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2008cc 20 Valve Turbo Stroker Build

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

  1. DaveB1970
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    DaveB1970 New Member

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    [Apr 2, 2011]
    Andy pop in for some proper anti squeal shims, got a b5rs4setup as well for buttons best price on the discs though is 440!!!!!
  2. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Apr 16, 2011]
    Cheers fella, that is exactly what I intended when I set out with this project, build a beast for the road pure & simple. No flash paint jobs, pulled arches, stretch, poke or any kind of bags for me. Just a purpose built point to point animal and think I've achieved my goal and I can honestly say I'm almost content with it the way it is, well almost :)

    I will try & pop round sometime during the week, it'll be good to see you again matey its been a while. I'll give you a ring to see when your about.

    Well my goal was to re-assemble the A4 and have it ready for the 16th to take to Modified Live at Oulton Park. I've worked endlessly to sort out the issues make some changes and further mods. In the end I made it, just! I finally got the car road ready late last night for an 6:00 start this morning, in a tired daze I forgot my bloody camera though, idiot. I'm hoping someone else I went down with managed to snap a couple for me. Any who some pics of the recent changes

    I binned the standard oil cooler suspecting it to be a potential cause of the oil in coolant issue in favour of the Mocal unit, problem is there is sod all room in the front of these B5's without it turning into a hackjob. Heres where it ended up anyway

    [​IMG]

    I even got all fancy and used captive nuts, also note new rad as well!

    [​IMG]

    I know someone will say its upside down & I know this but its better to cool the heat exchanger than the pipe fittings right? Anyway it works a treat and oil temps are way down compared to the water cooled OEM unit, I've noticed the viscous fan also draws loads of air through it so even stood in traffic should be alright, it now maintains at about 80 even after a brief mash of the loud pedal, result.

    Mounting this cooler displaced the power steering cooler so it needed a new home, shoved it down here with another dodgy bracket I made.

    [​IMG]

    It didn't work and I think I may have boiled the fluid a little today, so it will need moving again, space is getting properly tight upfront now. And whilst on that subject I made some mods to the intercooler pipes as I will never get the S4 bumper grills in without making some changes.

    [​IMG]

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    Much neater I think you'll agree, I managed to remove two bends and considerable length from both sides so happy days. Also got the motor back in one piece thats obviously alright now, for the moment :whistle2:

    [​IMG]

    Well thats everything mechanical attended too. Now i thought it was time to try and work my way through the tar & bird bombs, find my paint and try and revive a little bit of shine on the old girl. No real before pics unfortunately but it was swirly mess.

    First I used these to prep the paint for polishing:-

    TFR
    Meg's gold class wash
    Tardis
    Iron-X
    Bilt Hamber clay
    Meg's Deep Crystal paint cleaner
    Masked off rubbers, headlights etc

    Set too with the DAS6pro & Sonus pads. I found the Sonus compounding pad with Menzerna 85RD3.02 removed all the bird etchings & heavy swirling and finished down quite well, still then buzzed over it with Menzerna final finish 3000. There is still some random scratches & swirling but not worth cutting out in my opinion, I took loads of pics but can't tell them apart my camera is ****! So here is the best one I have, this could well have been after I applied the carlack 68 nano systematic cleaner followed with two coats of carlack 68 long life sealant, the camera actually almost shows the flake pop.

    [​IMG]

    Wheels followed a similar pattern with cleaning, the Iron-x has literally repaired what I thought were knackered wheels, it removed all and I mean all the embedded rusty horrible mess from the inside of my wheels, proper chuffed. I then also used Carlack68 NSC to clean the wheels further followed with three coats of poorboys wheel sealant.

    [​IMG]

    Now the car was all shiny it was time to finally assemble all the bodywork in silver, the body shop did an amazing job painting it all, even came down to my house with spray samples testing colour match, I had a word with the sprayer and asked for a few extra coats of clear ;)

    Skirts & door mouldings on

    [​IMG]

    New rear bumper

    [​IMG]

    Oddly I dont have pic from the front, I will post one up tomorrow.

