Dan's A4 Cabriolet build thread

Northampton_ofn said:

I hope so mate, can't justify it at the moment but one day! So is it 3" all the way from the turbo to the split?

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Oh believe me you will!

Yes, for MAX power, its 3inch all the way as far as you can. As soon as mine splits to 2 pipes its 2.5inch. No restrictions just a slimmer back box. (2)

QuattroCalum said:

Do you have any drone with the exhaust considering there's no resonator on there now? Awesome build thread, well done mate!

I put the part number in Google for the rear anti roll bar and it came up as the front one? 8E0 511 409 AL

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Thanks a lot for your kind words QuattroCalum. Ive definitely learned quite a lot from your knowledge.

Quite surprised as there is virtually NO drone when driving both at low and high speeds.

I concede, if I drive at really low speeds and pop it into a high gear, it can drone a bit but this is only If i purposely do this as if to drive like a granny,

Anti Roll Bar: The part number above (the one you paraquoted) is definiitely for the rear. Im not sure there was a front RS4 anti roll bar made which could be the confusion. So to confirm; 8E0 511 409 AL is what you're after.

Please do this mod, pound for pound fantastic mod. Get it with the bushes too. I find myself throwing my car into corners at higher speeds with no body roll.

Exhaust Clip

https://www.dropbox.com/s/7ilq8tccjv4i0y6/Dans B6 Cab Exhaust Clip .mp4?dl=0

1st pull around 3,000RPM
2nd pull around 4,5000RPM

Toward the end of the clip there's a bit of burble when I took my foot off the accelerator.

..Sorry guys, its taken a while to get this uploaded. To be honest, its the 1st proper time im using my GoPro.

Unfortauntely the video doesnt do it justice at all really. Believe me, its a whole 'nuther animal when in real life.

I'll try to get better footage in the weeks to come.

Hope this tickles your fancy..

Thanks for the kind words Andy.

Im still in love with my exhaust as it truly does sounds epic being a 3'' stainless TIG welded exhaust.

Its been ages but next up is total overhaul of brakes and suspension and then FMIC and remap!!!

Andyb5tdi said:

Awesome, I look forward to seeing the progress

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Thank you dude. Hopefully soon! (work work work)

lee s4 cab said:

DrStrange gotta say she looks lovely like what you've done. couple questions don't suppose you can tell what bulb types are in the foot well lights the centre lights above the wind screen and the ones for the sun visors could you I want to do the same but don't want to strip it to have to put it back then to take it apart again.

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Hi Lee, thanks for the kind words.

That's an easy one mate, on ebay you'll find a lot of retailers selling these LED interior lights as a 'kit'.

I purchased the 'kit' for the avant but its exactly the same with a spare LED that ive kept.

This below is wht you're after;

http://www.ebay.co.uk/itm/AUDI-A4-2...355814?hash=item25ba8962a6:g:lX8AAOSwKfVXFixi

In the description section, it will illustrate exaclty what LED bulb you're getting and where it goes!

Any help, just give me a shout.

*MASSIVE UPDATE*

Sorry Guys, literally been SO busy with work and my car I haventreally had time to be on here at all! Rest assured, the modding bug is always in my blood and Will continue modding cars probably for the Rest of my life.

Problems

Oil Pressure - Nearly had catastrohpic engine failure when my oil pressure light/level completely failed and didnt notify me that i had no oil in my car! Luckily, I coulght it just before it was bone dry. My mechnic replaced the disintegrated one of the oil pipes at the rear of the engine. Steam cleaned after and then serviced. Phew!

Cv Joints - My whole suspension set up was completely shot due to the sh*t 20's that I ran a couple of years back (NEVER again). @DieselJake sorted me out with a WICKED set of control arms which came with bushes in them obviously. (Meyle HD brand)

ABS light on and traction control - A horrible horrible fault to have. Both lights come on intermittently make the speedometer cut out! AS in no reading on your speed! This in turns communicates with your ECU to protect the engine and you go into strange limp mode like symptoms and the gear changes are horrible cutting power to boost etc. Changed the wheel speed sensor as we thought this was the issue and it stll intermittently comes on. Ive been told its the dreaded ABS module! If so, I will have to remove it and get it sent off for checking. A VERY expensive job. (Please help if you know of this fault!)

