S6 conversion to RS6 [Archive] - RS6.com

SteveKen

May 3rd, 2013, 15:17

Thought I'd throw in a bit of a teaser pic (crappy at best) of the current status of converting my S6 into an RS6 (in most aspects) . Maybe I'll post some Friday updates if anyone cares...

http://www.kendrish.com/galleries/blackS6/RS6_Conversion/init_firewall_1.jpg

Note the brake vacuum water hose manifold is installed along with the coolant reservoir tray where the battery normally sits.

The car will be a 6 speed so I'm not using the brake vacuum pump and utilizing a Euro spec engine harness that isn't wired for the pump. Interesting fact is that the RHD ans Euro spec RS6 cars didn't come equipped with the pump.

Other custom items will include upgraded fuel pump/filter/lines/FPR, oil cooling and custom battery box to house one or 2 PC680 batteries where the SAI pump normally sits. The battery mod will also give me the full trunk along with a spare tire.

I'm waiting for a lot of parts to arrive from the UK and Germany before I can make some real progress. Clutch has been ordered along with the AMD manual stg1 tune.

Cosmetic items (aside from the RS6 body parts) are subtle. Maybe a new set of wheels (looking at Rotiform SNAs). I've already got all the aluminum trim back from the powdercoater (black optics matte black) and waiting to do some 'paint correction' before installing it.

I'm going to see how the car sits on the stock S6 suspension for now but will probably end up with PSS9s or KWs, even though coilovers are against my nature on a car that will not be tracked. Unless there's a shock/spring combo out there that I don't know of yet. Will definitely end up with adjustable UCAs and Hotchkis sways, too.

Might end up with a shortened JHM short shifter and some other misc stiffer bushings in the driveline (apikol, 034, etc)

Anyway... wish me luck.

SteveKen

May 3rd, 2013, 15:19

BTW, for all the purists out there, the car will not have the RS6 badging. I'll most likely have no badge.

MaxRS6

May 3rd, 2013, 15:46

Good luck! Thank you for taking the time to share the project with us

ttboost

May 3rd, 2013, 15:52

Yes..definitely good luck.

mrdave

May 3rd, 2013, 16:26

An S6 avant with RS6 drivetrain and a manual transmission is pretty much the perfect vehicle. Can't wait to see your progress!

nene

May 3rd, 2013, 16:42

Lots of luck and keep us updated on any progress and pix. S6-R maybe?

Mr. Rictus

May 3rd, 2013, 16:57

This is exactly what I want to do to my S6, now that my S6 has a manual transmission!

Lots of pictures are a requirement!!

ben916

May 3rd, 2013, 18:04

An S6 avant with RS6 drivetrain and a manual transmission is pretty much the perfect vehicle. Can't wait to see your progress!

That sounds like the complete SLEEPER if I have every heard of one!!!!

Primo

May 3rd, 2013, 18:19

Good luck, but I'd put some badges on ;)

bmwade

May 3rd, 2013, 20:00

I'll be following suit as soon as my beast sells and frees up some cash! I can't wait to see completed project and I'll be asking for parts list, etc!

Brav

May 3rd, 2013, 22:06

I would say you are good to badge it.. will have the heart and soul of an RS6. won't be pretend. Congrats on the endeavor!

bmwade

May 4th, 2013, 21:42

Interesting thought: how would the engine swap work into an Allroad?

SteveKen

May 5th, 2013, 00:35

Interesting thought: how would the engine swap work into an Allroad?

Any timing belt 4.2 would be tricky to install in any narrow bodied C5. The engine compartment, hood, fenders, etc. are around 50mm shorter than the wide bodied C5 cars. The allroad uses the timing chain 4.2 that's shorter.

I can't comprehend the work that would need to be done to twin turbo the timing chain 4.2. I still can't get past the fact that the chain assemblies, guides, etc. are a few grand to replace. (and the un-informed think that 35k mile T-belt jobs are reasons to stay away from the RS6........)

DHall1

May 6th, 2013, 17:48

Steve you are sooo right about the chain driven 4.2. There are several reasons why I dont own a vehicle newer than 2003.

Timing chain $$$$$ issues, FSI carbon deposit issues, all kinds of fuel system issues due to the 2004 EPA mandate to eliminate the fuel return and the list goes on.

As my S6 avant sits out in the garage and these 15k RS6s come across my desk....the temptation is there to do the swap. I'm actually leaning more and more to just keeping the S6 and doing the swap.

And for those that have not driven all three platforms. The S6 drives like the RS6 just a bit softer but the overall driving impression is very similar to the RS6. Just no power. Throw coilovers and 4.2tt and you will drive and feel just like the RS6 sedan. The Allroad feels heavy and super soft. All the interior components and fabric do not give you the feel of a RS6 at all. It would take a huge project and money pit to even make it come close to feeling like a RS6 inside. Excluding the wide body and narrow body differences. Never mind the steering rack ratios and a host of other differences that will make the Allroad conversion feel like a FrankenAudi. imho

Any timing belt 4.2 would be tricky to install in any narrow bodied C5. The engine compartment, hood, fenders, etc. are around 50mm shorter than the wide bodied C5 cars. The allroad uses the timing chain 4.2 that's shorter.