    As it stands now

    [​IMG]
  3. Foxmeister
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    Foxmeister Fired Up!

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    [Apr 17, 2011]
    Loooking fantastic mate, great once your over that almost finished hurdle eh? Then again, these projects are never finished really, just ready fir the next stage !!! Ha ha
  4. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Apr 17, 2011]
    Cheers mate, It does feel good when it all starts coming together especially considering how long I've been at it, I can't stop looking at it, just looks completely different now and dare I say actually looks quite mean. I will be leaving it alone till the end of summer now I think, just want to get out and about in it really, maybe a few more little cosmetic mods but nothing mental, might even turn the boost down a touch.

    Here's some pics from the front

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    And a comparison of when I got it to how it is now.

    Before

    [​IMG]

    After

    [​IMG]
  5. MUSH
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    MUSH MUSH Developments Ltd.

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    [Apr 19, 2011]
    Love this thread, ive checked in on it for quite a while now. Has given me great inspiration for my GT30 S3 project. Like the dedication you have given tot he project.

    Great stuff!!
  6. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Apr 19, 2011]
    fantastic work as always...proper sleeper :applaus:
  7. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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  8. crazy88
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    crazy88 Loving the anonymity

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    [Apr 19, 2011]
    That looks friggin amazing dude!!!! Bet you're loving it. Thanks for that final update, glad it all seems to be working sweet as a nut. I'll miss reading about your projects.

    Whats next? Hehe
  9. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Apr 20, 2011]
    Cheers dude, always good to hear people enjoy reading it, makes it all worth while, good luck with your build as well, you should start a thread. Its always nice to see what everyone else is up to.

    :beerchug:

    Cheers matey, she's gettin there hey.
  10. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Apr 20, 2011]
    :thumbsup:

    Thanks man, I have to confess I actually do love it, its awesome & beyond my expectations. I'm well chuffed with how its turned out, I'm still not done yet though, there a few more minor mods and of course some kind of footage to top it off, when I finally get my lazy arse round to it that is!

    Thanks everyone for your continued interest :salute:

    Andy
  11. MUSH
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    MUSH MUSH Developments Ltd.

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    [Apr 20, 2011]
    ive got a thread in the A3/S3 section mate, thought it was more relevant at the time and its just spiralled into a build thread.
  12. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Apr 20, 2011]
    Cool I will have a look during lunch see if I can find it and have a mooch.
  13. MUSH
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    MUSH MUSH Developments Ltd.

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    [Apr 21, 2011]
    Please do mate, your opinion would be great!
  14. LeeT
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    LeeT Member

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    [May 22, 2011]
    Awesome read! Great thread, thanks for sharing. Gives me plenty of ideas
  15. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [May 22, 2011]
    Cheers matey, glad you enjoyed the read. I still have a few plans left up my sleeve before I close the cheque book on this build but im staying tight lipped for the time being. Now I have the S2 also I think its time to start turning my spanners on that if I want to keep it, its easy to forget its 18 years old and defo needs some love, maybe I will start another build thread for it but im determined to keep the expenditure reasonable if thats at all possible lol.
  16. Teddy
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    Teddy New Member

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    [Jun 27, 2011]
    I've always wondered what this car had done to it when I walked past! I could see the fancy brakes so obviously something clever had been done to it.
    I liked the original wheels!
  17. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 27, 2011]
    Alright Teddy, you should say hello next time you walk by I'm normally faffing with one of the quattro's on the drive!

    I would have liked to have kept the original wheels but they didn't fit over the brakes and wheel spacers wasn't an option for this car, the wheels on there now are function rather than form, they're much lighter & wider than the original Ronals and much stronger. Have to admit though I do find myself constantly looking at wheels.

    I took the car to Wales over the weekend with a mob of other fast automobiles to drive round the EVO triangle, horseshoe pass and few other awesome roads I've forgotten, what an epic drive out it was and just on my doorstep, well nearly lol. The car performed faultlessly and im gaining confidence in it more & more.