Mods

Without further a do, I'll get onto what's been done. All of the above had to be addressed before stage 2 tuning.

New Discs, pads and brake lines - Purchased MTec Drilled rotors (just for a fancier look) front and rear, With EBC Redstuff pads and HEL braided lines.
Braking feels fantastic and can stop on a dime! The EBC Redstuff pads for medium to fast 'street use' are perfect. Impressed with the rotors also. Good quality. Hel Braided lines where recommended to me so for a little extra had them installed. I must admit, not much of a difference but a small one which helped with the braking feel when you put your foot on the brake. A tad sharper.
(Some crappy photos below - Sorry I couldnt take better ones. The blue line is obviously the HEL braided line. Plastic blue cover but braided inside)







(My caliper where also painted gloss black)

Meyle HD 16 piece control Arm Set and AP Coilovers - Unfortauntely no pictures (sorry) I forgot to take them in situ. Links below;

Control Arms - https://www.ebay.co.uk/itm/FOR-Audi...USPENSION-ARM-kit-16mm-MEYLE-HD-/161873978791

Sachs Flywheel and CG motorsport dual friction clutch - Spoke to the owner Mick who was extremely knowledgeable and friendly. My requirments where to stay with a DMF where the engagment and feel was virtually as a stock clutch was. Thrilled to find out, its an excellent clutch when driving. Feels totally OEM but with the ability to take up to say 300lb ft +
I also opted for a replacment fly wheel as mine was half worn.

TT 225 Injectors (386cc) - Fitted these as its been said the BFB injectors max out at like 230bhp.

Link to my clutch below;

http://www.clutch-specialists.co.uk/cg-motorsport-dual-friction-clutch-kit_p31015294.htm

AP Coilovers -


FMIC - Made by Mishimoto

Piping Kit -

Lots of bumper trimming to make the intercooler fit. It was on easy peasy but the pipes stuck out resulting in the front lower portion section to be trimmed as well as the lower side light grills. As you can see its not perfect. BUT I will attack this as soon as I have time and i'll make it sit properly mark my words.

The intercooler is lovely and stealth black so you cant see it behind the Grill.

However im after the agressive look so will remove the lower grill, Dremel the plastic guards off and expose the FMIC before putting on my painted gloss black splitter also.

The above kit was indeed the only kit thats actually plug and play for the B6! No one else makes one apart from CX racing over in the States. The ONLY Issue, is these boost pipes are 2'' and the inlet/outlet on the FMIC is 2.5''. My dumb mistake but Devil Devilopments down in Little Hampton sorted that for me.

As far as i know, there is just 1 other person crazy enough to put a FMIC on his Cabriolet and we are are mates haha. (Chris Brown - Facebook group 'VAG Gang')

Mapping Time - I chose Devil Developments in little hampton (Bognor Regis) as ive been follwing their 'VAG' remapper quite extensively on the 1.8T facebook tuning group. The guy's name is Ben Parsons and truly is an expert on all things VAG group related.

Set off down there early on a friday morning. They got straight to work!

Results -



Utterly disapointed to reveal that after all that commotion with the above, I got just a max figure of 198bhp and around 220ft lbs torque. So you know what this means?! The BFB turbo which is a K03-029 is a sh*tty ko3 and not an 'S' as all the tuners mention. I was livid, i have to be honest. TI A massive Thanks to Ben for maxing out on the turbo and bringing it from a down 140bhp to its max!

I proceded to tell all the tuners the BFB engine code turbo is a ko3. Most where totally clueless as all of their experience was with ko3, ko3s and ko4 transverse based turbos!

So, if anyone is ready this and you would like a plug and play upgrade turbo for the longitudinal based A4. Upgrade to;
The BEX Turbo which is a K03's' - Ko3-073 (Which can see 250+)
Or the K04-015 which will see around the same as above however not measured.