I can't comprehend the work that would need to be done to twin turbo the timing chain 4.2. I still can't get past the fact that the chain assemblies, guides, etc. are a few grand to replace. (and the un-informed think that 35k mile T-belt jobs are reasons to stay away from the RS6........)

DHall1

May 6th, 2013, 18:00

Oh yeah, I have offered my 65000 mile Atlas gray/black S6 avant to two members at $12500. They better hurry. ;)

ttboost

May 6th, 2013, 18:09

Before you change your mind? :lovl:

DHall1

May 6th, 2013, 18:31

All it takes is the right RS6 for sale in the SW region. Given the 15-18k price for some clean higher mileage RS6s that are complete... the swap makes more sense than buying a wrecked model with questionable components for 12k. I could then reinstall the S6 driveline back into the RS6 sedan and sell the hybrid RS6/S6 sedan for a few thousand to offset the conversion.

A pipe dream but what the heck. Audi is not going to bring us any S model avant. I would hand my wife the keys to the RS6 avant and she and the dogs would be in hog heaven. haha

SteveKen

May 6th, 2013, 21:26

I received my core support items form the UK today and I was disappointed at first, but it might be a blessing in disguise.

Apparently there's a 'non-hot' climate version of the radiator that doesn't have the third outlet. Therefore I don't need to add another thing that can break: the coolant solenoid that diverts water to the turbos at who knows what time. I'm eliminating around 6 - 10 clamping points that could leak and do not need to drill more mounting holes in the frame rails. I'm thinking I'm as close to a Euro zone LHD car than a US spec one. Not a bad thing, I guess.

SteveKen

May 16th, 2013, 00:21

I dropped by Shokan Coachworks on my way to NH from Pittsburgh to pick up an A/C line. The atmosphere around the place is really neat.

Among all the salvage cars, which all looked like they had been washed for some reason, they have a bunch of garages and barns. I'm guessing to house the collection they have. Truly awesome.

http://kendrish.com/galleries/misc/shokan.jpg

BTW, the RS6 Avant is for sale. I didn't even ask how much.

Cmnair

May 16th, 2013, 00:40

That is a cool place! I have seen that RS6

alrightroad

May 16th, 2013, 04:17

Would love to add that UR to my barn (if I had a barn).

SteveKen

June 25th, 2013, 14:31

Update: Nothing new, really.

Getting ready to weld the RS6 front engine mount to the S6 frame this week.

Still waiting on the clutch in order to get the engine & trans mated.

I'm going to have to replace some harnesses or make some, depending on how extensive the differences are.

Does anyone have the RS6's in-tank fuel pump out and handy? I'm wondering if I can get some specs on it. Recall it's just a transfer (feeder) pump to the in-line external pump. I'm afraid if I use the S6's stock in-tank pump, then the external pump (going with a single Bosch 044) will not be happy. If there was more room up front, I'd seriously consider a surge setup.

Onward...

SteveKen

June 25th, 2013, 14:46

Oh, and all my body parts acquired in Germany should ship within a week.

bmwade

June 25th, 2013, 23:36

I don't suppose you'll get bored and want to sell it a couple months after you finish it?

ttboost

June 26th, 2013, 00:02

I don't suppose you'll get bored and want to sell it a couple months after you finish it?

My guess is almost guaranteed.....

v8a6

June 26th, 2013, 02:13

SteveKen

June 26th, 2013, 20:45

I don't suppose you'll get bored and want to sell it a couple months after you finish it?

lol. Maybe.

SteveKen

June 26th, 2013, 20:54

Nice update Steve. I can't wait to see this machine in action.

BTW, Timmmy on Audizine might have the info you need on the fuel pump. He is running dual Bosch 44s on his project RS6, so he may still have the OEM pump kicking around.

Funny you mention this. We've just been going back and forth on this. I learned something new today, too on how the in-tank pump gets fuel from the other side of the 'saddle' shaped tank and how it can affect fuel pressure.

I'm going to pull out the pump today and run some numbers.

scottmandu

June 28th, 2013, 03:56

SteveKen

July 1st, 2013, 21:05

Does anyone have any pictures of the following:

Fuel pump control module in-situ behind the side bolster piece in the passenger side rear. It's directly under the seat belt mechanism.

The area under the coolant reservoir. There are two fuse blocks. I'm interested in the bracket the fuse blocks are mounted to. Reading a P/N off of this bracket would be a plus.

The back side of the lock carrier, showing the wire routing for the 600W fan. Finding a P/N on the extension cable for this fan would be a plus.

The area where all the plugs are mounted underneath the power steering reservoir cover. pics of the Euro version w/o brake vacuum pump would be a plus.

I'm still hip deep in evil with this conversion.......

bmwade

July 3rd, 2013, 04:24

I don't have any help to contribute, but this thread definitely has me questioning my sanity for wanting to start this project....

yokust

July 3rd, 2013, 04:28

Are you putting the battery in the trunk along with all the wiring?

SteveKen

July 3rd, 2013, 15:05

I don't have any help to contribute, but this thread definitely has me questioning my sanity for wanting to start this project....

