Im going six speed and selling some parts!!

[ttrs6]

Car is in for a sixspeed swap and gt's so I am selling my vast tcu,517 built tc,3"custom downpipes with testpipes,transmission,turbo,stock exhaust,ceramic manifolds,airbox and more. Pm me for more info.

[JSRS6]

Jeez, you gonna have a car left? :lovl:

Good luck, I'm going the same route when I get back from Afghanistan.

[ttrs6]

I will be selling full kits soon.

[DonS]

Another big-time project. We wish you 100% success.

Please explain the kits you are going to sell.

And, the Vast tuned TCU and ECU - are they VIN specific?

[ttrs6]

I will be making manifolds,inlets,intake,downpipes,and custom ecu tune. The tcu is not vin specific.

[DonS]

Okay, I thought you were making a 6 speed kit....

[ttrs6]

I have the first kit made but I think I can help u get one.

[ttrs6]

I am offering a custom made clutch with to springs for more clamping pressure.

[hahnmgh63]

JSRS6, do you know where you will be? I get to Bagram & Kandahar from time to time.

[JSRS6]

Should be Bagram.

[Carbonman]

Has the doctor started the swap surgery yet?

Keep us in the loop on the progress (pictures would be great)!

[nistah]

Hi I have been wanting to do the MTM TCU but have not yet b/c do not want to have 3 days downtime....Can you please advise how the VAST TCU compares to the MTM and also let me know the asking on the VAST TCU. Also please let me know what gains are associated with the Downpipes/test pipes Thanks,
Nistah

[1sadavant]

What happened to going "gt's" and "700hp" last October? I thought we were going to be seeing a new "beast" hitting the streets?

[4everRS]

Umm looks like its in the shop now for gt's. Unless I am reading the first post wrong.

[ttrs6]

Last year I was thinking of gts but I just up graded the wastegates figurige that it would be good enough for a while till I got the 6 speed adapter plate and misc parts. Now that I got the parts I'm doing rods,cams,lowering Compretion,gtx's and custom intake. Simpler to the mrc rs6. And maybe I didn't make 700hp I was pretty close judging by my esp light that wouldn't stop blinking. And yes the car is in the shop if you want to call it that in the state its in I will have some pics soon just have to download them from my phone.

[DMtechnik]

Some shots of Tommy's build coming along at our shop.

01E vs RS6 auto comparison.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/229279_10150180961338664_503038663_6786952_5646607 _n.jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230449_10150180960058664_503038663_6786943_2191493 _n.jpg

Some Spacer/ Flywheel mock up action ;)

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/226750_10150179904078664_503038663_6779259_8279135 _n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/222142_10150179901463664_503038663_6779252_6664532 _n.jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/227412_10150184331593664_503038663_6816737_1841518 _n.jpg
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/230427_10150179903498664_503038663_6779257_6061242 _n.jpg

[hahnmgh63]

Wow, first time I've seen the 01E next to a 5HP24A, quite the difference in size.

[DMtechnik]

The turbos we're considering for this project. GT2860s. paired with tial 44mm's on custom manifolds.

http://i41.photobucket.com/albums/e256/MilitantGrunt/gt28.jpg

Custom dual diaphragm clutch, 3800lb clamp load, inhouse design =).

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/217786_211696705523349_203469493012737_830173_3363 17_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/216566_211696738856679_203469493012737_830174_2819 253_n.jpg
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/215422_211696772190009_203469493012737_830175_4302 555_n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/217662_211696825523337_203469493012737_830176_2491 633_n.jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207031_211696865523333_203469493012737_830177_5715 216_n.jpg

[speedtrapped]

Ummmmm, maybe anyone want to buy my level10? Me thinks special sauce could use a 6 speed....damn couldn't stand another 2 months in shop( not inferring). But I am very interested in this project. Six speed would be perfection. Good luck, clutch looks sick.

[Jimmy Joe]

Awesome! very instructive. It's nice to know that there are people technically prepared and savvy enough to hot rod the german wunderwagen!

[SteveKen]

This is looking good and I'm glad to see the kit is finally making it's way into the car.

