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Thread: Manual Conversion Thread - RS6 with 01E

  1. #199
    Registered User hahnmgh63's Avatar
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    Brazing them shut would have probably been best but I used Silicone caps from 034 Motorsports. Much better quality than the NAPA caps.
    2003 White RS6 2013 Midnight Blue S5
    2013 Daytona RS5 2x944 Turbo's 1974 911 w/'91 3.6ltr motor
    Roy, WA

  2. #200
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    Quote Originally Posted by hahnmgh63 View Post
    Brazing them shut would have probably been best but I used Silicone caps from 034 Motorsports. Much better quality than the NAPA caps.
    Which ones did you use? 3/8" ID for the front one and 1/2" ID for the rear one?

    I looked high an low for these about a year ago and ended up sticking with the rubber heater hose caps. Never thought to check 034. I wonder if they make them? Since I can't find anything comparable anywhere else?

    Also, you can source the necessary hard pipes from a UK car or one that was spec'd without the hot weather package and not need the caps at all. I had these on them S6 Avant conversion.
    2012 Q7 TDI S-Line - 2010 GTI - 2007 A3 3.2 S-Line - 2003 RS6
    2001 Honda S2000 - 1977 Honda CBR 750-F2 - 1965 GMC 1500 WideSide

  3. #201
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    Quote Originally Posted by P1054 View Post
    I had the same issue with the rubber caps. After the first set started leaking, I decided to braze some copper caps on instead. It has now been several years (five?) and a lot of miles, and they’re still holding up great. Aluminum caps would probably be better since the lines are aluminum, but copper ones were more readily available.
    Did you have to take both pipes out to do that?

    any chance you could snap and share some pics?

  4. #202
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    I had both pipes out, yes. It was done during the manual conversion. I don’t have any photos, but I’ll see if I can get some.
    RS6 #1, 01E, 2.5" straight pipes, AMD Stage 1 6MT tune, 460awhp/530awtq on AMD's Mustang dyno. TOTALLED.. RS6 #2, Ebony Black Pearl on black/silver combination with carbon, up and running with 6 gears and AMD tune.

  5. #203
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    Front pipe is galvanized(?) steel; it's magnetic. I cut off the nipple and welded it shut after replacing the rubber caps multiple times.


    03 RS6 Avus/Ebony #905593 resurrected 6MT, 04 Avalanche Z71, 87 T-Bird Turbo Coupe (351W T5), 04 Aprilia RSVR Factory

  6. #204
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    Quote Originally Posted by bethridg View Post
    Front pipe is galvanized(?) steel; it's magnetic. I cut off the nipple and welded it shut after replacing the rubber caps multiple times.


    Did you do something similar to the crazy elbow piece near the coolant reservoir, too? I think it might be cast aluminum though.
    2012 Q7 TDI S-Line - 2010 GTI - 2007 A3 3.2 S-Line - 2003 RS6
    2001 Honda S2000 - 1977 Honda CBR 750-F2 - 1965 GMC 1500 WideSide

  7. #205
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    Quote Originally Posted by SteveKen View Post
    Did you do something similar to the crazy elbow piece near the coolant reservoir, too? I think it might be cast aluminum though.
    It did cross my mind...but I don't have anything to weld aluminum yet. Still rocking the rubber caps at that location. Should look into those silicone caps hahnmgh63 mentioned above. I go into panic mode when I start smelling coolant only to find the caps split again.
    03 RS6 Avus/Ebony #905593 resurrected 6MT, 04 Avalanche Z71, 87 T-Bird Turbo Coupe (351W T5), 04 Aprilia RSVR Factory

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