It's not too bad if you have a whole parts car on hand, but I'm working with essentially half of a parts car.

Are you putting the battery in the trunk along with all the wiring?

I thought about doing the battery in the spare tire well like the Euro avant, but am going to first try one or two PC680 batteries where the SAI once was. Since the distance from the battery to the starter is about as close as physically possible, I'm thinking I can get away with just one.

SteveKen

July 30th, 2013, 15:43

No major update on this aside from this is what the RS6 body harness looks like. Wife was not pleased that I took over the parlor. lol.

Also does anyone have a picture of the in-tank fuel pump assembly and the top where the harness plugs in?

http://www.kendrish.com/galleries/blackS6/body_harness.jpg

I'd say 35-40% of all this is dedicated to navigation, radio, antennas, etc...

v8a6

July 30th, 2013, 16:05

wow, that looks like a lot of work to sort out

... and a very expensive rug for the harness on which to lay :) My Wife would have a heart attack too

SteveKen

August 6th, 2013, 14:47

non-eventful update...

ST coilovers hopefully go on by Thursday
Engine & trans goes in by end of day Friday.

I lost the lease on my current 'project garage' so the car then gets flat-bedded on Saturday to my other garage and most likely goes into hibernation for a few months. My work schedule is limited at this location, with tenants living above my garage. With my schedule, I can only work on the car late at night, but that doesn't go over well if I want to collect rent checks.

bmlee007

August 6th, 2013, 21:01

I lost the lease on my current 'project garage' so the car then gets flat-bedded on Saturday to my other garage and most likely goes into hibernation for a few months. My work schedule is limited at this location, with tenants living above my garage. With my schedule, I can only work on the car late at night, but that doesn't go over well if I want to collect rent checks.

OT...

I would be the perfect renter for you. I'm only home 3-4 days a month, and those days I'd likely be right beside you in the garage.

I'm actually looking at buying an old Ford dealership close to home. There are two apartments above the showroom, and the service bay extends out away from the building so noise shouldn't be an issue. If all goes well, I would turn the showroom into a small business incubator, rent out the apartments, use the service bay, and turn the parts room into a small fab shop. Might take a while though, only getting to work at it for 3-4 days a month.

Back on topic...

I was online chatting with the Braille battery people recently. They have a line of lithium ion batteries that are very compact and light weight, and moving it up into the engine bay might work pretty well, especially in your case. They use the stock alternator for maintaining charge, but would require a dedicated charger if allowed to go completely dead. I asked about replacing our factory batteries with a smaller one in the fender well, he said it wouldn't be a problem if you drive it daily, or keep it on a battery tender. My car sits at the airport for long periods of time, I'm using a solar maintainer that I bought from Summit to keep it charged when I'm away. So far, no issues at all, even after being away for up to 3 weeks.

SteveKen

August 13th, 2013, 14:57

Update...

Coilovers installed, trans adapter/flywheel/clutch installed, engine & trans in. It's back to a roller.

It's now headed to my other garage. (from the operating room to intensive care I guess)

Picture of it in its natural habitat.

http://www.kendrish.com/galleries/blackS6/nat_habitat_1.jpg

Korben007

August 13th, 2013, 15:10

I have many questions for you and your amazing work. I just picked up a salvaged rs6 with a low miles motor. Still runs and drives. I hope the conversion is strait forward since I have everything. But I see your harness above and looks scary....

props to you for pioneering this platform!

SteveKen

August 13th, 2013, 15:40

Nothing is ever easy and this was not as straight forward as I'd initially thought. However, having an RS6 parts car will make it easier.

bmwade

August 14th, 2013, 01:50

Korben007

August 14th, 2013, 06:08

No not the same one

ttboost

August 14th, 2013, 12:01

SteveKen

August 14th, 2013, 14:42

By natural habitat, do you mean on a flatbed?

Yep. LOL.

SteveKen

September 20th, 2013, 13:42

Slowly trudging on with this. Leisurely gathering misc parts but not doing any real wrenching lately.

I have a question and a request:

Question for anyone that's replace the Climate Control Head Unit:

Does anyone know if the climate control unit for the RS6 is exclusive to the RS6? I already know that the output from the CC unit goes to different places than the S6 & 4.2 A6, but am wondering if it's merely a re-code or wiring change that makes the difference instead of the cc unit. If anyone has tried another unit, please let me know.

Request for anyone that has removed their SAI pump:

Do you still have the bracket that holds the pump to the frame rail / shock tower area? I need it for mocking up a custom battery mount. I had one but threw it away or sold it with the pump...

ttboost

September 20th, 2013, 14:44

I still have mine.

Korben007

September 20th, 2013, 21:19

Don't have an answer for you but I still have both S6 and RS6 fully functional if there is anything I can see with the vag com.

Im curious what differences there are electronically besides the engine harness.

SteveKen

September 21st, 2013, 04:34

SteveKen

February 14th, 2014, 14:33

belittle

February 14th, 2014, 15:34

I'm in need of the hard fuel (supply & return) + EVAP lines that run under the car.

Please PM me if you have them intact and in good condition. I can arrange for pickup or some type of shipping.