I'd love to get the weight difference between the transmissions.

I'm sticking with a stage 1 mods on my RS6 and have a Southbend Stage 3 clutch & pp ready for install.

With everything well sorted, you're probably going to have to think about beefier axles.

[terrytcl]

i've got all of my parts ready... just need the adapter kit and electrical help

:) can't wait to get rid of all of the heft and free up some room too.

[DMtechnik]

This is looking good and I'm glad to see the kit is finally making it's way into the car.

I'd love to get the weight difference between the transmissions.

I'm sticking with a stage 1 mods on my RS6 and have a Southbend Stage 3 clutch & pp ready for install.

With everything well sorted, you're probably going to have to think about beefier axles.


Axles shouldn't be concern, unless he plans on launching the car. At which point hes going to need more than just axles. Much like B5's with big power, you can tear the rear diff right out with a launch.

[ttrs6]

Yes steve its looking good nice job on the design. I just got the starter back but not in time to bolt up as you can see.The block is on its way the the machine shop for new rods and cam upgrades. CHA CHING!!!!:doh:

[ttrs6]

Yo speedtrapped you should get the vast tcu and a tune from my boy I think he can give you another 50 to the wheels. Your running almost the same set up as i was and i know i was putting down at least 500 with a stock tranny.

[speedtrapped]

TTrs6, ty for suggestion, as is the current set up on a Maha dyno produced 645/738, I am thinking more like closer to 700/800(crank), less 25% for awd/slush...I am going custom, since the FP is rated 750hp, the FI DBR(bosch 65lbs), 5bar FPR(bosch), DBR turbos,dbr 3"dp's, swapped intake for FMU's, wagners, stage 3 snow meth, the dbr chip runs strong, but I really want to customize ..... I have not changed internals, though I suspect and from what i understand, I am basically at peak power output for the cosworth.
Stephen

[1sadavant]

:lovl:
Axles shouldn't be concern, unless he plans on launching the car. At which point hes going to need more than just axles. Much like B5's with big power, you can tear the rear diff right out with a launch.

I am curious, is DMtechnik, SSP tuning under a new name/management? If so is Greg still in the tuning business? Best of luck with the build, should be a beast.

[DMtechnik]

SSP Tuning? That company is long gone, DM Technik is run by different owners and uses Greg for tuning purposes, good combination =).

[DMtechnik]

Some more tear down. The RS6 has a killer oil pick up, I don't see why the smaller motors don't have something this beefy. Motor is officially at the machine shop for pauter rods and full balance / assembly.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/228687_10150185777438664_503038663_6830338_7514248 _n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/228100_10150185777948664_503038663_6830340_86843_n .jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/222756_10150185778423664_503038663_6830342_980628_ n.jpg
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230596_10150185778663664_503038663_6830345_5951009 _n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230532_10150185778733664_503038663_6830346_4540040 _n.jpg

[4everRS]

thanks for the pics! Looks like quite a project, very cool. The casting marks on the rods on your pic looks as though they are forged. Are the new rods even stronger?

[skribe]

Nice build, nice-looking work.

I got introduced to disintegrating O1E's from highly tuned 2.7t's... Really the O1E can handle this kind of torque? Have the synchro issues been sorted?

[DMtechnik]

We're thinking about sending one of the stock rods to see their tensile strength. The machinist stated the rods are forged but not the quality as pauters or other aftermarket forged rods.

[SteveKen]

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230532_10150185778733664_503038663_6830346_4540040 _n.jpg

Don't forget to remove the plug that's in the crank. Sometimes it's stubborn and you have to use a special puller/slide hammer. I just drilled and tapped mine on my mock up engine and used a screw to push it out.

The flywheel will not fit without the plug removed.

Looks awesome. Good luck.

[SteveKen]

Nice build, nice-looking work.

I got introduced to disintegrating O1E's from highly tuned 2.7t's... Really the O1E can handle this kind of torque? Have the synchro issues been sorted?

The 01E is the best available as far as I know. The can be built to suit if you've got the money.

[RS6...]

