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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. olethalb
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    olethalb Member

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    [Mar 15, 2013]
    right....

    now i had the clutch and knee is a little better (not much) i decided i'd start the swap

    i've had the new engine for a while and other parts were slowly coming together

    well first (easy part) was to strip out the old engine

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    little clean up

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  2. olethalb
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    olethalb Member

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    [Mar 15, 2013]
    now i had the lump out i could start building up the new one

    90% of ancillaries are different from tranverse to in line

    swapped;

    alternator bracket

    alternator

    p/s pump

    a/c pump

    all water ways and hoses

    sump

    cambelt cover

    cam cover

    also A4 mounts bolted up

    the A4 uses a spigot bearing in the end of the crank so fitted one of them

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    fitted new clutch and fly

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    the dowels were longer on the A4 too so they had to be swapped out

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    the hybrid strapped on with proper k04 lines

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    new plastic water way as the original broke up on removal

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    now it was al fitted up with s3 injectors, new inlet mani, painted TB, new pump with original auto tech internals i wiped it over and
    sat it back in the bay

    [​IMG]

    [​IMG]
  3. olethalb
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    olethalb Member

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    [Mar 15, 2013]
    few other bits needed attending to while i was at it

    the decat pipe i got from the states pushed the lambda up against the heatshield, so i welded a new boss in

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    and heat wrapped it

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    new position, you can see issue where the blank is

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    also got another fmic core to modify to fit

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    new pipes made to be welded

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    new custom crash bar mocking up with 30mm 3mm wall tube

    [​IMG]
  4. olethalb
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    olethalb Member

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    [Mar 15, 2013]
    i also wanted to smarten things up, i never painted the lower boost hose and the throttle body one had been sanded for WMI injector and chipped. was also not happy with the cam cover

    so i braved the VHT wrinkle finish and set to work

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    lower boost pipe

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    tb boost pipe

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    turbo intake pipe

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    fitted the TB boost pipe and DV etc

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    popped off the old cam cover and looks like new :)

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    fitted the new cam cover

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    unfortunately thats as far as i've got it's been raining heavy all day, i'm going to run the old FMIC while the new one is welded and i
    can properly fit and paint the crash bar

    also got this to modify on somehow, it's from a mondeo to replace my existing p/s cooler

    [​IMG]
  5. jetskijimmy
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    jetskijimmy QUATTRO

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    [Mar 16, 2013]
    Hi olethalb

    Ive got the same sprint blue DTM :beerchug:I want to upgrade to s4 discs 345mm what will I need to adapt this Mod ive seen something before about changing the caliper bracket

    Cheers
  6. ANDYTQ
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    ANDYTQ Active Member

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    [Mar 16, 2013]
    Nice work ,if you get bored when yours is finished i'll leave mine with you for a month .lol.
  7. ANDYTQ
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    ANDYTQ Active Member

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    [Mar 16, 2013]
    Which flywheel did you get ? ,steel single mass or alloy with steel insert?,this is my next job,i was thinking of getting a clutch off drake on audizine he does modified rs4 clutch kit,i'm just not sure which flywheel.I need to get them ordered as mine is getting a bit worn.cheers Andy
  8. Golfedd
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    Golfedd Member

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    [Mar 18, 2013]
    Nicely done Olly, that VHT stuff gave a good finish! mmmm the painful memories of wrinkle haha.

    Looks good!
  9. Golfedd
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    Golfedd Member

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    [Mar 24, 2013]
    imagine, how epic it would be... to have like, some kind of RS4 style start button, that would flip up in the cigarette lighter?

    #BITTER!
  10. olethalb
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    olethalb Member

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    [Mar 24, 2013]
    cheers chaps, will reply when i get a little more timewell the engine was fitted idled perfectly, took it out for a spin and got a misfire on boost on cylinder 3 swapped loads of parts including 4 new gen plugs and coilpacks.
    yesterday i took out the injectors (PITA job) and swapped cylinder 3 injector to #4, took it out and misfire on #4 so seems one of my 3k old S3 injectors are dead, looked it up on ETKA and they're £150 each. also been getting 'low fuel pressure' code so looks like intank pump is dying - another £300 :( - ah well pics of the progress anyway

    fitted pics and painted parts

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  11. olethalb
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    olethalb Member

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    [Mar 24, 2013]
    next i plucked up the courage to hack two grils apart to make one...

    removed the frame and trimmed the edges off the RS6 grill

    http://i276.photobucket.com/albums/kk32/ollethalb/dtm/CFC79E6C-8FD6-48B4-B0C9-400E0A43C2D7-957-
    000001059CFCBF76_zps896bf83b.jpg