    A pic from the weekend

    [​IMG]
  18. jasona3turbo
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    jasona3turbo Member

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    [Oct 12, 2011]
    best read by far mate amazing work and effort well done!!
  19. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 13, 2011]
    Why thank you fella:salute:

    I'm glad you enjoyed the read and actually left a reply, most wouldn't and don't, hence I don't really frequent this forum anymore, plus im spuds deep into my S2 so far too busy, the A4 has also naturally evolved, maybe one day I will take the time to bring the thread up to date.

    Cheers, Andy
  20. oubas2
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    oubas2 New Member

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    [Nov 8, 2011]
    thankyou for spending the time to do a detailed build thread, looking forward to doing mine, cheers
  21. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 9, 2011]
    Cheers mate, always nice to hear someone has enjoyed reading the thread. If you need any help regards your build feel free to PM me, I didn't include all the technical info as it tends to make for a very boring read! If you want to discuss tolerancing of a 500+HP motor I will gladly chew your ear! The specs are very different to an OEM motor. My engine has done over 11K miles now running circa 2BAR boost and pulls better than ever:thumbsup:

    Make sure you start a thread matey, we all like a proper build thread.

    EZ
  22. StaceyS3
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    StaceyS3 Well-Known Member

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    [Nov 13, 2011]
    Have just read this from start to finish and what an amazing build and effort, the workmanship is second to none i have just rebuilt my motor after failure and although i was fairly thourough i wish i had taken the effort to put i n as much attension to detail as yourself

    Have you had it back on the rollers since turning the boost up a wee bit?
  23. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 15, 2011]
    Thanks for the kind words matey, it took me two years to complete the car. Its been just over a year since it hit the road but in my eyes its never been finished properly! I bought an S2 to use as my daily but it really needed some serious attention and came off the road which meant the A4 was needed for daily duties, a year later and I can't continue to beat its head in everyday! I have just decided to cut my losses and part the S2 out! I plan to buy a diesel so I can retire the A4 back to toy status and finish it, I would like to re-do some stuff and upgrade certain items so I can get the most out of the setup. I might continue to update this thread once I get the A4 off the road!

    The A4 hasn't seen the rollers since it was mapped, I plan to change some stuff and upgrade the ignition coils and head back there after Xmas, I do expect it to be alot closer to 500HP this time, I do have plans to further upgrade the car but who knows weather it will ever happen! :beerchug:
  24. flatshifter
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    flatshifter New Member

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    [Feb 4, 2012]
    Ive been a lurker here for a while now and found this thread by accident....I must say what a brilliant build thread.:applaus:

    Getting it right takes time and not guaranteed. I bought my psiconcepts 520 turbo(MHI TD05H-20G turbo) kit last September after noticing the engine is taking a fair bit of oil and narrowed it down to the K03(200,000km +23psi spike lol). Suppose to get all the stuff installed this coming March but a few days ago a compression test revealed that I may have to pull the engine apart to get re-ring'ed or a complete rebore, which means another delay :( but thats life, you can't win all the time.


    With the car being a daily driver, how's the clutch like? are they heavy?
  25. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Feb 6, 2012]
    Alright mate, thanks for the props, glad you enjoyed the read. The car did take a little time to get right and I'm still tweaking it now to get more & more power from it :yes:. I'm sure you'll get yours all sorted eventually and pushing bigger numbers, shame you've got to rebuild it though, have you not considered getting another lump to swap in rather than rebuilding yours? It will work out cheaper in the end, unless of course you plan to uprate some internals in the process, rods aren't expensive these days and are good insurance against any knock induced failures, just food for thought.

    As for the clutch I'm running, I don't think its too bad, it is heavy but you get use to it. Others that have tried it and asked me how I drive it about as often as i do! I suppose you eventually build the muscle needed lol. Anyway good luck with yours mate, you should start a thread for it :salute:
  26. flatshifter
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    flatshifter New Member

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    [Feb 9, 2012]
    Mate, I would love to get another engine and rebuild it but wreckers/breakers here in Australia think they're like gold.