I just bought a set from audis4parts.com and they kinked them, putting them in the container. :(

Sorry the lines didn't work out, we just underestimated the length of the lines. These cannot ship through UPS Ground service as dimensionally they are over 9feet long with a height of at least 3 feet. You would need multiple frig boxes to ship without damage.

Korben007

March 11th, 2014, 05:05

Was wondering you plan on tackling the tune since you dont have the vacuum pump installed. Having a harness without it doesn't do much except eliminate wires. The ECU should still be expecting it!

SteveKen

March 11th, 2014, 11:31

Was wondering you plan on tackling the tune since you dont have the vacuum pump installed. Having a harness without it doesn't do much except eliminate wires. The ECU should still be expecting it!

Starting with the OEM tune from Euro III should work. Same situation for the coolant afterrun solenoid and pump.

Bigglezworth

March 11th, 2014, 18:42

I'm in need of the hard fuel (supply & return) + EVAP lines that run under the car.

Please PM me if you have them intact and in good condition. I can arrange for pickup or some type of shipping.

I just had a set shipped to me but they got kinked during the packaging/shipping. :(Why can't you just introduce mechanical coupler(s)??

SteveKen

March 11th, 2014, 20:42

Why can't you just introduce mechanical coupler(s)??

The lines hug the body pretty closely and splicing in or using a partial piece just seems like a pain to me. The couplers will have to stand off away form the body and require special fastening in lieu of using the OEM fasteners.

I'd go with SS hard lines or carbon infused flexible silicone lines, but then I'm up in price where the OEM lines are at. I'm trying to keep it as clean and/or stock as possible, too.

SteveKen

March 17th, 2014, 12:56

Removing the fuel tank is not fun. End of update...

jibberjive

March 17th, 2014, 22:41

Any chance I could get you to post a pic of the S6 fuel tank? And possibly the RS6 fuel tank?

Korben007

March 18th, 2014, 03:23

i would be interested in seeing the pics as well!

SteveKen

March 18th, 2014, 12:35

Any chance I could get you to post a pic of the S6 fuel tank? And possibly the RS6 fuel tank?

i would be interested in seeing the pics as well!

Anything in particular you want pictures of?

The only external differences are the additional flanges that are plastic 'welded' on to accommodate for the fuel filter. The external pump mounts where the S6 filter originally sits. Using the S6 tanks would mean that the fuel filter would be dangling unsupported.

The internal differences are the pump, itself, and suction jet mechanism that utilizes the return flow to suck fuel from the driver's side of the saddle to the passenger side. I"m pretty sure that retaining the S6 guts would not give the correct fuel pressure.

Also, externally, the evap lines are different, although similar in shape, just have different lengths and fittings.
The fuel supply line is probably 150% larger in diameter, too. And it's a different shape in the engine compartment from the S6 to the RS6.
The return looks to be the same but it's also a different shape in the engine compartment from the S6 to the RS6.

SteveKen

March 19th, 2014, 13:19

Body panels get delivered to the paint shop today.

Front bumper and sensors (Euro spec bumper has front parktronic)
Under headlight trim
Mirror caps
Flat door blades
Sideskirts
RS6 Avant spolier
Rear liftgate
Rear bumper and sensors

All to be painted LY9B

Hopefully the car is rolling and maybe running by the time I get them back.

1sadavant

March 20th, 2014, 19:11

Steve,

Who are you using for the paint work?

Body panels get delivered to the paint shop today.

Front bumper and sensors (Euro spec bumper has front parktronic)
Under headlight trim
Mirror caps
Flat door blades
Sideskirts
RS6 Avant spolier
Rear liftgate
Rear bumper and sensors

All to be painted LY9B

Hopefully the car is rolling and maybe running by the time I get them back.

SteveKen

March 20th, 2014, 19:41

Steve,

Who are you using for the paint work?

I'm taking a chance using a guy that's local to me who comes highly regarded. Not a very high tech or technical setup, but he's been doing it a long time.

I didn't' get to look in his paint booth but we ended up setting all my parts on his 63 impala in a separate garage that was covered in dust. Also had a 70 Camaro with so much stuff piled on it that I had to ask what kind of car it was.

He said he'd have the parts ready the end of next week so I can give you a report then. Probably a mistake, but I told him to take his time with them since the car won't be ready for a while.

Korben007

March 21st, 2014, 05:40

Moving along nicely. So is the engine in the bay yet?

Kgnast

March 21st, 2014, 12:58

I agree. It'll be a fabulous car.

An S6 avant with RS6 drivetrain and a manual transmission is pretty much the perfect vehicle. Can't wait to see your progress!

SteveKen

March 21st, 2014, 14:21

Moving along nicely. So is the engine in the bay yet?

Yes, since August, but I'm going to remove it all again. I put it together in haste to get the car transported from a garage I was renting across town to the 'carriage house' adjacent to my house.

1sadavant

March 22nd, 2014, 00:01

I'm taking a chance using a guy that's local to me who comes highly regarded. Not a very high tech or technical setup, but he's been doing it a long time.

I didn't' get to look in his paint booth but we ended up setting all my parts on his 63 impala in a separate garage that was covered in dust. Also had a 70 Camaro with so much stuff piled on it that I had to ask what kind of car it was.