Nice project as it's very simliar to the one I am about to start and I know what you mean about having parts to sell..... LOL

I would be keen to hear what you will be doing about pistons, rings and the bore if anything?

Good luck!

[DMtechnik]

Nice project as it's very simliar to the one I am about to start and I know what you mean about having parts to sell..... LOL

I would be keen to hear what you will be doing about pistons, rings and the bore if anything?

Good luck!


The machine shop we sent the motor to specializes in VAG engines, he stated that the cylinder walls are coated in Nikasil, hence you cannot hone or bore them. Its essentially a straight drop in of new components. We will most likely be using Goetze OEM piston rings paired to the oem pistons (They are forged.)

http://www.federalmogul.com/en/AftermarketSolutions/EMEA/EngineSolutions/Products/PistonRings/GoetzePistonRings/

As far as the transmission goes, the 01E we're using has been rebuilt, and has a new 1-2 shift collar. Should be more than adequate as long as hes careful not to miss a gear. If you really want to go crazy, I'm sure you can use an 01X from the newer B6 S4's, the center casing on that tranny is significantly more beefed up, as Im sure the internals are as well. Unless you go with straight cut gears, the power levels we're shooting for here, you'll break just about any trans if you're not careful about it.

[RS6...]

The machine shop we sent the motor to specializes in VAG engines, he stated that the cylinder walls are coated in Nikasil, hence you cannot hone or bore them. Its essentially a straight drop in of new components. We will most likely be using Goetze OEM piston rings paired to the oem pistons (They are forged.)

http://www.federalmogul.com/en/AftermarketSolutions/EMEA/EngineSolutions/Products/PistonRings/GoetzePistonRings/

As far as the transmission goes, the 01E we're using has been rebuilt, and has a new 1-2 shift collar. Should be more than adequate as long as hes careful not to miss a gear. If you really want to go crazy, I'm sure you can use an 01X from the newer B6 S4's, the center casing on that tranny is significantly more beefed up, as Im sure the internals are as well. Unless you go with straight cut gears, the power levels we're shooting for here, you'll break just about any trans if you're not careful about it.

Nice project if I say so myself :)

The block is actually Alusil and it is not a coating but rather a surface finish that occurs due to a chemical process. The bores can be honed using the correct methods but if the bores measure up and the surface is not thining re-using the bore's is perfectly fine as you are doing.

I would be interested to know where you will be purchasing the OEM pistons as I want to do the same and was unaware Audi would sell just the pistons. I am familiar with those rings and they are also the one's I will be considering dependant on the pistons so I will appreciate any info on this.

I will be using the 01E and once the car is sorted if the gearset becomes an issue I have a friend who works at Pfitzner (www.ppggearbox.com.au (http://www.ppggearbox.com.au)) who would be able to sort me out a synchro mesh gearset that will provide more torque handling without the harshness of a dog box.

What are the plans for the headend? I am having the heads ported and match porting all other thing on the intake side. I am looking for camshaft options and even considered using the S8 cams but I am not sure if they are any different to the RS6 ones apart from part number. I would only need to make power until 7500-7800rpm max as the torque will be massive and I will probably just reatin the OEM valvetrain.

Keep up the goods work and information!

[hahnmgh63]

Speaking of porting the RS6 heads, does anyone know if the exhaust ports are ceramic lined like Porsche does? If so, you can not port them without breaking the ceramic inserts. I would think Cosworth did a pretty good job on the head mods.

[ben916]

Nice project if I say so myself :)

The block is actually Alusil and it is not a coating but rather a surface finish that occurs due to a chemical process. The bores can be honed using the correct methods but if the bores measure up and the surface is not thining re-using the bore's is perfectly fine as you are doing.

I would be interested to know where you will be purchasing the OEM pistons as I want to do the same and was unaware Audi would sell just the pistons. I am familiar with those rings and they are also the one's I will be considering dependant on the pistons so I will appreciate any info on this.

I will be using the 01E and once the car is sorted if the gearset becomes an issue I have a friend who works at Pfitzner (www.ppggearbox.com.au (http://www.ppggearbox.com.au)) who would be able to sort me out a synchro mesh gearset that will provide more torque handling without the harshness of a dog box.

