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2008cc 20 Valve Turbo Stroker Build

Discussion in 'The Project Room' started by IN 2 Deep, Oct 14, 2009.

  1. INA
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    INA http://www.inaengineering.com

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    [Oct 18, 2009]
    Good good
    You dont need to cryo treat the block.It is fine the way it is.

    Once it is a wideband ME-7 from a late 2001 then you will be fine to run it Mafless.If you are going to STAY DBC then 034 would be your best bet as they have alot of the DBC 2.0 20V here from builds done in the past.
    The clutch between the 01A and 01E will be the same as both boxes have the same splines on the input shaft.You WILL need the entire assembly from the 01E though which is a bummer....
    If you are considering the VR6 then definately go with a standalone system that will allow both 4 and 6 ignition inputs.
    Good to go Id say
    #41
  2. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Oct 18, 2009]
    Issam , nice to see you imparting your wisdom over here too. I have seen you many times educate the masses on the Zine.

    I am not sure we had ME7 until the B6 as our quattros are AJL engines, which are basicly hte same as AEB but with 30 BHP more. DBW was only used on our small port APU engine, but that was only the later unit, and again still not 100% it's a wideband unit.

    Would an imported ECU from the US code to work with our dash/immo system
    #42
  3. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 18, 2009]
    Issam, Thanks for the advice, regards the 01E set up do I need the S4 rear subframe as well and what about rear drive shafts? The 034 EFI set up would literally be plug & play with the 034 AEB loom on my AJL? And are you saying it could be supplied with a decent base map? Would it be sufficient to break the engine in intially. This is one part of the build im still unsure of, The other being the vacuum set up as I will be ditching the PCV set up.

    Byzan A4 I had a quick read of some of the ECU testing you've been doing. All very clever stuff, I have no idea about any of that. Am i right in thinking your trying to find a flashable OEM solution for the AJL?
    #43
  4. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Oct 18, 2009]

    Yes thats the plan mate !!
    #44
  5. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 18, 2009]
    Interesting! I will be sure to keep an eye on your progress:icon_thumright:
    #45
  6. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Oct 18, 2009]
    I am hoping its the way to get a flashable ECU into a B5. Only pitfall is the fact it's not wideband...

    I know JCB has imported a chip/ECU to run his 2.0 stroked AEB not 100% What style of ECU it is.
    #46
  7. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Oct 19, 2009]
    Quick question, the BIG turbo in the pic, that a copy for mock up purposes?

    No Garret markings on it..
    #47
  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 19, 2009]
    Nice build... similar route to what I was initially planning on my S3.

    I was going to go stroker but decided against it due to the expense of it all and would rather use the money on something that gave me better bang for buck.

    Only thing I would do differently on mine now is the valve gear while the head was off but didn't really have the money at the time. Those and a clutch are next on my list.

    Be interesting to see how the 2008cc helps the spool etc... at some point I will look at an overbore to 1.9 but doubt I will go the full stroker route myself now.

    Good luck with it mate, doing a great job :)

    <tuffty/>
    #48
  9. INA
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    INA http://www.inaengineering.com

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    [Oct 19, 2009]
    Glad to be here
    It should,dont see why not as VAG didnt change connections between RHD and LHD thats for sure.

    Rear drive shafts should work between 01A rear and 01E rear but you will be hard pressed to find a pick and pull that will sell you a gearbox,prop shaft and rear diff WITHOUT the rear axles.
    Harness will be built for a DBC 1.8T motor whether ADR.AEB or AJL...does not matter where you pout the ecu to be honest.
    #49
  10. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 19, 2009]
    I believe it to be a Garrett GT3076R with a Kinetic Motorsport ported compressor housing. It does say Garrett on the turbine housing. Any other way of checking for sure? I've never really thought to check!

    Thanks Tuffty.

    I too cannot wait to see how this thing will spool. Regards the build, I knew from the start that I would need a built motor, solid clutch and head that would take a kickin. So while looking at my options I realised to stroke it would only take a bit of extra time so what the hell! The cost differential is only very small, while the difference in CC could be as little as 38cc the rod ratio's are different.

