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

Discussion in 'Audi S4/A4/A4 Cab (B7 Chassis)' started by olethalb, Nov 16, 2012.

  1. rezulteo
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    rezulteo Site Sponsor Site Sponsor

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    [Nov 22, 2012]
    Really nice car and in great condition too
    #41
  2. Golfedd
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    Golfedd Member

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    [Nov 23, 2012]
    Digging out the Rotary today man, see what bits I need and then we'll get yours in and shine her up!.. Going to attack mine today / weekend and reduce the swirl-tacular body. Like old times with new toys :sex:
    #42
  3. olethalb
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    olethalb Member

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    [Nov 26, 2012]
    thanks chaps

    well got my RS4 fuel pressure regulator and 'K' revision fuel pressure sensor / thrust sensor on friday, after reading up on how to fit the FPR it seemed Audi want £200 and 2-3 hours labour and others have done it in about 45mins but require special tools.

    i got up saturday morning (in the rain) and decided i'd crack on, started at 8.50 and by 9.10am it was all back together with new thrust sensor too and no special tools required just a section of 12mm id hose to locate the new FPR before screwing it back in.

    can't say i've noticed any real difference but i'm convinced my intank pump is dying a death so will be upgrading pump for a better flowing item. hoping to order a WMI kit today so when i get that on and the new intank pump i'll be getting it mapped again and hopefully crack the 400bhp mark so the RS4 FPR will help there.
    #43
  4. olethalb
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    olethalb Member

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    [Nov 26, 2012]
    lovely, pics (non iphone) please thank you
    #44
  5. Golfedd
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    Golfedd Member

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    [Nov 29, 2012]
    I say... white light on the way for ya bolloywood :hubbahubba: haha
    #45
  6. olethalb
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    olethalb Member

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    [Dec 3, 2012]
    My AEM WMI kit came during the week and i had the day off work today so decided i'd start fitting the kit

    [​IMG]

    i'd decided the best option was to install the tank (5 litre) and pump in the boot, looked like the passenger side would be the best option as the tank has to be higher than the pump

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    the pump looked fairly large and has rubber feet so thought it best if i make a wooden floor (also not keen on screwing through the body of the car) so i made a template

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    then made it out of MDF

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    it fitted snug but there was a stud so i used a golf trim screw to stop any vibrations, i then made a template and transferred it to wood to mount the tank on

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    made some brackets to secure it to the car without screwing into the body

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    then trimmed the carpet around the board

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    next was to mount the pump

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    and tank

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    soldered and extended the looms

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    and ran the lines and loom up the inner arch

    [​IMG]

    then fitted it up

    [​IMG]
    #46
  7. olethalb
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    olethalb Member

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    [Dec 3, 2012]
    i ran the lines down the passenger side to the front kick panel

    [​IMG]

    [​IMG]

    and ran into the bay via a grommet next to the A/C pipes

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    while i was at it ran a vac line to the cabin that will connect to the boost sensor in the WMI controller

    [​IMG]

    [​IMG]

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    after a lot of soldering and trimming wires the controller is mounted in the glovebox

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    [​IMG]

    i am waiting for a vac / boost take off from forge and need to get an ally threaded boss made up so it can be welded in my boost pipe to mount the injector. ran a test program and it worked well
    #47
  8. olethalb
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    olethalb Member

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    [Dec 3, 2012]
    oh and a pic of the thrust sensor and fuel pressure reg pre fitting

    [​IMG]
    #48
  9. olethalb
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    olethalb Member

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    [Dec 5, 2012]
    i've decided i will completely hide the tank so have ordered another level sensor that i will fit at the top of the tank but spun 180*, i will hook this up to an led that will be mounted near the fill spout. this will light up when the tank is full so there will be no need to see the tank or have and overfill / spill in the boot.
    #49
  10. Golfedd
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    Golfedd Member

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    [Dec 5, 2012]
    sounds like it was nagging in the back of your head to be done! haha! Nice man... tidy little install waiting on results
    #50
  11. olethalb
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    olethalb Member

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    [Dec 5, 2012]
    did it all in one day and takes a lot longer than i thought, started in the rain - worked through the cold and into the dark. get it fitted properly and functioning was the order of the day.

    i've ordered some carpet and trying to locate a skoda filler neck to make it look more OEM, want it to be easy to live with, reliable and not look like it's been thrown in.

    i took the injector nozzle to my engineer friend yesterday so he can make an ally threaded boss so i can pop my boost pipe down and he can weld it in. after christmas (and uprated intank fuel pump is done) i'll probably order a flow rate monitor to keep an eye on things.
    #51
  12. Golfedd
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    Golfedd Member

