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

olethalb

Registered User
when i joined i said i wasn't going to make a 'build' thread as not a lot was going to be done to this one, unlike my old bora.

this is still the case but i had a little thread on uk-audis as a record of what has been done, but they've recently upated the site and i cannot get on with it at all so i'll transfer what i have done so far.

spec - A4 TFSI permanent quattro DTM LTD edition made in 2006 to celebrate audis success in DTM racing

as i bought it - 220bhp k03 turbo recaro half leathers and DTM specific carbon extras

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first things first - new fuel pump tappet and cam chain and tensioner to keep things sweet

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and after the work spruce the bay up a little

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olethalb

Registered User
after the engine had been treated it was time for wheels, these came up fairly cheap so snapped them up

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next was to 'joey' the headlights and de tango

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soon after the long awaited coils arrived

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and with 12mm spacers a little fitment

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also ebayed a leather arm rest

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olethalb

Registered User
more power was on the cards so started accumulating parts

k04

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DV

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one stage cooler plugs

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s3 injectors

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with more to follow.....

the DTM comes with 320mm front discs which aren't the best so upgraded to S4 345's

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aux belt tensioner started clicking so on with a new one

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olethalb

Registered User
the rotis came with tyres but size wasn't ideal so i changed them for 215/35's and tweaked the ride height a little

and purchased a new reg from DVLA

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after having a lot of bits and bobs on order from UK and USA they started trickling through

ATP 3" decat

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polybush snub mount

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milltek cat back system

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Autotech HPFP internals

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olethalb

Registered User
the day of exhaust fitting came

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when i removed the original cat the wastegate flap had disintegrated from vibration

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all i could do at that piont was weld the flap back to the arm....

fitment of the milltek went well until it came to the tailpipes

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they stuck out far too much so had to trim an inch off each tailpipe trim

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they still didn't sit evenly in the cutouts in the bumper so i had to cut a bracket off that regulated the distance between the pipes and weld a correct sized rod in between

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the left pipe would not sit high enough no matter how much tweaking so i had to splice the tailpipe trim and reweld

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perfecto
 

olethalb

Registered User
as i was gearing up for the K04 swap i spoke to MRC who advised FMIC - the kits i had seen weren't too impressive, either required bumper chopping or losing the crash bar, neither was an option

i measured up and went for a core intended for another audi

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then set about mocking up custom hard boost pipes with a variety of ally bends

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mocked them all up to size and correct path making no contact and gave them to my ally welder

also decided to weld the s3 dv flange to the boost pipe

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painted and fitted

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olethalb

Registered User
next was the modified k04

tt225 outlet welded on

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downpipe bolts repostitioned and rethreaded

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test fitted

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bolted up

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intake with recirc inlet for DV

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front end slotted back on with no mods or trimming :)

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DIY heatshield box

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now it was all up and together next was MRC for mapping

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made 330bhp and 350 torque but had budget fuel and clutch was dying :(

well fitted a new clutch yesterday, brimmed it with optimax and went to RR day today but was too low for the rollers :(
 

olethalb

Registered User
oh one from Surrey RR day today - ignore the tit in the wifebeater

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few more pics - one from players

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one with new honeycomb satin grill

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and completed the de-chroming with some carbon fibre mirrors

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olethalb

Registered User
also fitted BSH PCV fix but will be making custom catch can set up

refitted stock 'D' diverter valve

near future mods include:

better custom intake set up

custom manifold / turbo heatshield

better p/s fluid cooler

WMI kit

uprated intank pump

make a new crash bar

source 'open' grill or make my own

remap (3rd time lucky)

next year will be fbsw and some new wheels i think
 

mancdan

Registered User
Excellent write up and cracking looking car. Hats off to you sir.
Did you wrap the chrome mirrors in Carbon or replace them completely?
 

olethalb

Registered User
mancdan - thanks, i replaced the covers completely. got these ones from felondnb off edition38 :)
 

OCDetails

Registered User
Soooo unfair! :( I wanted rotiform blq 19's on mine once lowered! You beat me too it :/ looks sweet too!

Did you have to add spacers with them? What kind of alignment settings you running too? How far did you lower by also?

