheap so snapped them up

A4DTM21712001.jpg

A4DTM21712002.jpg


next was to 'joey' the headlights and de tango

partsforsale23712004.jpg

partsforsale23712002.jpg

partsforsale23712007.jpg


soon after the long awaited coils arrived

partsforsale23712009.jpg

partsforsale23712013.jpg


and with 12mm spacers a little fitment

partsforsale23712014.jpg


also ebayed a leather arm rest

partsforsale23712011.jpg
 
more power was on the cards so started accumulating parts

k04

audidtm31712002.jpg


DV

audidtm31712001.jpg


one stage cooler plugs

A4DTM22712-1.jpg


s3 injectors

audidtm2812002.jpg


with more to follow.....

the DTM comes with 320mm front discs which aren't the best so upgraded to S4 345's

a4DTM8812002.jpg

a4DTM8812003.jpg

a4DTM8812004.jpg


aux belt tensioner started clicking so on with a new one

a4DTM8812001.jpg
 
  • Like
Reactions: Alex banu
the rotis came with tyres but size wasn't ideal so i changed them for 215/35's and tweaked the ride height a little

and purchased a new reg from DVLA

audidtm3812001.jpg

audidtm3812005.jpg


after having a lot of bits and bobs on order from UK and USA they started trickling through

ATP 3" decat

a4DTM10812003.jpg

a4DTM10812001.jpg


polybush snub mount

A4DTM17812007.jpg


milltek cat back system

A4DTM17812001.jpg


Autotech HPFP internals

A4DTM17812010.jpg

A4DTM17812011.jpg
 
  • Like
Reactions: Alex banu
the day of exhaust fitting came

A4DTM17812002.jpg

A4DTM17812003.jpg

A4DTM17812005.jpg

A4DTM17812004.jpg


when i removed the original cat the wastegate flap had disintegrated from vibration

a4DTM10812004.jpg


all i could do at that piont was weld the flap back to the arm....

fitment of the milltek went well until it came to the tailpipes

A4DTM17812006.jpg


they stuck out far too much so had to trim an inch off each tailpipe trim

A4DTM17812008.jpg


they still didn't sit evenly in the cutouts in the bumper so i had to cut a bracket off that regulated the distance between the pipes and weld a correct sized rod in between

A4DTM1912001.jpg

A4DTM1912002.jpg


the left pipe would not sit high enough no matter how much tweaking so i had to splice the tailpipe trim and reweld

A4DTM1912003.jpg

A4DTM1912004.jpg

A4DTM1912005.jpg

A4DTM1912006.jpg

A4DTM1912007.jpg


perfecto
 
  • Like
Reactions: Alex banu
as i was gearing up for the K04 swap i spoke to MRC who advised FMIC - the kits i had seen weren't too impressive, either required bumper chopping or losing the crash bar, neither was an option

i measured up and went for a core intended for another audi

A4DTM21812007.jpg

A4DTM21812008.jpg


then set about mocking up custom hard boost pipes with a variety of ally bends

a4DTM26812b004.jpg

A4DTM21812004.jpg

A4DTM21812005.jpg

A4DTM21812009.jpg


mocked them all up to size and correct path making no contact and gave them to my ally welder

also decided to weld the s3 dv flange to the boost pipe

a4DTM26812b001.jpg

A4DTM28812003.jpg

A4DTM29812001.jpg

A4DTM29812008.jpg

A4DTM29812005.jpg


painted and fitted

A4DTM29812010.jpg

A4DTM29812009.jpg

A4DTM29812014.jpg

A4DTM29812024.jpg

A4DTM29812019.jpg
 
  • Like
Reactions: GDCAUDIA4B7
next was the modified k04

tt225 outlet welded on

A4DTM29812b002.jpg

A4DTM29812b003.jpg

A4DTM29812b005.jpg


downpipe bolts repostitioned and rethreaded

A4DTM29812b004.jpg


test fitted

A4DTM30812001.jpg

A4DTM30812002.jpg

A4DTM30812003.jpg


bolted up

A4DTM30812012.jpg


intake with recirc inlet for DV

A4DTM30812015.jpg

A4DTM30812017.jpg

A4DTM30812020.jpg


front end slotted back on with no mods or trimming :)

A4DTM30812021.jpg


DIY heatshield box

A4DTM1912010.jpg

A4DTM1912009.jpg


now it was all up and together next was MRC for mapping

dtmatmrc.jpg


made 330bhp and 350 torque but had budget fuel and clutch was dying :(

well fitted a new clutch yesterday, brimmed it with optimax and went to RR day today but was too low for the rollers :(
 
  • Like
Reactions: James.c
oh one from Surrey RR day today - ignore the tit in the wifebeater