    [​IMG]

    stock SE grill

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    frame removed and measured up against the RS6 item

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    i decided i'd trim the outer edge off of the SE grill as i did with the RS6 grill and glue them together as the witdth and angles were pretty close

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    once i'd trimmed the RS6 to size i secured it with cable ties then glued it

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    after leaving it to set for a week with the cable ties holding it in position i removed the ties and painted the surround wrinkle black

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    also did this, not sure if i like it yet will need to use it some more

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    also ordered a lot of bolts / clips and a new drivers vent, i'd noticed a few rusty looking bolts mainly on the front panel and a few damaged plastic loom clips when i swapped out the engine

    [​IMG]
  12. N8
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    N8 Kowalski Details VCDS Map User

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    [Mar 24, 2013]
    Saw the pics of FB earlier Oli, love your work, looking forward to seeing it in the flesh, and you of course :wub:
  13. S3 Rav
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    S3 Rav Well-Known Member

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    [Mar 24, 2013]
    Looks great.
  14. harvey01
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    harvey01 Member

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    [Mar 24, 2013]
    hi mate looks good did you bake it all to get the wrinkle
  15. olethalb
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    olethalb Member

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    [Mar 28, 2013]
    Nate - thanks bud, DC was last time i saw you. i was with Dele and the hamster :D

    Rav thanks

    harvey - no i just heated it up carefully though as it's mainly plastic

    yesterday i went and picked up a new injector and RS4 in tank pump, unfortunately the fuel filter was out of stock

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    took out the old pump and the gauze was floating around in the bottom of the tank

    http://i276.photobucket.com/albums/kk32/ollethalb/dtm/FC063C54-C902-4325-9F97-02FA9839402D-6967-
    0000065CF5EFC923_zpsbd2a264d.jpg

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    while i was at it i dropped the tank to fit the RS4 pump controller

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    and removed the old one

    http://i276.photobucket.com/albums/kk32/ollethalb/dtm/7EF24F53-E34F-4121-A2AC-6121A957AA01-6967-
    0000065CFD54EED5_zps60d0e513.jpg

    got a call from audi to say my filter and new brake light switch were in stock, while i was collecting them the welder called to say the FMIC was ready for collection

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    mounting brackets fabricated

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  16. Golfedd
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    Golfedd Member

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    [Mar 28, 2013]
    not seen the detail on that new IC - looks good man! looking forward to this being on the road, ripping up the road.
  17. olethalb
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    olethalb Member

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    [Mar 29, 2013]
    me too Eddwin


    well thought i'd set about getting this front end sorted today

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    dropped the bumper off

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    removed the old fmic and started mocking up the new crash bar

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    welded 16mm thick wall tube to the crash bar mounting points

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    test fitted the bar

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    then offered up the FMIC - unfortunately there had been a miscommunication in measurements so i had to mod the pipes

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    then trimmed the mounting brackets, added some rivnuts to the bar and bolted it up

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    once that was in place i needed to mount the horns so i welded the brackets to the crash bar mount

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    popped some paint on

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    fitted the 'new' grill in the bumper

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    and test fitted the bumper

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    that was it for now 'crash bar' has been painted but need to get the pipes rewelded and my welder is away this weekend :(
  18. weekenny
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    weekenny Member

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    [Mar 30, 2013]
    Looks great, what was the original front mount from?
  19. AudiB7Jay
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    AudiB7Jay Member

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    [Mar 30, 2013]
  20. olethalb
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    olethalb Member

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    [Mar 30, 2013]
    weekenny - the one i removed or the new one?

    Jay - i'm happy with the wa mine's turned out

    magic happend today, i called my welder, not only did he answer the phone on his day off he agreed to run a couple of welds for me :)

    got to work and dropped some paint on the cooler pipes, as soon as was touch dry set about fitting it up with the painted crashbar

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    next i had to address the power steering cooler - not many pics as it was snowing on and off so no time for pics. mounted the
    mondeo cooler

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    with bumper fitted

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    all back together

    [​IMG]
  21. weekenny
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    weekenny Member

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    [Mar 30, 2013]
    The one you removed. Cheers.
  22. olethalb
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    olethalb Member

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    [Mar 30, 2013]
    it was from a B6 1.8T kit, i only needed the core so ditched the pipes and welded my own ally pipes on to give clearance for the bumper
  23. weekenny
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    weekenny Member

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    [Mar 30, 2013]
    Cheers looked great.
  24. olethalb
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    olethalb Member