He said he'd have the parts ready the end of next week so I can give you a report then. Probably a mistake, but I told him to take his time with them since the car won't be ready for a while.

Look forward to the results and your impression, need to have the hood and bumper redone on mine this spring/summer and would prefer to have a quality but inexpensive job done, not many options for this type of work locally.

SteveKen

March 24th, 2014, 17:49

Update: RS6 fuel tank is in.

I sourced some RS6 fuel lines and hope to have them in and routed by the end of the week.

I swapped out the S6 e-brake cables for the RS6 ones. Confirming: The RS6 cables are longer by 1 - 1.5 in.

I hoped to swap out the rear bearing carrier assemblies, but I think I might need to source a set of rear rotor dust shields first. Anyone out there have any? The S6 shields are sandwiched between the bearing assemblies and carriers, but I've not taken a close look at the RS6 ones yet. Will do that tonight and determine whether I can install them and add the dust shields later.

Also, the bearings are pressed into the carrier assemblies (steel) on the RS6 but the S6's are similar to the front with bearing cartridges bolted into the aluminum carriers. I would love it if the S6 ones would work with the RS6 rear brakes and rotors ans save some weight, but I do not think it will work...

Slow progress but my carriage house renters are supposed to be moving out soon, so I'll be able to pick up the pace.

Since I'll have more space, I'm thinking of purchasing another sandblast cabinet and maybe a welder, too.

BTW, I forgot to take pictures of the RS6 fuel tank while it was sitting out in the open. I did manage to take some pics of the "areas of difference" with it in place, though.

Korben007

March 24th, 2014, 18:06

Just went through all the rear brakes stuff. The rs6 calipers don't fit the s6 hub carriers. Also have to swap rear tie rods as well. I give you part number when I get home. The dust shields are not interchangeable either. Give audis4parts.com a call they should still have rs6 rear dust shields. Hopefully they can't mess up the packaging on that!

SteveKen

March 25th, 2014, 16:18

Anyone have a set of front calipers?

ttboost

March 25th, 2014, 16:27

I would imagine everyone has a se....oh wait....you mean an extra set...you have the patience of a saint...

SteveKen

March 25th, 2014, 16:43

Grr.

Anyone have an extra set of C5 (4B) RS6 front calipers that they would be interested in selling?

Mr. Rictus

March 28th, 2014, 13:31

I could possibly get a set for you from my parts guy. They'd be brand new.

Amulet-S6

March 28th, 2014, 19:48

I would imagine everyone has a se....oh wait....you mean an extra set...you have the patience of a saint...

Max changed his front brakes out to StopTech, so he may have a set of calipers laying around...

Amulet-S6

March 28th, 2014, 19:49

SteveKen

April 21st, 2014, 05:18

Double posted for some reason. See next post for a little update...

SteveKen

April 21st, 2014, 05:25

I've dis-assembled all four corners. Cleaned up the rear suspension components. Blasted the upper and lower control arms and rear bearing carriers and repainted everything. I currently only have pics of the rear carriers which started like this:

http://www.kendrish.com/galleries/blackS6/brg_housings/rbrg_hsg_1.JPG
http://www.kendrish.com/galleries/blackS6/brg_housings/rbrg_hsg_2.JPG

Finished prior to install:

http://www.kendrish.com/galleries/blackS6/brg_housings/recon_hsg_1.jpg
http://www.kendrish.com/galleries/blackS6/brg_housings/recon_hsg_2.jpg

I've redone the rear calipers and will clean up and shine the fronts along with Stop-Tech ss lines all around.

I opted to have my spare rotors reground on a Blanchard grinder and they look spectacular. Especially from my wallet's point of view. $140 for all four.

FYI, the RS6 front brake dust shields are the same as the S6 ones.

I also pulled the motor and am taking things apart to tidy and button things up.

Gutted the precats, too. 4 hrs. Ugh.

Oh, also I found a set of one month old cast Rotiform SNA wheels. 19 x 10 ET35. They're currently being powdercoated a color similar to Titan Gray with maybe a little more metal flake in them. I've got a set of 265/35-19 Bridgestone Pole Positions waiting to go on them. They were on sale at TireRack and figured I'd give them a shot....

SteveKen

April 21st, 2014, 05:38

Some background and a proposal on removing the coolant after-run system.

I'm implementing a low mileage RS6 motor and engine harness from a LHD Euro Zone car and things just aren't the same in comparison to the US Spec RS6, which all were essentially 'super hot' weather packages with respect to cooling. Here's the diagram from the US spec car:

http://www.kendrish.com/galleries/blackS6/misc/rs6_cooling/us_spec.png
The after-run pump (#1) gets coolant from a third outlet in the radiator through a solenoid (#11) and feeds the coolant lines to the top of the turbos (#21). The check valve (#9) is used to circulate coolant in the opposite direction than it normally runs when the engine and mechanical water pump are running.

http://www.kendrish.com/galleries/blackS6/misc/rs6_cooling/us_spec_supply.png
The return (or supply depending on whether the engine is running or not) from the turbos is here in #34.