Or hyrids of the above.

'Mamba' turbos make a K04 hybrid. Actually 2 versions;
1 is named the K04 pro which can see upto 300bhp with all supporting mods
The other is the K04 Extreme which can see upto 350bhp. Apparently all plug and play. But dont install this without dropping in up rated rods and exhhaust valves minimum!

Anyways guys. Ive calmed down and am happy for the time being. Going to enjoy the car for summer (The exhaust HOWLS past 3000rpm) so will still have fun with it. Its now sharper, better throttle response and past 4k rpm, it has a nice little torque shove.

When i get bored, I may buy the KO4 pro by mamba and I will be back to document.

Little Pre mapping video;
https://www.dropbox.com/s/te3qb6h3emkbsam/Pre Map Wash.MOV?dl=0

Recorded some clips with my GO pro and unfortauntely the only one worth showing is this.. (Revving). Will upload more VERY soon.
But this is revving near to redline. (Decat, running Vpower and remapped)

https://www.dropbox.com/s/rc1ou02cd9wauh5/Exhaust Rev.MP4?dl=0

Little burble and pop going on..

Cheers dude. Yes you do, but you're doing the sensible thing! Bricks and Mortar before cars.

The exhaust only drones in low gears at 2k rpm and below.

*UPDATE*

After sorting out horrible ABS module issues, My car is now with Devil Devopments in Little Hampton (Bognor Regis) in for stage 3 upgrades.

I've purchased a Mamba K04-015 - 023 hybrid.

Full spec list and photos to follow..

Oh and ive also purchased an Audi S3 8V Flat Bottom Steering wheel and got it wrapped in Alacantara. Coutesy of Royal Steering wheels. Just need airbag and to put it on..

QuattroCalum said:

Niiice mate

Sent from my ANE-LX1 using Tapatalk

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Thanks Mate

Just wanted to publicly say a MASSIVE thank you to Ben Parsons at Devil Developments for giving my old heavy girl the stage 3 treatment.

My car started life off with a K03 163bhp turbo.
It’s now up to 236bhp.
Mamba K03-k04 longitudinal upgrade. Just so you know, these turbos are heavily hotside restricted so no way on earth they will flow claimed 350bhp. It’s been said between 250-280 MAX!!
Due to the weather being seriously hot when mapping (approaching 30) and my not very good and small FMIC he had to taper it down to 236bhp. At one point it actually made *265bhp* but the intake temps where sky high.

Not anywhere near some of you boys power but to be honest, I don’t really care. The car has transformed the way it drives and when it hits boost, it’s lovely.

Him taking the time to refine the mapping (not to mention some issues I had along the way) just shows his customer service is excellent. So it’s not always about huge HP numbers as I’m sure some will agree.

20 days in an I’m over the moon. Will go back to him in winter with a colder engine and 550cc injectors.

Engine specs;
Stock Engine
3” Decat, full Custom exhaust
Forge Silicone Tip
Mamba Turbo hybrid
Piper Cross panel filter
Mishimoto FMIC with 2” pipes.
Forge 008p Recirc Valve.

Ps. The graph is only HP with stage 2 (198bhp underlaid)

antwan64og said:

Interested to see the final outcome of this.

At this point the devil is in the details to keep the temperature down and let the car accept more timing to make power.

Thanks Dude, sure is! Will give it back to him hopefully around Dec/Jan when its super cold and a set of 550cc injectors and see what he can get addtional. I can tell you now, it is NO slouch. Its a heavy car and yet can move when it gets into the upper rev band.

Ported stock exhaust manifold or preferably the AH one from a BEX motor.

Spot on, yes. Never Knew the BEX manifold was slighlty different to begin with.

Phenolic spacer for the inlet manifold, personally I’d use a drill and a carbide bit to gasket match the inlet manifold while it’s off.

Good shout, thanks. (May not do this as imreaching the end of my tuning interest with this car)

Taking the car to a fabricator and getting 63mm boost pipes made up will reduce IATs too.

Thank you, something I've over looked.

550cc injectors will help but is this on the stock fuel pump?

