Thread: 2008cc 20 Valve Turbo Stroker Build

And just to update further on more planned / in progress mod's.

Bumpers are being replaced with these, Also have side skirts & lower door mouldings to match:-





Modified front S4 B5 bumper, centre grille & bar removed and flushed ~ Work in progress




S4 B5 rear bumper

And the interior mods thus far, as always more to come:-





Carbon fibre belt line trim, Gear surround, front & rear ash trays, hazard light surround, steering column surround. Centre trim to be finished.

After Byzan A4 got me wondering exactly what turbo this was, I had a quick look. The CHRA has a Garrett plate on it, as well as the hot side shell (sigh of relief!) and it is a Garrett GT3076R. Im guessing the compressor housing is just a kinetic motorsport ported piece.



And the 38mm TiAL wastegate, No more internal wastegates for me

Nice one, was worried for you. I like the CF bits, you doing them? Or having them made?

I do all my own CF work, I'm still perfecting my process to be honest but its certainly coming along, The part in the picture is the exterior B pillar trim made entirely of carbon fibre not a skinned part.

I really hope thats a 2.5" 4 bolt discharge...LOL

Well to update on progress, I have placed another large order to keep this project progressing. Hopefully all the parts are making there way into a box right now with my name on it!

Ordered:-

Southbend Stage IV clutch & Steel billet flywheel
SPA Turbo manifold
Turbo Oil & coolant lines
V band exhaust housing adaptor
Catch can
Fuel rail
Engine mounts
Snub mount and bracket
Gearbox mounts
Rear diff mount
diff carrier mounts
rear subframe mounts
front subframe mounts
Phenolic inlet spacer
and a few nuts, bolts and gaskets!

Pictures will follow when it gets here.

Just a taster of what's to come:-





Lovin it!

Well just to keep the thread updated, I'm still awaiting my parcel from the states, I believe its the clutch holding up the show. In the mean time I have managed to piece together all the parts for my final brake set up, I now have the S4 hubs/uprights, S4 driveshafts and correct size gearbox drive flanges to mate to the S4 shafts courtesy of Aragorn, Nice one fella!

I have also negotiated a deal for some 4 pot Brembo mono calipers, 345mm discs, custom S4 carriers & pads from a good friend, your a star Dave. The donor vehicle for the calipers was a Ford GT40! The piston sizes calculate real well to work with the master cylinder, I just need the RS4 B5 rears to balance it all out and should be good to go.

please just ban him! He's been nothing but annoying and ruining this forum

here, here.........

"I asked how where you get adapters to mount the calipers noobs" - Doesn't make any sense but with bolts I guess!

"you need brackets so you get them from someone or you make them yourself" -Either way you've answered your own question.

Simple question don't think of yourself as some holy god -I don't! Simple question from a simple person, if you expect a serious answer I suggest you adjust your attitude clever arse.

Originally Posted by RyanJonS4

here, here.........

Glad to see I'm not the only one annoyed with this 'tard

Guys this is not what the forum is about, using language like that is totally out of order, tone it down or mods will be along & the thread then will be closed.

As I asked before, please can a mod remove all the rubbish posts & get it back on track, as it was fairly good before this ridiculous childish attitude started from a number of members, not just 1.

That sort of language is totally unacceptable on ASN GGrmk. You seem to have a great ability in annoying others, perhaps it's time you learned to get along with people and learn how to act like an adult instead of lashing out with childish verbal abuse.

Gents there's a useful tool in the User Control Panel where you can ignore other users. I think this is a good opportunity to try it out.

very nice build mate well done did you ever get the cat cams?

Originally Posted by billybravo

very nice build mate well done did you ever get the cat cams?

Cheers fella, The cat cams are still on the shopping list at the moment. I intend to pick these up in the new year sometime, I would really love to see some dyno graphs to compare the cat cams Vs the OEM ones. Any chance you have something like that?

i can ask the Question but i doubt it alot of ppl run these cams out in the states so there might be more info out there but everyone's set up is different.

Was it you who rang me regarding these cams

you will have to come by the shop one day when she is done would love to see this car.

I realise its a bit of a strange request because every car is different, Just interested to see the difference in power delivery really.