    If I had to start from scratch I would go all out and get a 1.9 TDI tall block(long rod) and FSI crank with AJL/AEB head, or at least run an 06A block (more aftermarket bits e.g Fluidampr harmonic damper)

    Any hook ups on a good/cheap wrecker in the UK? :)

    Btw, I have a Eurodyne Maestro Tuning Suite 7 for my 557P ECU box( originally 558DA) but I may go with the Haltech PS1000 in the future as there's so much you can play around it.


    ps: I already have a build thread on audiforums.com.au but I will copy and paste it here soon lol...just too lazy to type :D
  27. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Feb 9, 2012]
    Ahh I didn't realise you were down under mate, there a very common motor over here to be honest and I could find you one for a very good price, however shipping it to you would very expensive I would think.

    I have watched many builds of the tall deck motors with 20valve heads grafted on, they never normally last that long to be fair although on paper they do look a lot more promising. For me its all about cost to build, ease & availability of parts. The one thing that makes these 058 blocks cheaper to build is the fact no one wants them anymore really and the 92.8mm cranks are very very cheap here with stacks of spares in breakers yards, the FSI cranks are harder to come by used and normally folk end up buying brand spankers for big money, 06A blocks are also a bit harder to find for reasonable cash, plus you then need to find a big port head! just makes the cost alot heftier. But as they say, each to there own. There are plenty of folk out there making 600HP+ on the 058 blocks with 92.8mm cranks and they can be put together for peanuts compared to an 06A build and thats enough potential for my driving abilities :yes:

    Not sure which parts you are thinking are available for the 06A & not the 058!?! My 058 has a fluidamper pulley in fact there isn't much I haven't included in my build.

    As for ECU's there are plenty out there, some better than others, it all depends on what your trying to acheive and how much dosh you've got to burn!

    Anyway I could rabbit on forever dude, stick a link up to your thread I would like to have a nosey :icon_thumright:
  28. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Mar 13, 2012]
    Well it’s been a very long time since I updated this thread with any progress on the car, I wasn’t going to bother but I’ve been asked to keep the thread up to date by some friends so here goes. I’ve had my hands full with the demise of my S2, that’s now gone albeit in many pieces but gone she has.

    [​IMG]

    [​IMG]

    As they say every cloud has a silver lining and that is that it was worth a small fortune in piecesJ. So Now I trundle about in a diesel ahem, Volvo, It’s allowed me to turn my attention back to the A4 and obviously keep it as a toy instead of a daily which was killing me if im honest! So the days of the sleeper are over, now its time to make a menace of my A4

    [​IMG]

    So I have taken the decision to make the car a lot more track orientated, there are many reason why I have taken this decision and I’ve thought it through for long enough. I know there will be plenty of divided opinion on this but hey, it’s done now! To put it bluntly I was going to kill myself / someone else, fact! The car was / is ridiculously quick and I can’t help myself but drive it like a loon, the horns just came out every time I sat in it, plus if the filth ever spotted me driving like an idiot which was also going to happen if I didn’t die first, I would lose my job when they put me behind bars. So justification over with, time for some pictures.

    First job was to remove all the stupidly heavy interior and unnecessary widgets, its all free horsepower and God knows I’ve spent enough money already on that stuff! So some action shots!

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    All this was far too much for the cat to bear, he just couldn’t look any longer!

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    Then time to work my way through all that nasty wiring!

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    The list of stuff to be removed consist’s of radio, speakers, auto-changer (which gave up the ghost anyway), airbags, ABS, carpet, plastic trim, inertia reels, redundant wiring, sound deadening, roof lining, a ton of brackets, **** Audi pedal box (the worst design ever) If you can heel & toe this pedal box, you must be wearing ski’s! Servo etc etc, now this is still a work in progress but I’m slowly getting there. If you need any spares then now’s the time to shout up.

    With all that plushness removed its time to introduce the more hardcore replacements!

    The new captains chair!

    [​IMG]

    That should help keep me still! Now time to address the stock pedal box, In a moment of madness I splashed out for one of these

    [​IMG]

    [​IMG]

    That should make it a tad easier to drive on the limit, bit of work required first off to get it all mounted & plumbed up but I'm sure it will pay dividends in the end!