Yes, according to the Ben at DD, this is in good nick.

I take it this is quattro so needs the fuel basket modifying for a DA-31/walbro/Bosch versus the simple drop in pumps for FWD.

Yes! However was told, a new OEM one is more than suffice. (Even Nicky at R-Tech confirmed this)

How did you fit the Forge TIP on the Turbo? The Mamba inlet looks at least 50mm versus the stock 46mm that the Forge is designed for

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Unfortuntely I think the above measurements are wrong somewhere as looking at where the TIP goes into the Turbo, it fits just fine.

Sorry I dont have precise measurements.

MASSIVE thanks to @VagPro for sorting out my roof, coming all the way down from Leicester to offer his services.

Granted my issue ended up being something very small, but his wealth and knowledge on roofs and other bits is amazing!

ANY cab owner, see him if you have an issue!

Massive thanks to Ash at Audi_Retrofits for fitting this for me. Cruise control added too.

Completely Transformed the cockpit.

Massive thanks to Jack at Royal Steering wheels for the retirm.

Let me know if you have any questions.

Thanks a lot Ben!

Its so lovely to touch haha.

So, I knew there would be a point where Photofu*ket fails (Lol) so i've always been taking pictures, storing them on a folder on my PC and uploading them straight to here. So they are stored on my computers hard drive.

I wish mate, Im on holiday from the 10th for 2 weeks!

Thanks Mark, appreciated!

Of course..i dont get when people choose not to tell.

I accumulated parts over many months to not feel so damn heavy on my pockets.

Ebay steering wheel and airbag. £150 each.

Retrim, was exactly £150 from Jack at Royal steering wheels. Great guy and good price for what he's doing.

Thanks a lot mate!! Appreciated.

Yes, Im honestly very happy. I promise you when i say this, the car is NOT slow.

Build boost to 3,000 rpm then mash the throttle.. and the car MOVES!!

Thing is, It's my own fault but the car is being heavily held back by the very small FMIC and 386cc injectors.

So I will go back in December with hardware tweaks to see what she can really do.

Dan.

Just Purchased these bad boys;

Fuel Injectors
https://www.fuelperformance.co.uk/index.php?route=product/product&product_id=8421&search=550cc

And larger FMIC
https://www.ebay.co.uk/itm/302143132216

Booked myself in at Devil Developments in November to see what power we can make.

Also purchased these;

Digital Boost Gauge
https://www.ebay.co.uk/itm/52mm-Aut...itm=360662700849&_trksid=p2047675.c100623.m-1

Snub Mount
https://www.ebay.co.uk/itm/362043400933

Whilst i know SO many people getting rid of their B6's, im keeping mine!

*Jan 2019 update*

As promised, I took the car back to Ben at Devil Developments for further hardware upgrades and what I call my final 'mapping session' No more engine tuning past this point!

Mods;

All of the above!

Results;

Settled for 260 BHP with 285 lbs ft Torque.



My thoughts and Reactions;

Im massively happy. Over the past 5 years or so, my car has been completely transformed from a heavy boat like cabby to quite a quick car!

I mean breaking this down, I've got brake upgrades, suspension upgrades and a Rear RS4 anti roll bar so it makes this thing handle wonderfully! NOT to mention the powerflex snub mount which makes it feel so planted and firm with ZERO engine vibration, when changing gear and accelerating.

Of course the car is and will always be heavy but it has more torque than a stock Golf 7R ! Feels lovely when you hammer it.

..Oh and when you red line and change gear, I've got a few machine gun pops. Tunnel runs are hilarious.

Happy New Year Everyone

Thank you! It has indeed. It did actually come from being 140bhp. When it was dyno'd it had lost 23 ponies from stock!

Yes the FMIC made a massive difference with my IAT's being super low now (Usually sub 20 degrees)

The turbo itself does have more to give. Only running 1.2bar (Capable of 1.5) so well under threshold. No more tuning for this cabby.

Ok, so some Phucking Kunt kicked my wing mirror off a few weeks ago. Clean off! So had to get a replacement on Ebay.
It cost just £35 quid but fitting was a *******.