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    [Apr 1, 2013]
    will be on ebay this week :)

    gave it a wash

    [​IMG]
  25. DTM_T4
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    DTM_T4 New Member

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    [Apr 1, 2013]
    On eBay? You selling up dude?
  26. Steve220
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    Steve220 Member

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    [Apr 1, 2013]
    Is that a 2" core? Bit thin for your turbo spec isn't it?!
  27. olethalb
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    olethalb Member

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    [Apr 1, 2013]
    the old FMIC will be on ebay bud :)

    ran some logs earlier to measure intake temps and normal driving was around 22* with ambient of 9.5* and spirited driving with WMI was seeing as low as 2* so seems to be performing well, no noticeable lag over old item :)
  28. Golfedd
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    Golfedd Member

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    [Apr 4, 2013]
    Took a trip over to see the scruffy DTM. It was in much need of a day's worth of Detailing up, paint was faded and dull and the sprint blue certainly can shine.

    With the up coming show at Elemental it was time to sort it out...

    Products:

    Two Bucket wash: Fairy liquid
    Cleaned off: Tardis all round
    Clayed with: Elite Fine Grade
    Rinse and Dry
    Taped up and prep for rotary
    Stage 1 all over: Lake Country Pads - S3 Gold class
    Stage 2 on some areas: Lack country Pads - S17
    Stage 3 all over: Lake country finish pad - S40

    Rinsed down and gentle dry
    Dodo Juice Acrylic Spritz sealant
    Dodo Juice and Smartwax finish



    The Photos
    General dull paint

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    Ready to go
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    Driver door comparison
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    Rear Quarter comparison
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    Mirror- light buff as it's a soft clear coat on these
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    had to be a bit gentle around the arches, they are a tad - frail
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    Bonnet after stage 2 pass
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    Boot done final stage (no protection)
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    Exhaust tips got a quick whip over
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    Finished up
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    [​IMG]


  29. olethalb
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    olethalb Member

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    [Apr 8, 2013]
    Oh Edd she's so shiny and clean :)

    thanks bud, was good to catch up with you and the lads saturday
  30. mancdan
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    mancdan Member

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    [Apr 8, 2013]
    Fairy Liquid, is that not the devil for detailing cars.
  31. GeoffDunk
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    GeoffDunk Active Member

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    [Apr 8, 2013]
    Should never use fairy washing up liquid anywhere near quality paintwork, It's full of salt and will ruin a good shine.
  32. Golfedd
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    Golfedd Member

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    [Apr 8, 2013]
    haha yup, you're both right. I didn't use Fairy - Used meguiars Gold wash, then a rinse down with Auto-Glym Shampoo etc etc etc
  33. mancdan
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    mancdan Member

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    [Apr 8, 2013]
    Phew, thats good then :arco:
  34. olethalb
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    olethalb Member

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  35. craichouse
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    craichouse Member

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    [Apr 11, 2013]
    there is 2 new pic's for my desktop wallpaper :respekt:

    there my only be 213 of them left but this surely is the best one of them all, :applaus:
  36. olethalb
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    olethalb Member

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    [Apr 12, 2013]
    Wow, thanks for compliment bud

    spent the day at MRC today and i got a good service and a fair amount of tweaking

    [​IMG]
  37. craichouse
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    craichouse Member

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    [Apr 12, 2013]
    does that say 363 BHp?
  38. Chris-Vspec
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    Chris-Vspec Member

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    [Apr 13, 2013]
    Amazing build, just been engrossed in it for an hour reading every post, what an amazing car also thanks for all the useful information in your thread.
  39. olethalb
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    olethalb Member

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    [Apr 22, 2013]
    craic - indeed it does, was hoping for more to be honest

    Chris - thanks for taking the time to read :)

    didn't do much at the weekend but it was nice weather so could take my time on the long over due rear brakes

    when i bought the car it had just had new rear pads so plan was to get a bit of like out of them before doing anything with them, recently been getting a very annoying brake squeal so enough was enough.

    i bought a pair of drilled and grooved discs to match the front, rears on DTM are 288mm but unfortunately solid

    anyway, a pic of the nasty nasty rear set up

    [​IMG]

    after a good clean up, regrease, blue paint, new discs, mintex pads and repainted splash shield

    [​IMG]

    [​IMG]

    hoping this is going to be new turbo week :)
  40. DOHxP
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    DOHxP New Member

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    [Apr 22, 2013]
    alot of good work going on here

    but out of curiosity, why didnt you just go ahead and buy yourself an rs4 for the money you spent on this?

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