    Isaam whatever happened to that 2.2 20V long block motor? Would love to hear that on a dyno.
    #50
  11. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 19, 2009]
    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:-

    [​IMG]

    [​IMG]

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


    [​IMG]

    S4 B5 rear bumper

    [​IMG]
    #51
  12. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 19, 2009]
    And the interior mods thus far, as always more to come:-

    [​IMG]

    [​IMG]

    Carbon fibre belt line trim, Gear surround, front & rear ash trays, hazard light surround, steering column surround. Centre trim to be finished.
    #52
  13. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 20, 2009]
    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.

    [​IMG]

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

    [​IMG]
    #53
  14. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Oct 20, 2009]
    Nice one, was worried for you. I like the CF bits, you doing them? Or having them made?
    #54
  15. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 20, 2009]
    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.
    #55
  16. INA
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    INA http://www.inaengineering.com

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    [Oct 22, 2009]
    I really hope thats a 2.5" 4 bolt discharge...LOL
    #56
  17. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 22, 2009]
    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.
    #57
  18. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 22, 2009]
    Just a taster of what's to come:-

    [​IMG]

    [​IMG]

    Lovin it!
    #58
  19. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 29, 2009]
    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.

    [​IMG]
    #59
  20. RyanJonS4
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    RyanJonS4 Drive It Like You Stole It

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    [Oct 31, 2009]
    here, here.........
    #60
  21. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 31, 2009]
    "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.
    #61
  22. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 31, 2009]
    Glad to see I'm not the only one annoyed with this 'tard
    #62
  23. NHN
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    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

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    [Oct 31, 2009]
    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.
    #63
  24. Staz
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    Staz is a retronaut Staff Member Moderator VCDS Map User

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    [Oct 31, 2009]
    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.
    #64
  25. billybravo
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    billybravo MODERATOR

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    [Oct 31, 2009]
    very nice build mate well done did you ever get the cat cams?
    #65
  26. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 31, 2009]
    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?
    #66
  27. billybravo
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    billybravo MODERATOR

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    [Nov 1, 2009]
    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.
    #67
  28. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 1, 2009]
    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.
    #68
  29. satans child
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    satans child project...satans child

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    [Nov 3, 2009]
    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...:icon_thumright:

    anyone intrested in this sort of thing please do contact me...
    #69
  30. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 3, 2009]
    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!
    #70
  31. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 8, 2009]
    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.
    [​IMG]


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

    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.

    [​IMG]

    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
    #71
  32. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Nov 8, 2009]
    I have a spare s4 upright here and some Cvs if anyone needs them for project work or similar.
    #72
  33. INA
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    INA http://www.inaengineering.com

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    [Nov 8, 2009]
    These are the ever famous calipers mate?
    #73
  34. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 8, 2009]
    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.
    #74
  35. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 22, 2009]
    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!

    [​IMG]
    ARP Main Cap Studs in

    [​IMG]
    Crank torqued down.

    [​IMG]
    Rods in with ARP fasteners and Calico Coated Race Bearings.

    [​IMG]
    Pistons finally moved into there new home!

    [​IMG]
    ARP Head Studs Installed

    [​IMG]
    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.

    [​IMG]
    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?

    [​IMG]

    [​IMG]
    3" downpipe test fitted.


    [​IMG]
    #75
  36. NHN
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    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

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    [Nov 22, 2009]
    Oooooooooohh this is looking lovely
    #76
  37. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 24, 2009]
    She is getting there! Not much left to sort out now. Wont be long before the dyno videos are posted!
    #77
  38. NHN
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    [Nov 24, 2009]
    You're a tease, lol
    #78
  39. INA
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    INA http://www.inaengineering.com

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    [Nov 29, 2009]
    its amazing how CLEAN UK engines always are.
    #79
  40. Mattfaced
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    Mattfaced Member

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    [Dec 15, 2009]
    :blackrs4: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?:blackrs4:
    #80

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