Yeah that was me who called you, glad I was sat down at the time! LOL There not cheap hey.

Sure if I'm ever over your way I'll be sure to stop by and take you for a blast.

damien ....

any questions you have about cat cams .. feel free to ask me bud..
i can offer you a few different profiles, depending on useage... ie, dd or strictly track/drag

im suprised you didn't ask me .. as ive said .. heads are my thing...

anyone intrested in this sort of thing please do contact me...

Cash is tight at the moment fella but we do need to have chat soon my man. Still awaiting my parts, seems there is a problem!

Update, I couldn't find this information prior to buying the parts so I thought I would share with you all the differences between the A4 & S4 hubs carriers as im sure this will be of interest

The brake carrier lugs are alot further apart on the S4 and the S4 also uses an M14 bolt over the A4 M12's which should make for a stiffer set up. You can also see that the diameter of the driveshaft splines is larger, therefore you need at least the S4 outer CV to fit the S4 uprights to an A4 using the A4 driveshaft.



Also the lugs are alot further back on the hub which allows fitting large brembo's alot easier, there also noticeably meatier.


Here is also a picture of my brakes test mounted to the upright. I managed to get my hands on some used ECS tuning two piece 350mm discs to go with the Ford GT calipers, needs a little tweaking yet but its within a few mm's so will only needs a lick taking off the carrier.



Sorry for the blurry pic's only had my iPhone.

My parcel has now landed in the UK from Fremont California, I should receive it any day now. Updates will follow

I have a spare s4 upright here and some Cvs if anyone needs them for project work or similar.

These are the ever famous calipers mate?

That's right mate, these are the ones. Interestingly they have a small Aston Martin symbol in the casting, They are definitely Brembo's and I suppose Ford now own Aston Martin, looks like they may have borrowed some brakes for there GT.

Been very busy lately so progress has been a bit slow, good news though I have received the clutch & flywheel along with some other goodies, this meant I could finally get the entire rotating assembly balanced and crack on with building the motor back up. Fetched all the parts this Saturday morning and got busy building!


ARP Main Cap Studs in


Crank torqued down.


Rods in with ARP fasteners and Calico Coated Race Bearings.


Pistons finally moved into there new home!


ARP Head Studs Installed


Cylinder head fitted.

I couldn't stop there, I had to fit everything else just to see how it would look. I still need the gaskets, seals, nuts & bolts for most of the ancillary parts.


The red parts have come out a funny colour in the pictures, looks totally different in the flesh. Still contemplating repainting the red in silver?




3" downpipe test fitted.

Oooooooooohh this is looking lovely

Originally Posted by NHN

Oooooooooohh this is looking lovely

She is getting there! Not much left to sort out now. Wont be long before the dyno videos are posted!

You're a tease, lol

its amazing how CLEAN UK engines always are.

Exellent, should have gone to bed hours ago but found this!! Looks great so far, When runnig a car of this power is it a constant battle with problems stuff breaking ect? Or if you do your research can these problems be avoided?

Wow, this thread is great...good work on the project. I am rather excited to see the dyno'd engine!

brilliant read keep up the good work

Thanks for your comments guys, a bit of encouragement always helps. It amazes me how lazy i can be with this project considering I cannot wait to drive the piss out of it!

Mattfaced I have no idea what problems im going to encounter with this motor, I have done a fair bit of research about though and they do seem fairly stout, that said I have seen a good number fail also but im hoping that i have learnt from others and will do everything possible to avoid the usual failures, most motors die becasue the keyway on the crank timing pulley shears off losing the timing and its game over. I have dowel pinned my pulley to the crank so if the keyway shears the dowel will keep the timing. My other concern is for the gearbox, although again these have been used on some serious horsepower drag cars. Im sure with a little mechanical sympathy it should hold up just fine.

Progress has been slow since its getting cold and dark at night now, I have just bought myself a TIG welder which Ive been meaning to buy for a long time now, this will enable me to construct the exhaust piping and the intercooler charge piping once the weather permits. Im hoping to get this lot finished, tuned and rolling before summer! Lots to do still but Ive broken the back of it now so it should come together fairly quickly.