    I've been at it for just over a week now, I've ordered some more shiny bits for the car as well but I'll save that for another day :rockwoot:
  29. Foxmeister
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    Foxmeister Fired Up!

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    [Mar 13, 2012]
    Nice!!!!

    Good to see you back mate, get the pics up! lol
  30. slepy
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    slepy Extremely smart and handsome person. VCDS Map User

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    [Mar 13, 2012]
    Ohhh I'm well jealous :( Lovely car mate.
  31. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Mar 13, 2012]
    Cheers dude! Its been a while but now I've got the headache out of the way (S2) and a daily to run around in I can go nuts! More pic's as it progresses. I've been bitten by that bug again and I can't wait to drive it again so I'm hoping for a quick turn around. This time I promise some footage :beerchug:

    Cheers mate :icon_thumright:
  32. joedredd
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    joedredd 2006 A6 S line 3.0tdi Quattro Avant

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    [Mar 17, 2012]
    Glad to see this build up and running again. One of my favourite builds, and just so amazing.
  33. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Mar 31, 2012]
    I'm just as stoked mate, using the car as a daily was killing me! One because of the fuel bills and two because it was getting ruined on the salty roads, so time to sort it out! But good to hear you enjoy the read!

    So I've continued to strip the car down to remove as much weight as possible for all the non essential items. Since the last update I've removed a load more non essentials!

    ABS pump, bracket & wiring
    Servo, master cylinder & pedal box
    Stock ECU box
    Battery & Battery tray to name a few!

    [​IMG]

    [​IMG]

    Then I decided to pull the dashboard out to remove all the heavy **** underneath!

    [​IMG]

    I pity those who have a heater matrix go pop! What a job to get at it. But I didn't stop there, I carried on to get at all the proper heavy bits.

    [​IMG]

    So I've now removed the climate control box, the underfelt from the bulkhead, sound deadening & dash airbag which was about 15KG's!!! So sinced I've now removed all that I have a load of holes in the bulkhead, I made up some plates & started to rivet them to the bulkkhead with some seam sealer,

    [​IMG]

    [​IMG]

    Today I managed to refit the dash bar and resecure the central electrics loom back in place. I decided to paint the ends of the dash bar black as you will see them now as I won't be fitting the lower dash pieces or glovebox and I'm not really into the look of cold galv! I also removed some of the brackets that aren't needed any more just to keep things neat.

    [​IMG]

    [​IMG]

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    So tomorrow I'm hoping to finally clean up the remaining adhesive from the floorpans & trans tunnel, I will be very glad to see the back of that job! I've removed 9KG of sound deadening from the floorpans & bulkhead alone. I still need to de-tar the boot area & parcel shelf, can't wait to finish it all off! I just need to blank off the air-con hole in the bulkhead & holesaw through for the MIL-spec ECU connectors, as im now planning to mount all the electronics in the rear of the car and I have some tricky connectors to go in the bulkhead, I have ordered some flying leads from 034 Motorsport to make up the looms inside the car, then just chop off the ECU connectors from my engine loom and wire up the tricky ones and jobs a good'an and I can refit the dash.

    So enough of the boring half stripped interior pictures! Time for some shiny stuff, I've had lots of bits arrive and I'm still waiting for a couple of bits.

    Cobra steel side mounts
    [​IMG]

    After much maths and head scratching I decided upon my master cylinder sizes for the pedal box and ordered all three as well as the Tilton throttle linkage to dial in the throttle sensitivity :rockwoot:

    [​IMG]

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    So while the missus watched the box I assembled it

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    Still need to tune the lengths of the pushrods to get the pedal positions right but its looking good.

    And the tricky MIL spec bulkhead connectors for the ECU, I have three of these, 40 pins each so that should easily cover off everything I need.

    [​IMG]

    Still waiting on some holesaws to fit the connectors, the flying leads from 034 Motorsport, a battery bulkhead connector so I can mount the battery in the boot, I've also ordered a subframe for the Cobra bucket seat which should arrive next week, once thats fitted I can start to fabricate the mount for the pedal box and sort out the plumbing.