See here for the way the non-hot weather cars are plumbed using a normal V8, 1 inlet - 1 outlet radiator (btw, the P/N is the same for the non-hot weather RS6, S6, A6 4.2 radiator):

http://www.kendrish.com/galleries/blackS6/misc/rs6_cooling/uk_spec.png

This after-run circuit looks to be consistent to what's in the RS6 study guide and I'm personally having a hard time figuring out where the 'cooler' coolant is heading to the turbos from. Is it from hose #26 through the bottom, or hose #11 through the top? I guess it really doesn't matter to me as long as coolant is flowing through the turbos.

Also, from this diagram, I'm not quite sure how coolant can even flow through the turbos at all unless the circulation of coolant from the mechanical pump actually turns the after-run pump in the opposite direction that it pumps when it's running?

Here's the page from the RS6 Study Guide showing coolant action with the engine running:

http://www.kendrish.com/galleries/blackS6/misc/rs6_cooling/normal_op.PNG

Here's the next page stating that the after-run pump moves the coolant in the opposite direction from the norm when the engine is off and the electric pump is running.

http://www.kendrish.com/galleries/blackS6/misc/rs6_cooling/run_after.PNG

So, I'm committed to deleting the after-run pump if I can be assured that the mechanical water pump will flow coolant through the turbos when the engine is running. Here's what I propose:

http://www.kendrish.com/galleries/blackS6/misc/rs6_cooling/sjk_proposed.png

I really think I should be OK since there's coolant flowing through the turbos with the after-run pump. I actually think there should be more flow without it, since it will now be an unobstructed path by comparison.

I'll the drawback is that I just have to implement some sort of turbo timer or some other cool down procedure. However, I'm nopt convinced that I've ever heard the pump run after shutting down a few of the RS6's I've worked on. (At least not prior to replacing them and, in my experience, having seen no damage to turbos as a result on their in-operation for N number of months or years, too.)

Plus this will be one less moving part to have to remove the intake to replace.

Lastly, if someone were to unwittingly think that hot wiring the after-run pump to run while the engine was always running would be a benefit, I think it would be doing more harm than good.

SteveKen

April 24th, 2014, 20:32

Little bit more progress. Rear suspension is together and brakes, lines, etc installed.

<img src="http://kendrish.com/galleries/blacks6/misc/rear_brakes.jpg">

Got these back from the powdercoater yesterday:

<img src="http://kendrish.com/galleries/blacks6/misc/PCd_SNA.jpg">

I'll hopefully have the tires mounted and balanced this weekend

Korben007

April 24th, 2014, 20:56

Did you use rs6 or s6 parking brake cable?

SteveKen

April 24th, 2014, 21:16

Did you use rs6 or s6 parking brake cable?

RS6

I think I mentioned in an earlier post that the S6 cables are about 1-1.5 in. shorter.

Korben007

April 25th, 2014, 16:31

Yeah I know they are different but the s6 ones still seem to connect fine.
Thank you for all the coolant system info it is proved useful. Making good progress! Definitely further along then me!

SteveKen

April 29th, 2014, 14:13

Before I order one from the dealer, does anyone have a spare foglight grille?

4B3807682D3FZ

Passenger side.

Other_Erik

April 29th, 2014, 14:18

Interchangeable with the A6 grille? Someone on Audizine is selling a full C5 facelift grille kit for $200, and I need the lower center grill 4B3807647F1L1

SteveKen

April 29th, 2014, 14:53

None of these are compatible with the RS6. The S6 and A6 4.2 lower center grille might fit (don't think so, however) for your application but it will not have the same grille pattern.

Bigglezworth

April 29th, 2014, 15:21

Before I order one from the dealer, does anyone have a spare foglight grille?

4B3807682D3FZ

Passenger side.http://www.rs6.com/showthread.php/26575-FS-Stock-Parts-from-RS6-6MT-swap

P1054

April 29th, 2014, 19:53

Before I order one from the dealer, does anyone have a spare foglight grille?

4B3807682D3FZ

Passenger side.

I've got one. Along with the whole fog light assembly. The driver side one is gone. Send me a PM if you're interested.

SteveKen

April 29th, 2014, 20:43

I've got one. Along with the whole fog light assembly. The driver side one is gone. Send me a PM if you're interested.

PM Sent. Thanks.

Korben007

May 1st, 2014, 15:44

You cool and system diagrams just solved my problem. Thank you for the post. More stuff was missing from my parts car then I thought!

SteveKen

May 1st, 2014, 15:56

You cool and system diagrams just solved my problem. Thank you for the post. More stuff was missing from my parts car then I thought!

I've got a bunch of extra stuff with respect to cooling, so if you need something, email me.

ttboost

May 1st, 2014, 22:34

Interchangeable with the A6 grille? Someone on Audizine is selling a full C5 facelift grille kit for $200, and I need the lower center grill 4B3807647F1L1

I have a lower center grill, but no trim ring.

SteveKen

May 12th, 2014, 14:37

Bigglezworth

May 12th, 2014, 19:44

Dammit. I'd like to think I'll make it to Carlisle with this car but I keep breaing stuff and realizing that I'm missing parts.

Does anyone have a passenger side engine bracket (cracked mine)?

