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

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

    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







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





    and after the work spruce the bay up a little

    Last edited by olethalb; 16th November 2012 at 13:41.

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  3. #2
    olethalb's Avatar
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    after the engine had been treated it was time for wheels, these came up fairly cheap so snapped them up




    next was to 'joey' the headlights and de tango





    soon after the long awaited coils arrived




    and with 12mm spacers a little fitment



    also ebayed a leather arm rest


  4. #3
    olethalb's Avatar
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    more power was on the cards so started accumulating parts

    k04



    DV



    one stage cooler plugs



    s3 injectors



    with more to follow.....

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





    aux belt tensioner started clicking so on with a new one


  5. #4
    olethalb's Avatar
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    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




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

    ATP 3" decat




    polybush snub mount



    milltek cat back system



    Autotech HPFP internals



  6. #5
    olethalb's Avatar
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    the day of exhaust fitting came






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



    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



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



    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




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







    perfecto

  7. #6
    olethalb's Avatar
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    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




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






    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







    painted and fitted






  8. #7
    olethalb's Avatar
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    next was the modified k04

    tt225 outlet welded on





    downpipe bolts repostitioned and rethreaded



    test fitted





    bolted up



    intake with recirc inlet for DV





    front end slotted back on with no mods or trimming



    DIY heatshield box




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



    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

  9. #8
    olethalb's Avatar
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    oh one from Surrey RR day today - ignore the tit in the wifebeater



    few more pics - one from players



    one with new honeycomb satin grill



    and completed the de-chroming with some carbon fibre mirrors




  10. #9
    olethalb's Avatar
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    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

  11. #10
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    Excellent write up and cracking looking car. Hats off to you sir.
    Did you wrap the chrome mirrors in Carbon or replace them completely?
    2005 B7 A4 2.0T in Moro Blue

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


  12. #11
    olethalb's Avatar
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    mancdan - thanks, i replaced the covers completely. got these ones from felondnb off edition38

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    whats edition 38?
    Also,dso you still have your chrome mirrors?
    2005 B7 A4 2.0T in Moro Blue

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


  14. #13
    Macdoon's Avatar
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    Quote Originally Posted by mancdan View Post
    whats edition 38?
    Also,dso you still have your chrome mirrors?
    Here ye go fella

    Edition 38

    Mac
    A4 B8 (09) 2.0 TFSI (211)

    Black Gloss RS4 style mesh grille, Black Gloss fog grilles, Black Gloss splitter trim, Ice White fogs, Tints, Black A8 boot rings, Black Badges, Dynamik boot spoiler.

  15. #14
    stuiwhite's Avatar
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    Car looks awesome!

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

    Just, I want one!

    Thanks,

    Stui
    Past fleet:

    2001 Saxo VTR (To bridge gap to A4!)
    1996 Toyota Starlet GlanzaV
    2001 Ibiza Cupra
    1996 Honda CRX Del Sol (B18C4 powered)
    2008 SEAT Ibiza
    1998 Peugeot 106


    http://www.audi-sport.net/vb/project-room/171641-stuiwhite-a4-b7-1-9-tdi-se-build.html#post1706798

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    Is that all you've done lol

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    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

  18. #17
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    my DTM 'build' - story so far, hybrid K04 - custom FMIC

    This is a great thread! Exactly what I want to be doing to mine!! Are the s4 pads and discs a straight fit?
    Imola Yellow A4 DTM. Retro fit cruise and arm rest.
    Contact Admin to advertise please

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    ANDYTQ's Avatar
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    Looks stunning, i'll be the last to fit my ko4 at this rate lol,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.

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

    Doubtful Andy ill be one of the last! Lol
    Imola Yellow A4 DTM. Retro fit cruise and arm rest.
    Contact Admin to advertise please

  21. #20
    CHEZ's Avatar
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    easily the best DTM i have seen!
    well done fella!
    .................................................. ..........


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

    Agreed!!!
    Imola Yellow A4 DTM. Retro fit cruise and arm rest.
    Contact Admin to advertise please

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    That car looks mint mate credit to u fella I have a yellow one great car

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    What a beaut! Do the s4 disks and pads just fit the original dtm callipers or would I need a fitting kit ? Cheers! ❤

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

    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!
    Imola Yellow A4 DTM. Retro fit cruise and arm rest.
    Contact Admin to advertise please

  26. #25
    Molnboman's Avatar
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    Wow.....that's a lot of beer tokens spent on that! Amazing stuff and lots of ideas there too! Well done Sir.

    Cheers
    A

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    BA4
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    really really nice car, best of luck with it

  28. #27
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    Awesome DTM, given me some ideas!

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    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

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    ANDYTQ's Avatar
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    Pipework looks really neat,where did you source the front mount from?
    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.

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    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 ))

  32. #31
    Olly P's Avatar
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    Clear corner mod:
    DIY: CC (Clear Corner) Mod

    Replacement covers (can just leave them off):
    EURO CLEAR CORNER LENSES NOW AVAILABLE FOR PURCHASE!

  33. #32
    solaris's Avatar
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    Well done, good to see another DTM with a KO4
    If it's not longitudinal and it's not Quattro..it's not an Audi
    VCDS (VAG-COM) HEX-CAN USB cable carrying member
    2005 A4 DTM 2.0 TFSi Quattro :364Bhp/477NM - Mapped by MRC Tuning
    Hybrid K04 Project ongoing (link to Build thread)

    DMFW + Clutch For Sale



  34. #33
    olethalb's Avatar
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    Jez - i just went at it 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.

  35. #34
    olethalb's Avatar
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    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

  36. #35
    Golfedd's Avatar
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    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!

  37. #36
    olethalb's Avatar
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    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....

  38. #37
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    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!
    Past fleet:

    2001 Saxo VTR (To bridge gap to A4!)
    1996 Toyota Starlet GlanzaV
    2001 Ibiza Cupra
    1996 Honda CRX Del Sol (B18C4 powered)
    2008 SEAT Ibiza
    1998 Peugeot 106


    http://www.audi-sport.net/vb/project-room/171641-stuiwhite-a4-b7-1-9-tdi-se-build.html#post1706798

  39. #38
    olethalb's Avatar
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    haha - there's one on ukmkivs but it's about 70 pages long.... here's the revised one for the US market

    VWVortex.com - UK white bora build

    from



    to






  40. #39
    stuiwhite's Avatar
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    WOW!

    Ill watch this thread with eager eyes!

    *Tail between legs* - Back to work I go!
    Past fleet:

    2001 Saxo VTR (To bridge gap to A4!)
    1996 Toyota Starlet GlanzaV
    2001 Ibiza Cupra
    1996 Honda CRX Del Sol (B18C4 powered)
    2008 SEAT Ibiza
    1998 Peugeot 106


    http://www.audi-sport.net/vb/project-room/171641-stuiwhite-a4-b7-1-9-tdi-se-build.html#post1706798

  41. #40
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    All I can say is mint well done

 

 
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