So jealous right now lol sweet car :)
 

chrisa4quat

Registered User
This is a great thread! Exactly what I want to be doing to mine!! Are the s4 pads and discs a straight fit?
 

ANDYTQ

Registered User
Looks stunning, i'll be the last to fit my ko4 at this rate lol,cheers Andy
 

chrisa4quat

Registered User
Doubtful Andy ill be one of the last! Lol
 

CHEZ

moderately amusing
Supporter
easily the best DTM i have seen!
well done fella! :wub:
 

Jez-dtm

Registered User
What a beaut! Do the s4 disks and pads just fit the original dtm callipers or would I need a fitting kit ? Cheers! 👍❤
 

chrisa4quat

Registered User
I'm still waiting to see if they do too Jez. That would be my next mod if they do as I need brakes soon!
 

Molnboman

Registered User
Wow.....that's a lot of beer tokens spent on that! Amazing stuff and lots of ideas there too! Well done Sir.

Cheers
A
 

olethalb

Registered User
wow - quite a response over the weekend :0

mancdan - it's a vag forum. i think the covers got thrown out, it wasn't 'til i removed them i saw they were ebay copies.

Macdoon - thanks

Stui - yes ebay item, i was after the more open holes but it's only available from Australia at the mo with £145 postage

Morgan46 - yes, not a lot in comparison with my last car :)

AudiB7Jay - they have 12mm spacers on the rear, all allignment is stock but obviosly had to have tracking done. i didn't take measurements, just lowered it so the front and rear arch to tyre distance was even and there was no contact.

P.S Roti's will be for sale next year

Chris - i was told to fit S4 fronts all you need is discs pads and S4 carriers, i fitted the carriers to my DTM calipers and popped the discs and pads on but the very top and bottom of the caliper contacted the disc. i could have ground a bit out but i picked up the proper calipers for cheap enough and bolted them on.

ANDY - thanks, i still have my dead one sat on the bench :(

CHEZ - thats quite a compliment, thank you

Sewell - thanks, do you have a thread? i'd like to see a yellow one

Jez - see reply to chris above RE brakes :)

Molnbowman - i had my last car 'show car' bora up for sale but decided to break it so when something sold i'd treat the A4.

BA4 - thanks, i need some after my turbo died

Olly - thanks, and thanks for spelling 'Olly' in the correct way :)
 

ANDYTQ

Registered User
Pipework looks really neat,where did you source the front mount from?
 

Jez-dtm

Registered User
Cheers mate! One more quick question....
Do you have a guide, or a link to the one you used to get rid of those awful orange reflectors?

thanks :)))
 

solaris

Registered User
Well done, good to see another DTM with a KO4 :happy:
 

olethalb

Registered User
Jez - i just went at it :yes: i think i must have seperated and redone my bora headlights in different styles about 6 times.

Olly - thanks, i just went for the leave them off with them chrome / orange bulbs

Solaris - my turbo died a short time after my first MRC mapping session, so i went to turbo dynamics and bought a brand new item and had hybrid work so it should be the same spec as yours now. ordered a new K revision thrust sensor and RS4 pressure regulator yesterday, next will be uprated intank pump then WMI. i'm hoping to crack 400bhp with the hybrid.

i'll also be making a tubular crash bar so i can expose the full fmic and will have to buy / make a more open grill - remove or reduce number plate plinth.
 

olethalb

Registered User
ANDY - nearly missed you out :0 it's from an ebay kit for a B6, i looked at a lot of cores from jap to RS500 but this fitted my dimension needs best. the hard pipes, silicon joiners and clamps were all binned and custom pipework made up. the pipes that came with the kit were ridiculously narrow :haha:
 

Golfedd

Registered User
looking good Olly man, Nice to see the full pics and the bits you've done! Didn't realise the level of love you gave this one (it comes as no surprise though) haha. Catch you soon no doubt for some A4 rolling times! :rockwoot:
 

olethalb

Registered User
i'll be happy when it's making good power with a decent map, you know i can't leave things alone. the bora was supposed to be my sensible car....
 

stuiwhite

Registered User
Any build thread of this Bora you speak of :) - would be nice to see other pieces of art you have mastered!

Really jealous of this one - wish i had the funds to buy such a gorgeous vehicle!

Ill have to stick to me SE TDI!
 
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