Also one or two MAF o-ring seals?http://www.photoplace.com/Miscellaneous/RS6-Parting/General-Parts/21544211_wCVdQ7#!i=2374186190&k=vJp8DZ7

SteveKen

May 12th, 2014, 20:06

I think this link is for the other non-o-ring seals that are inside the aluminum pipes. I needed the actual round o-rings that go between the airbox ans the MAFs. I actually measured the one and gambled by ordering a set of 10 o-rings from McMaster-Carr (P/N 9262K418) and lo and behold, they seal really, really well. They actually are fitting tighter than the OEM one I have.

Also, I found another engine bracket locally (enough) and it should arrive tomorrow.

Anyway, it's still going to be a long shot to get to Carlisle.

I'll post another update soon:

Painted body parts are done and I pick them up today or tomorrow
Custom oil cooler lines were made by combining the E30 oil cooler lines and the stock RS6 ones. Finishing touches on the custom bracket tonight.
Doing the timing belt and water pump tonight.
Still have to figure out how I'm mounting the battery.

Also the car is rolling and I can actually see daylight between the tires and the uprights.

nistah

May 12th, 2014, 22:51

Anyway, it's still going to be a long shot to get to Carlisle.

Custom oil cooler lines were made by combining the E30 oil cooler lines and the stock RS6 ones. Finishing touches on the custom bracket tonight.

SteveKen, Good luck getting to Carlisle!! Did you use an oem oil cooler or upgraded aftermarket one ?

SteveKen

May 13th, 2014, 19:31

SteveKen, Good luck getting to Carlisle!! Did you use an oem oil cooler or upgraded aftermarket one ?

I used OEM one from an E30 BMW. The size is nearly spot on. Hoses look great, too. Need to post some pictures.

I was able to do the cam seals, timing belt and water pump stuff last night by now my new issue is that I can't seem to locate my crank pulley. Of course, without it, I don't have a chance at making it to Carlisle.

SteveKen

May 14th, 2014, 03:32

What do they say about best laid plans?

The car will not be finished by Friday unless I can get a crank damper pulley and a set of four inter cooler hoses by Thursday...

im im not sure that I ever had these pieces since I bought the engine in 2009.

P1054

May 14th, 2014, 03:58

SteveKen

May 15th, 2014, 07:17

Latest dilemma: I don't posses the mounting bracket for the p/s pump and A/C compressor.

The local Audi junk yard has one on an engine and I might be able to get it today. Fingers crossed.

Pics of the oil cooler and lines:

<img src="http://kendrish.com/galleries/blacks6/oil_cooler/E30_oil_cooler_1.jpg">

<img src="http://kendrish.com/galleries/blacks6/oil_cooler/E30_oil_cooler_2.jpg">

Current status. Don't laugh, I'm sure she will clean up nicely ;)

<img src="http://kendrish.com/galleries/blacks6/misc/14_may_14_progress.jpg">

DHall1

May 15th, 2014, 17:56

I have a crank pulley damper

ttboost

May 15th, 2014, 18:08

I have a crank pulley damper

Good news for Steve, but still not getting him to Carlisle..at least with THIS car...

SteveKen

May 15th, 2014, 18:20

I have a crank pulley damper

I'm guessing no A/C P/S bracket though?

DHall1

May 15th, 2014, 18:31

I dont think so but the engine crate is not at home.

I have the pulley in the garage.

SteveKen

May 15th, 2014, 18:41

Pulley will arrive tomorrow.

Just sourced a bracket but I will not receive it until Wednesday.

Oh well.

Now I focus on other things. Going to pick up all the freshly painted goodies now...

SteveKen

May 15th, 2014, 20:51

back from the paint shop

<img src="http://kendrish.com/galleries/blacks6/misc/painted_euro_parts.jpg">

SteveKen

May 21st, 2014, 05:56

Little update, as I'm back at it.

Looks like I lucked out with the RS6 SAI pump bracket. I'll be able to make some modifications to use it for mounting the PC680. It ends up looking very clean where I'm able to place it. I had to make a small tweak to the A/C hose and drier to clock it a bit, but I think it looks good. Also need to reroute the N80 valve a bit, but I've got plenty of room.

The holder I end up making will probably be Rev.0.7. I'm probably going to incorporate some shielding in a later revision. Maybe an enclosure in another...

<img src="http://www.kendrish.com/galleries/blackS6/PC_680/PC680_1s.JPG">

<img src="http://www.kendrish.com/galleries/blackS6/PC_680/PC680_2s.JPG">

SteveKen

June 10th, 2014, 17:25

Little update. I never made it to Carlisle and have now slowed down with this since I don't technically have a deadline.

I've gutted the interior and have started wiring in the fueling and other necessary circuits.

Also, I eventually got around to testing my stock intercoolers and couldn't believe how bad they leaked, as they would essentially hold no pressure at all.

I knew they leaked and was under the assumption that there might have been some pin-hole leaks and boy was I wrong.

They're being 're-cored' with Bell cores.

SteveKen

July 16th, 2014, 16:20

Another little update on this.

The project as a whole is slow going.

I'm waiting for another pair of T-Bolt clamps for the lower IC hoses.