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    [Dec 5, 2012]
    Nice...probably be one of the cleanest installs of WMI yet lol... where you thinking of installing the injector? just after the welded flange already and underside hidden?
    #52
  13. olethalb
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    olethalb Member

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    [Dec 7, 2012]
    will probably be on the side, the injector has a 1 way valve so ends up being about 50-60mm long then the 1/4" pipe comes off it so would struggle for room and pipe angle underside.

    hoping to get a new filler for the tank in the next few days, ordered a few more parts off ebay to complete the install, the 'full tank' led turned up and some dark grey acoustic carpet. also 'forge' boost take off came through but have to say it looks like copy tat, the seal is now a cork gasket not an O ring as shown on the website.

    also got cheapy digital boost gauge on the way so i can keep an eye on boost levels, had to be digital so it can be easily read - i'll be mounting it out of direct sight.
    #53
  14. olethalb
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    olethalb Member

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    [Dec 8, 2012]
    got a couple more bits through toward completing my water meth install

    vag oem washer bottle filler neck, level sensor and caravan waste outlet

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    fitted the caravan waste outlet to the AEM tank cap also got forge bost take off and 12v green LED

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    my grey carpet came through too

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    [​IMG]
    #54
  15. pburv
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    pburv Member

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    [Dec 8, 2012]
    Hope it wasn,t a second hand waste outlet!:jester:Nice install mate.Wish I had the patience,time and money to do this.Respect...Paul:o.k:
    #55
  16. olethalb
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    olethalb Member

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    [Dec 9, 2012]
    thanks Paul, finished the install side today

    first job for the day was to make a board to hide the tank

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    then a couple of pieces to space it out

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    then i removed the tank and fitted the second level sensor

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    made a loom for the LED

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    bound the looms and outlet pipe in fabric tape

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    made looms for the level sensors and to connect to the LED, also wrapped in fabric tape

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    fitted tubing to outlet on cap and made cut out in the board

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    next i made a stainless bracket for the fill pot

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    covered the board, fitted the LED and fill pot

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    tested the 'FULL' LED

    [​IMG]
    #56
  17. Golfedd
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    Golfedd Member

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    [Dec 9, 2012]
    So clean and OEM... nice one ollywood! ( cough cough UD? cough)
    #57
  18. olethalb
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    olethalb Member

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    [Dec 9, 2012]
    Cheers Eddwin, just wanted it to look tidy and be easy to live with. got a suitable sized bottle i'll make a bracket for on the other size to keep for when the 'low level' light on the dash comes on.
    #58
  19. MartayMcFly
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    MartayMcFly Well-Known Member Regional Rep VCDS Map User

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    [Dec 9, 2012]
    Fair effort to keep it nice and behind-the-scenes.
    #59
  20. olethalb
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    olethalb Member

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    [Dec 10, 2012]
    thanks Martay, i think i'll paint the stainless bracket black and see if i can pull it 10mm closer to the edge.
    #60
  21. Adam.
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    Adam. Meow.

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    [Dec 11, 2012]
    lol'd @ edwin giving it the real Miami.
    #61
  22. olethalb
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    olethalb Member

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    [Dec 11, 2012]
    sweaty barefoot on my carpet :(
    #62
  23. D2NY G
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    D2NY G Well-Known Member

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    [Dec 11, 2012]
    that set up looks spot on mate, oem+ indeed
    #63
  24. olethalb
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    olethalb Member

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    [Dec 15, 2012]
    thanks bud :)

    well a lovely rainy day and no batteries for my cam so iphone pics it is.
    my box of pipes arrived this morning
    [​IMG]
    i've been trying to sort out a better solution to my turbo intake so bought several bends to try and make something i could keep away from the turbo.
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    after tring a few different routes i've settled for this but still not happy with it but it'll have to do for now
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    once that was mocked up i wanted to hard pipe the DV return too
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    i'm still nt happy with the intake, it'll function better as the filter is now away from the turbo and near the drivers side bumper vent but just looks rubbish :(
    also fitted the LED boost gauge in the glovebox to keep an eye on things when needed
    [​IMG]
    #64
  25. Morgan46
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    Morgan46 Member

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    [Dec 16, 2012]
    I revert to my 1st reply......is that all haha looks awesome and by looks and sounds of mods it's gonna be a beast ,wish mine was like that especially as the other day a B6 S4 pulled up beside me ,we both nailed off lights mine spun like a ***** (was very damp) his s4 just flew away lol bet when they see yours with 2.0turbo on it an s4 driver is gonna be like see ya then like WTF haha
    #65
  26. Golfedd
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    Golfedd Member