In order to fix, you MUST take off the whole door card, Which is more difficult with the B6 Cabby compared with the Saloon and Avant.




How to remove door card on Cabby

Pop off tweeter speaker with prying tool. there is a screw behind it. Pop off door card plastic trim with prying tool. Start from the side nearest to the speaker and work your way back.

The plastic trim has a hook so be gentle with it. This reveals 3 or 4 screws behind it. Off they come.

Very gently, pry open the window switch. To do this, you stick a long thin prying tool, down the end closest to the door handle as the pic shows. Pop it up. Its quite stubborn so give it a hard pull. But be careful as its attached to the door card of course. Screw behind there.

Then, in line with the window switch at the very bottom of the door card, there is another LONG screw. Remove that too.
Give the door card a gentle pull from the door starting from the bottom to the top. There are various catches and latches so be gentle.

You must then (VERY annoyingly) Remove the whole soft plastic lining that covers the entire door card and wing mirror to have access to the 2 very long screws in the door itself, which hold the wing mirror in place. If you do not remove this lining, you will NOT have access to the 2 screws in the door.

After you have removed this, you will see that you can now remove the wing mirror and replace.

Apolgies, this is not the best write up but I do hope it helps at least one person!

Let me know if you need help.

Whilst all of the above was going on, I decided to continue to with the mini project i've wanted to do for YEARS.

Basically I always knew that the new FMIC and its piping would get in the way of putting the lower fog side grills back as the bumper had to be trimmed to accomodate much bigger pipes.

I've always liked honey combe RS type Grills so purchased this below and got to work haha.

https://www.ebay.co.uk/p/Universal-...oiler-Bumper-Vent/1942336726?iid=221533152369

Sorry for the lack of photos and can always provide more but basically, I trimmed the lower side grill down massively to be able to accomodate the bigger pipping. I then cut a square hole where the picture suggests.


I used Maplins dremel for this. Also ensuring the actual frame of it is still intact (Made a boo boo and cut the frame so had to bond it back up haha)

Then, I cut the RS Grill in the same shape or near enough as I could get it, so that it would fit inside the square. I then glued it up, left for a day, then gave it a lick of glosss black paint.



Sorry for the quality of the pic (Can take more) But as you can see it came out quite good. It does poke out a bit from the centre sides but this has to happen.

Also, as you MUST dremel the tabs off, I used a black cable tie to tie the gril to the IC piping behnd the Grill.

Summer is near. Cant wait to put the roof down and have a right 'hoon' off my car.

Looking to upload pops and bangs and flames from my car next.

Hey Guys, thanks for prompting me.

Still enjoying the car. In fact, I only drive it on the weekends now so Im enjoying it even more. (If that makes sense)

@quattrogone - The AP coilovers are fantastic. Zero complaints. Glad I went with a good brand. I've lowered all 4 corners so that there is no arch gap and that's how i like it. I dont like it any lower. Feedback is that on any road with no holes its fine. Very nice in fact. Not bouncy, crash-ie or anything like that. However, when you have a road with potholes or lots of uneven surfaces, you have to be careful obviously and drive slower as if you go over a pothole especially with my 235/35/19 tyres....the car doesnt like it! (As you can imagine) To be honest, I drive like im drunk, avoiding EVERYTHING at will and dont really care who i **** off behind me.

@winterrB6 - Here you go buddy. Lots of various clips of extreme popping and banging when I went out for an open top rip with my nephew. (He was filming with his Iphone potato so forgive him)

CLEAN CAR Clip - https://www.dropbox.com/s/whak2oax8dwdv8m/vid_20190824_192216.mp4?dl=0

Clip 1 - https://www.dropbox.com/s/t7dpttcie9ag325/vid_20190825_010137.mp4?dl=0
Clip 2 - https://www.dropbox.com/s/ftzm1jmdb8qh7po/vid-20190826-wa0008.mp4?dl=0
Clip 3 - https://www.dropbox.com/s/ar9rgdsqzl3f35j/vid-20190826-wa0006.mp4?dl=0