What are the plans for the headend? I am having the heads ported and match porting all other thing on the intake side. I am looking for camshaft options and even considered using the S8 cams but I am not sure if they are any different to the RS6 ones apart from part number. I would only need to make power until 7500-7800rpm max as the torque will be massive and I will probably just reatin the OEM valvetrain.

Keep up the goods work and information!

Could you update your location please?
Sounds like/looks like AU but not 100% sure..


EDIT: your link doesn't work...

[DMtechnik]

Nice project if I say so myself :)

The block is actually Alusil and it is not a coating but rather a surface finish that occurs due to a chemical process. The bores can be honed using the correct methods but if the bores measure up and the surface is not thining re-using the bore's is perfectly fine as you are doing.

I would be interested to know where you will be purchasing the OEM pistons as I want to do the same and was unaware Audi would sell just the pistons. I am familiar with those rings and they are also the one's I will be considering dependant on the pistons so I will appreciate any info on this.

I will be using the 01E and once the car is sorted if the gearset becomes an issue I have a friend who works at Pfitzner (www.ppggearbox.com.au (http://www.ppggearbox.com.au)) who would be able to sort me out a synchro mesh gearset that will provide more torque handling without the harshness of a dog box.

What are the plans for the headend? I am having the heads ported and match porting all other thing on the intake side. I am looking for camshaft options and even considered using the S8 cams but I am not sure if they are any different to the RS6 ones apart from part number. I would only need to make power until 7500-7800rpm max as the torque will be massive and I will probably just reatin the OEM valvetrain.

Keep up the goods work and information!


Thats incorrect, the block IS Alusil, but like I stated, the cylinder walls are coated in Nikasil and should not be honed. Trust me on this =). We're reusing the pistons from the block, the stock pistons are forged, theres no reason to get new ones. I have local wholesale supplier that can get me the rings, unfortunately I cannot divulge that information. The plan for now with the heads is sending the cams for a regrind, and we're considering doing springs / retainers / exhaust valves, std size.

As far as the situation with the rods, they're about 5-6 weeks out from Pauter.

[hahnmgh63]

I have never heard of a Alusil block with Nikasil cylinders. Alusil seems to be the preferred material nowadays with low or highers sulfur fuel (just ask the BMW crowd). BMW swapped to Alusil in the late 90's after many problems with the Nikasil blocks and the higher sulfur content in our (N. America) fuels. For those of you with a chemistry background you may remember about the adverse affects of Sulfur and Nickel, bad joo joo. Alusil is a process where an Silcone/Auminul sleve is cast into the block and honed in an acid wash process that leaves a hardened Silicon carbide surface. Nikasil is a coating of Nickel and Silicon that is added to a soft alloy block's cylinders. The idea of Nikasil and Alusil is the cylinder walls are very hard and soft rings are used. This means typically all that is required for a rebuild is new rings. Also, to keep Aluminum to Aluminum oxidation or electrolysis at bay, many Alusil blocks will have their Aluminum pistons skirts coated with iron. This is somwhat simplified, but by soft rings, I mean pretty much standard rings for most applications since the cylinder walls are harder. Alusil is a cast block with the aluminum etched from the walls with an acid paste & hone, Nikasil is a coating put on the softer aluminum block in various ways after casting.

[hahnmgh63]

Just found this on Wiki, a pretty good Alusil explanation: http://en.wikipedia.org/wiki/Alusil
http://www.rheinmetall.de/index.php?fid=1364&qid=&qpage=5&lang=3 I believe Kolbenschmidt also casts the 4.2 blocks.
Here you go for the 4.2 block: 'Alusil (http://en.wikipedia.org/wiki/Alusil)' aluminium (http://en.wikipedia.org/wiki/Aluminium)-silicon (http://en.wikipedia.org/wiki/Silicon) alloy (http://en.wikipedia.org/wiki/Alloy) (AlSi17Cu4Mg) with a closed-deck design, mechanically stripped hard silicon crystal integral liners, honed under simulated mechanical stress.