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    [Dec 16, 2012]
    Can you not stainless heat shield around the turbo a bit more, three bolts into the top of the drivers chassis leg, then it bends towards the plugs like this angle > / then bends and covers the manifold and hot side mostly. here's a SHOCKING drawing... LOL


    [​IMG]
    #66
  27. olethalb
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    olethalb Member

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    [Dec 17, 2012]
    thanks Morgan, i just want it to go as well as it looks :)

    Eddwin - i have a sheet of stainless on order to make a better heatshield and been considering ceramic coating the decat pipe. the plan originally was to have a 90* bend out of the turbo towards the rear of the car, then 180* back towards the front and sweep down to behind the headlight but there just isn't room for the angles with the 3" piping :(
    #67
  28. andymartin045
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    andymartin045 Member

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    [Dec 18, 2012]
    have you seen the carbon fibre difuser for the dtm valance from osir design usa, it might just finish your car off a treat since your a subscriber to genuine carbon
    #68
  29. olethalb
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    olethalb Member

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    [Dec 19, 2012]
    andy - i'd always wondered if someone produced a rear panel like that. thanks for the company name, at $500 + shipping i'll try and put some money by next year once i've finished messing in the engine bay.

    my stainless sheet arrived last night, hopefully if i can get this mk2 golf 20vt i'm building done i may have a little time for my car :)
    #69
  30. olethalb
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    olethalb Member

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    [Dec 19, 2012]
    #70
  31. andymartin045
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    andymartin045 Member

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    [Dec 19, 2012]
    TTS Roadsport in Bedford are the UK agents for OSIR. They ordered it from Hong Kong (a 4 week wait) and fitted it for around £300 I think. The weave is the same thickness as the weave in the DTM's dash and the quality is fantastic.
    #71
  32. olethalb
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    olethalb Member

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    [Dec 19, 2012]
    AWESOME! thanks Andy

    i take it you have it on yours then? any pics? was looking at the pillars too ;)
    #72
  33. andymartin045
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    andymartin045 Member

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    [Dec 19, 2012]
    Ive had it fitted yes. Im out of the country at the moment and so cant post any pics. But I would recommend it. The red towing eye draws the eye and the diffuser completes the look. Now I just need to dremmel the front and rear vents. Do you think you'll get the b pillars?
    #73
  34. olethalb
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    olethalb Member

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    [Dec 28, 2012]
    thanks Andy, had a look on the website and says £400 so i'll await pics before taking the pluge :)

    now for quite possibly the most boring update i've ever posted

    got my carbon fibre gearknob through today, i'm not a fan of non oem and hate things that look 'bolted' on so some modification was required

    the gearknob
    [​IMG]
    the DTM knob / surround
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    stripped apart from the gator
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    trial fit of the sleeve against the new knob
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    cut the gearknob shaft in half, needed the lower section to secure the gator and part of the upper to secure the sleeve
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    gator secured
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    sleeve in place
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    gator on and slid down, rubber sleeve fitted
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    gearknob tightened down
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    gator slid back up and secured
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    done
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    unfortunately the carbons not an exact match but i'm happy with it :)
    #74
  35. olethalb
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    olethalb Member

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    [Dec 28, 2012]
    oh also took delivery of 25 litres of virgin grade methanol over christmas so i can knock up a 50 / 50 mix and have 50 litres ready to use.

    and less excitingly bought a new battery as the cold and 1 mile journey to work has taken it's toll on mine :(
    #75
  36. Golfedd
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    Golfedd Member

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    [Dec 28, 2012]
    what if you forget where a gear is... there is no like diagram and stuff?


    haha - does it sit a bit taller or is it just the photo?
    #76
  37. olethalb
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    olethalb Member

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    [Dec 28, 2012]
    same height good buddy :)
    #77
  38. olethalb
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    olethalb Member

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    [Dec 29, 2012]
    the little lady had these made up for me for Christmas

    [​IMG]

    and she also fot me a new 3" neck filter in blue which will go on with my new intake when it's finished

    [​IMG]
    #78
  39. olethalb
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    olethalb Member

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    [Dec 30, 2012]
    yet another 'mod' i'm not sure i like the look of, i can already see it being removed or reworked - anyway....

    decided to have a crack at heatshiled, removed original

    [​IMG]

    made a cardbord template of the shape i was aiming for

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    unpacked the stainless

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    marked it out

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    started to take shape

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    drilled hole for lambda

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    trimmed a little further

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    fitted

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    i don't particularly like the look :(
    #79
  40. Inertiauk
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    Inertiauk Member

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    [Dec 31, 2012]
    I love your DTM

    I want it!

    b7 + Quattro + lots of boost. What a combo.
    #80

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