I want more!!!Great job.

Cracking detail and work goin into this mate, keep up the good work.

Know wot u mean about getting lazy, ive got wheels to paint, bodywork and kit to prep, etc etc and really want to see it cum together but cant seem to muster the energy sumtimes!

How did you make the carbon interior pieces? Did you skin these parts or are they done completely in a mould etc???

Sorry for the lack of response I've been a tad busy with all this Christmas stuff!

Spyrious - Stay Tuned more is on the way! In the New Year this thing is going to get finished and as usual I will take loads of pictures

Foxmeister - Thanks for the kind words, Crazy how lame I can be! Chucked loads of cash at this project so far and the car itself has hardly changed. I find it easy to get lazy with the cold nights and the fact im slowly getting addicted to Call of Duty Modern Warfare 2!

On a positive note I have been negotiating the use of a large heated workshop so I can crack on in the New Year and get this project moving again, My plan is to take the Audi off the road while I complete the rest of the work, I reckon a couple of months and i can have this lot done.

The CF interior bits are skinned original parts, why do you ask? Are you going to do the same?

Originally Posted by IN 2 Deep

The CF interior bits are skinned original parts, why do you ask? Are you going to do the same?

Done so mate, been working on them the last month. Just wondered if somebody had actually done moulds etc as i just skinned my parts also.

Doing some more parts soon.

Where are my updates?

Small update! I have now received the front snub mount and bracket as well as the turbo oil & coolant lines from the states, many thanks Issam for sorting that out.







My only concern with the hoses are weather I can clock the turbo correctly to keep the oil way axis vertical, its all a bit tight under there! The other thing is don't want the hoses resting on the manifold without some kind of heatshield to protect them, anyone got any ideas what to use?

Im hoping to get this project moving again now Christmas and New Year are out the way! I will be ordering all the seals, gaskets, oil pump, head chain tensioner nuts and bolts I need to finish the motor next week.

Issam I've heard it said that the 1.8T rear crank seal doesn't seal all that well on these 92.8mm cranks, do you know if the crank seal from the parent engine would fit the 058 block? Or any other suggestions?

I need to order up some more parts fairly soon:-

Intercooler set up - Anyone any suggestions, I could buy the cooler and fabricate the piping myself but this will take time, a complete kit would be better something like the Evolution Racewerks item looks favourite.

ECU - Thanks to Jack for sourcing me a 034 stage IIc ECU, just need a loom now, i was wondering if i could use the loom 034 sells for the AEB motors with this ecu and run sequential ignition? Don't like the sound of 7100rpm red line! Also what do I need for the wideband with the 034 ECU, Issam please educate me on the options here.

Fuel pump, regulator and injectors - I was going to use the 034 Motorsport intank 044 Bosch unit again for simplicity of installation. What regulators would you recommend and which injector type do i need for the 034 Ecu? Low or high impedance? what size also i was thinking 840cc?

One last thing, whats the word on these Fluidamper pulleys Issam? Are they worth the $? I have read alot of threads where engines have vibrated to pieces, do these pulleys really help that much?

Sorry for all the questions!

Originally Posted by Foxmeister

Done so mate, been working on them the last month. Just wondered if somebody had actually done moulds etc as i just skinned my parts also.

Doing some more parts soon.

Good work! Its not easy though is it! But practice makes perfect. The one thing that I found helps more than anything is the temperature your working in, if its cold or humid then your buggered. Have you noticed any milky patches in your finish?

Originally Posted by IN 2 Deep

Good work! Its not easy though is it! But practice makes perfect. The one thing that I found helps more than anything is the temperature your working in, if its cold or humid then your buggered. Have you noticed any milky patches in your finish?

Not easy at all mate, very time consuming also but i love the stuff!

True with the temp also, had been doin mine in the garage there but with it being so cold i had to do some of it in the house.

Managed to complete everything without any milky patches, i found using a hairdryer after each application of topcoat helps to clear the small air bubbles which cause the milky appearance. Also, i tend to apply one or two more topcoats than is advised, this gives more material to rub down at the end to flat parts out and more chance of sanding away any air trapped near the surface. Get some more pics up of your other stuff, looks good. Mine are in the thread in the project room if u want a butchers!