    So since this is a track car now I can't really get the most out of it on stock dampers and Eibach springs so I decided to blow the last of my budget on a cheap set of coilovers, after much deliberation I plumped for the BC Racing offerings and I have to say for the money I'm quite impressed of the quality and adjustment they offer, they use a standard size spring so changing spring rates will be easy enough and there is 30 damping adjustment settings which can be done on the car unlike most others!

    [​IMG]

    And thats it for now!
  34. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Apr 1, 2012]
    Wow you have been a busy lad ! Loving the track car direction you are taking! You still taxing this for the road or is it a dedicated track car ? Either way awsome :D
  35. joedredd
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    joedredd 2006 A6 S line 3.0tdi Quattro Avant

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    [Apr 1, 2012]
    Pedal Porn..............love it, this car has taking a massive turn to becoming a track car now.
  36. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Apr 1, 2012]
    Alright chap, how we doing. What happened to the Imola? she was a beauty. The track car thing was a logical progression in my mind, hooning around in a 400HP+ car is fun for a while but your always behind another car if you know what I mean! I will attempt to get it through the MOT but it might be difficult with all these new crazy rules brought in at the beginning of the year but we will see, its not due till November so until then I will Tax it and enjoy it while I can, hoping to get some track time in during the summer months, but I think it would be wise to trailer it there just in case.

    There is no going back now mate! But it will be more awesome for it I'm sure :icon_thumright:

    So I managed to get a bit done, the floorpans are now cleaned up apart from a few skiddies! Thats seam sealer which will stay for now.

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    Also managed to get the head liner out along with all the attached gubbins, I also removed the wiring loom extending across the roof.

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    Check out the freaky storm trooper looking bush in the background lol.

    Anyway, feels like I'm slowly getting there now. Can't wait to drive it again now its been on a diet, it better feel more agile for it!
  37. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Apr 16, 2012]
    Update time!

    So the work has been completed on the bulkhead now, all the holes have been blanked where not needed, and some new ones opened up where I do need them :yes: Got the brake line bulkhead fittings & feed hose grommets in as well as the connectors for the ECU & gauges, I'm still waiting for a couple of more widgets to fill the other holes, all will be revealed in time.

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    So with all the work done on the bulkhead it was time to refit the dash, centre console & steering column.

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    And this is why I painted the ends of the dash bar black!

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    You can't really see them now, the normal galv finish would have stood out like a peedo in a playground!

    Next job was to mount the seat in the car, now the MOT requires the seat to be adjustable so I thought I would just buy a subframe, bolt it in, job done! Yeah that didn't work. This is what I mean!

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    Now that just won't do! So rather than box it up and send it back, I thought I would remanufacture it! I dropped the subframe by about 3.5" and reduced it in length by 70mm so it fits behind the cross member on the floorpan. After all I want the bucket as low & as rearward as physically possible to help with weight distribution and COG height. After a bit of cutting, grinding & welding the seat is in a much better postion now :rock:

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    It can also still move back on the sliders as well so happy days! Now the seating postion is fixed I can crack on and mount the pedal box, then start on the false floor.

    I've already made a start at mounting the three Tilton reservoirs for the pedal box, rather than make up a braket I thought I would just drill & tap the strut bar which is conveniently placed in the plenum! Should get that finished off and mounted again tonight.

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  38. pioneer181
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    pioneer181 Torque talks

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    [Apr 16, 2012]
    I just happened to stumble across this thread, and what a thread it is. It's guys like you that push the boundries on what a car should be that make us modfiers as skint as we are. The lengths you've gone to are amazing and would love to see this ripping up the quarter mile. As far as I'm concerned, sleepers are the ultimate cars. Great read and can't wait to see a video if you finally treat yourself to a camera. :respekt:
  39. ColganRaz
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    ColganRaz Member

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    [Apr 27, 2012]
    Best build thread I have ever read, just spent nearly am hour or so reading through everything, wicked read and much respect
  40. Rhysd1309
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    Rhysd1309 New Member

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    [May 5, 2012]
    After reading through all 359 posts, I am a changed man lol

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