[4everRS]

I would be very surprised if the ports on these heads aren't cnc'd along with the intake runners. Hence no need for "port-matching". We all know there is a ton to be gain from the old detroit V8's, but everything was just cast back then and bolted together. If cosworth had the where-with-all to use sodium filled exhaust valves in this engine, I bet the heads have pretty great efficiency.
Speaking of porting the RS6 heads, does anyone know if the exhaust ports are ceramic lined like Porsche does? If so, you can not port them without breaking the ceramic inserts. I would think Cosworth did a pretty good job on the head mods.

[RS6...]

As far as the situation with the rods, they're about 5-6 weeks out from Pauter.

I havent had time to measure up the rods so would you mind/be able to give me the following dimensions?

- Length (Centre to Centre)
- Big End Bore
- Small End Bore
- Big End Width
- Small End Width

Preferably in metric units.

Thanks in advance

[Greg@DMtechnik]

I havent had time to measure up the rods so would you mind/be able to give me the following dimensions?

- Length (Centre to Centre)
- Big End Bore
- Small End Bore
- Big End Width
- Small End Width

Preferably in metric units.

Thanks in advance


Jordan i have ordered myself a new digital caliper my old one broke so as soon as it comes in i will do exact measurement with pictures for you

[Greg@DMtechnik]

Project still moving along waiting on all parts to come in :)

[yokust]

I would be very surprised if the ports on these heads aren't cnc'd along with the intake runners. Hence no need for "port-matching". We all know there is a ton to be gain from the old detroit V8's, but everything was just cast back then and bolted together. If cosworth had the where-with-all to use sodium filled exhaust valves in this engine, I bet the heads have pretty great efficiency.


Sadly I wish this was true. But I have my extra motor and a normal 4.2 and they have the EXACT same head castings on intake and exhaust side.

The exhaust side is MUCH smaller port then the manifold, just like most cars.

The intake side is much larger then the manifold port, oppisite of most cars.

[4everRS]

Well then, count me very surprised. This seems really dumb to me that they didnt do it. I guess costs have to get cut out of production somewhere, but I thought they did enough of that with the TC.
Sadly I wish this was true. But I have my extra motor and a normal 4.2 and they have the EXACT same head castings on intake and exhaust side.

The exhaust side is MUCH smaller port then the manifold, just like most cars.

The intake side is much larger then the manifold port, oppisite of most cars.

[hahnmgh63]

Yokurst, can you tell if the exhaust ports on the head are ceramic lined? Porsche has been doing this, at least on their Turbo cars since the late 80's. If not I guess you could do a little Port matching but if so, I wouldn't mess around with the ceramic liners.

[r8dream]

interesting project, this may be helpful for 4.2 rebuild info http://www.motorgeek.com/viewtopic.php?f=10&t=37611&sid=f65f86b8a16b705bd3697e60af31a36f

[yokust]

Yokurst, can you tell if the exhaust ports on the head are ceramic lined? Porsche has been doing this, at least on their Turbo cars since the late 80's. If not I guess you could do a little Port matching but if so, I wouldn't mess around with the ceramic liners.

They do not apear to be coated, would really have to be cleaned in a hot tank to really tell. But I have never known any VW/Audi to coat any of the ports

[Mikk23]

On a side note...either of you fellas make it over to the Jalalabad area every now and then? Good to know I'm not the only RS6 owner who's beloved car is on the other side of the world. I get to Bagram every once and a while as well.

[JSRS6]

So is your car in syracuse and you are overseas, or the opposite? I might be in Bagram for the better part of next year.

[hahnmgh63]

I've made it to various spots in Pakistan now and then but really try to avoid the place. JSRS6, I'll have to look you up if I head to Bagram. I have a civilian contracter friend that just took a pretty sweet job there working for Evergreen. They are over on the JSTOF compound.

[Mikk23]

Lol...my car is in Syracuse...well in my garage up towards Fort Drum. I am in Jalalabad...which is about a 20 minute flight east of Bagram. I'll be here another few months and my year will be up...thank goodness.