Originally Posted by Foxmeister

Not easy at all mate, very time consuming also but i love the stuff!

True with the temp also, had been doin mine in the garage there but with it being so cold i had to do some of it in the house.

Managed to complete everything without any milky patches, i found using a hairdryer after each application of topcoat helps to clear the small air bubbles which cause the milky appearance. Also, i tend to apply one or two more topcoats than is advised, this gives more material to rub down at the end to flat parts out and more chance of sanding away any air trapped near the surface. Get some more pics up of your other stuff, looks good. Mine are in the thread in the project room if u want a butchers!

Very time consuming indeed! All that flatting back will eventually make you insane.

The milky appearance is caused by the excessive moisture in your working environment which reacts with the air and the epoxy obviously its known widely as an amine blush, proper nightmare really. I made a small oven out of a cardboard box with a single 60 watt bulb in it, insulated under some blankets (sounds dangerous I know) but this works a treat, leave everything to cure in there and jobs a good'an. I will be sure to check out your progress in your thread and i will post up some pic's of some of the stuff I've done later, need to clean the car! I quickly moved away from skinning because of all the sanding, working from moulds is the way forward i think as the carbon looks so different out of a mould. I intend to re-do the parts I've done at some point by making moulds for everything. Which epoxy system do you use?

Originally Posted by IN 2 Deep

Very time consuming indeed! All that flatting back will eventually make you insane.

The milky appearance is caused by the excessive moisture in your working environment which reacts with the air and the epoxy obviously its known widely as an amine blush, proper nightmare really. I made a small oven out of a cardboard box with a single 60 watt bulb in it, insulated under some blankets (sounds dangerous I know) but this works a treat, leave everything to cure in there and jobs a good'an. I will be sure to check out your progress in your thread and i will post up some pic's of some of the stuff I've done later, need to clean the car! I quickly moved away from skinning because of all the sanding, working from moulds is the way forward i think as the carbon looks so different out of a mould. I intend to re-do the parts I've done at some point by making moulds for everything. Which epoxy system do you use?

Good idea about the oven, maybe try make one myself at sumpoint.

Im still using the original kit that i started with from Carbonmods, but found a different supplier for carbon that ive since bought and will look for individual resins etc when needed as i wont be needing a complete kit all the time.

Well grab those proper light bulbs while you can! Someone somewhere decided to stop making them. They don't seem to last that long either and go a bit brittle after getting pretty hot so watch those fingers! Next your gonna want a vac pump and some moulds! Checked your thread out, ****s looking good fella.

I better get my finger out!

Originally Posted by IN 2 Deep

Well grab those proper light bulbs while you can! Someone somewhere decided to stop making them. They don't seem to last that long either and go a bit brittle after getting pretty hot so watch those fingers! Next your gonna want a vac pump and some moulds! Checked your thread out, ****s looking good fella.

I better get my finger out!

Cheers mate.

Yep, gonna look into wot i can do with moulds in the future, really interested in goin that route aswell. Will get some more done soon as the weather decides to stay above freezing!

Well now its above freezing I've been in the garage sorting a few little problems out, number one was to sort out the three bottom exhaust manifold studs that were stopping me mounting the manifold up. Had them turned down to make this a bit easier to do! Did the same with the back two turbo to manifold studs as they were a nightmare to get the nuts on.






Need to wrap the downpipe and fit heat sleeves over the turbo hoses that are resting on the manifold, ordering all the other gaskets, seals and sensors from Audi on Saturday to finish this motor off until it goes in the chassis.

Next task for me is to sort the wiring! Please tell me someone can help? Anyone have a wiring diagram?

bud .. get some oil wiped on that manifold and your turbine housing before it goes even more rusty..

Good shout fella, don't know why I didn't think of that In fact I'm going to do it right now!

Diagram for which bit?
All the sections are seperatly shown in ELSAWin

Originally Posted by Byzan A4

Diagram for which bit?
All the sections are seperatly shown in ELSAWin

The ECU pinout would be a great help. Where can i get a copy of ELSAWin?