DTMsurreyRR.jpg


few more pics - one from players

dtmplayers8.jpg


one with new honeycomb satin grill

AudiDTM131012001.jpg


and completed the de-chroming with some carbon fibre mirrors

AudiDTM131012004.jpg

AudiDTM131012002.jpg

AudiDTM131012003.jpg
 
  • Like
Reactions: Ricky Burrows
also fitted BSH PCV fix but will be making custom catch can set up

refitted stock 'D' diverter valve

near future mods include:

better custom intake set up

custom manifold / turbo heatshield

better p/s fluid cooler

WMI kit

uprated intank pump

make a new crash bar

source 'open' grill or make my own

remap (3rd time lucky)

next year will be fbsw and some new wheels i think
 
  • Like
Reactions: countwilliam
Excellent write up and cracking looking car. Hats off to you sir.
Did you wrap the chrome mirrors in Carbon or replace them completely?
 
mancdan - thanks, i replaced the covers completely. got these ones from felondnb off edition38 :)
 
Car looks awesome!

Is that grille off eBay? - apologies if this offends!

Just, I want one!

Thanks,

Stui
 
Soooo unfair! :( I wanted rotiform blq 19's on mine once lowered! You beat me too it :/ looks sweet too!

Did you have to add spacers with them? What kind of alignment settings you running too? How far did you lower by also?

So jealous right now lol sweet car :)
 
This is a great thread! Exactly what I want to be doing to mine!! Are the s4 pads and discs a straight fit?
 
That car looks mint mate credit to u fella I have a yellow one great car
 
What a beaut! Do the s4 disks and pads just fit the original dtm callipers or would I need a fitting kit ? Cheers! 👍❤
 
I'm still waiting to see if they do too Jez. That would be my next mod if they do as I need brakes soon!
 
Wow.....that's a lot of beer tokens spent on that! Amazing stuff and lots of ideas there too! Well done Sir.

Cheers
A
 
wow - quite a response over the weekend :0

mancdan - it's a vag forum. i think the covers got thrown out, it wasn't 'til i removed them i saw they were ebay copies.

Macdoon - thanks

Stui - yes ebay item, i was after the more open holes but it's only available from Australia at the mo with £145 postage

Morgan46 - yes, not a lot in comparison with my last car :)

AudiB7Jay - they have 12mm spacers on the rear, all allignment is stock but obviosly had to have tracking done. i didn't take measurements, just lowered it so the front and rear arch to tyre distance was even and there was no contact.

P.S Roti's will be for sale next year

Chris - i was told to fit S4 fronts all you need is discs pads and S4 carriers, i fitted the carriers to my DTM calipers and popped the discs and pads on but the very top and bottom of the caliper contacted the disc. i could have ground a bit out but i picked up the proper calipers for cheap enough and bolted them on.

ANDY - thanks, i still have my dead one sat on the bench :(

CHEZ - thats quite a compliment, thank you

Sewell - thanks, do you have a thread? i'd like to see a yellow one

Jez - see reply to chris above RE brakes :)

Molnbowman - i had my last car 'show car' bora up for sale but decided to break it so when something sold i'd treat the A4.

BA4 - thanks, i need some after my turbo died

Olly - thanks, and thanks for spelling 'Olly' in the correct way :)
 
Cheers mate! One more quick question....
Do you have a guide, or a link to the one you used to get rid of those awful orange reflectors?

thanks :)))
 
Jez - i just went at it :yes: i think i must have seperated and redone my bora headlights in different styles about 6 times.

Olly - thanks, i just went for the leave them off with them chrome / orange bulbs

Solaris - my turbo died a short time after my first MRC mapping session, so i went to turbo dynamics and bought a brand new item and had hybrid work so it should be the same spec as yours now. ordered a new K revision thrust sensor and RS4 pressure regulator yesterday, next will be uprated intank pump then WMI. i'm hoping to crack 400bhp with the hybrid.

i'll also be making a tubular crash bar so i can expose the full fmic and will have to buy / make a more open grill - remove or reduce number plate plinth.
 
ANDY - nearly missed you out :0 it's from an ebay kit for a B6, i looked at a lot of cores from jap to RS500 but this fitted my dimension needs best. the hard pipes, silicon joiners and clamps were all binned and custom pipework made up. the pipes that came with the kit were ridiculously narrow :haha:
 
looking good Olly man, Nice to see the full pics and the bits you've done! Didn't realise the level of love you gave this one (it comes as no surprise though) haha. Catch you soon no doubt for some A4 rolling times! :rockwoot:
 
i'll be happy when it's making good power with a decent map, you know i can't leave things alone. the bora was supposed to be my sensible car....
 
Any build thread of this Bora you speak of :) - would be nice to see other pieces of art you have mastered!

Really jealous of this one - wish i had the funds to buy such a gorgeous vehicle!

Ill have to stick to me SE TDI!
 
WOW!

Ill watch this thread with eager eyes!

*Tail between legs* - Back to work I go!
 

Similar threads

Replies
12
Views
4K
Replies
90
Views
11K
Replies
57
Views
5K
Replies
159
Views
20K