I finished plumbing up the E30 oil cooler and put 8.5 quarts of M1 0W40 for initial running but noticed that the oil pan RTV has failed and is leaking. I think I might have pulled on a glob of old 'ooze out' during cleanup and maybe pulled too much out and broke the seal. At least that's what I hope, since the engine has been sitting for 8 yrs or so.
For battery relocation, I fabbed up a neat little tray and top hold down out of some aluminum rod and sheet stock I had.

Finished up the battery install:

I fabbed up a neat little tray and top hold down out of some aluminum rod and sheet stock I had.

The tray mounts directly ot the bracket that once held the SAI pump.

http://kendrish.com/galleries/blackS6/PC_680/PC680_bracket.jpg

Here's a top down view with the bracket/tray assembly installed:

http://kendrish.com/galleries/blackS6/PC_680/PC680_home.jpg

Here's the final resting place of everything:

http://kendrish.com/galleries/blackS6/PC_680/PC680_located.jpg

I'm using the OE odyssey heat shield/box which is then wrapped with a starter heat shield/blanket.

Luckily there was enough slack in the hoses to run the N80 in back of the battery, next to the fuel and A/C lines.

I hope it all works.

fbatwork

July 16th, 2014, 18:08

Looking great!

Other_Erik

July 16th, 2014, 18:55

Here's the final resting place of everything:

Edited for brevity - that sounds a little ominous.

Looks like you're doing one hell of a job on that conversion, absolutely cannot wait to see the finished product!

lswing

July 16th, 2014, 18:55

Very cool, thanks for the quality photos and details. I do wonder how much the extra heat will wear/damage the battery? Maybe not, but it sure gets toasty in there...

I'm over 2 years in on my little 925 Odyssey battery, still cranking away, gets a bit weak if left sitting for a week or two.

SteveKen

August 1st, 2014, 13:41

Just an FYI.

I was in need of a set of fog light assemblies and ended up getting them directly from Hella via Amazon.

Total was around $225 shipped for both R & L units.

The Hella P/N's are: H12942011 and H12942001.

This is about 45% less than the cheapest I could get them through the discount online dealer sources.

Project status: Wiring underway...

SteveKen

August 20th, 2014, 18:08

Small update.

Wiring is completed for everything but the horns.

I went a bit OCD on the interior, reverse and engine harness wiring. Everything looks stock with the clutch, reverse, etc. circuits all routed through the appropriate harness plugs and pins.

I hope to be turning the key very soon.

Next up is installing the front sway bar, front fender wells, lock carrier, coolant, P/S fluid and rest of the interior.

Tidbit of the day: the leak detection pump is not standard on C5 cars (among other Audis) outside the US market.

SteveKen

September 2nd, 2014, 03:06

The hibernating beast finally made it out of the garage (more like a cocoon) under its own power today.

Started on the second turn of the key. This engine came from a Euro car and has been sitting since probably 2006 or so. I knew not to freak out for teh 3 seconds or so until the cam adjusters and lifters built up enough pressure. Very nice...

<img src="http://www.kendrish.com/galleries/blackS6/RS6_Conversion/1_Sept_2014/front_2.JPG">

<img src="http://www.kendrish.com/galleries/blackS6/RS6_Conversion/1_Sept_2014/rear_pass_side.JPG">

I think I'm going to need to use those 5mm spacers on the front.....

<img src="http://www.kendrish.com/galleries/blackS6/RS6_Conversion/1_Sept_2014/front_wheel.JPG">

Because of this, I done feel comfortable with the length of the stock lug bolts. Probably going to go with a et of longer studs and nuts. Any recommendations on this?

DHall1

September 2nd, 2014, 04:00

Congrats Steve

Find me a blown up S6 please. I have the donor RS6 sedan.

kruat

September 2nd, 2014, 04:08

Dear lord, it's not even complete and it's sexy as hell....

nistah

September 2nd, 2014, 04:15

looking real nice, props to all your hard work on this!

Bigglezworth

September 2nd, 2014, 04:58

I don't feel comfortable with the length of the stock lug bolts. Probably going to go with a et of longer studs and nuts. Any recommendations on this?I just purchased wheel spacers c/w longer studs off ePay. They all work just fine. Definately don't use the OEM length as you certainly don't have sufficent threads left for proper torquing.

mik15

September 2nd, 2014, 07:27

the BEAST is alive, it looks awesome and knowing all the work you did it must be quite a unique feeling to finally start it for the first time, something like when your first child comes along i guess :), i am sure that's how it would be for me.

Korben007

September 2nd, 2014, 15:36

Very nice Steve. Get ready for other audi on the road to swerve and rubber neck hard core when they see you. I've already had someone turn around on me! Car is absolutely beautiful!

lswing

September 2nd, 2014, 16:12

Very nice Steve. Get ready for other audi on the road to swerve and rubber neck hard core when they see you. I've already had someone turn around on me! Car is absolutely beautiful!

Did you ever post pics? Is it one of the imports or a conversion? I remember hearing about this a while ago...

alrightroad

September 3rd, 2014, 01:07

Steve, looks excellent. Wheels are money. For lugs try http://store.blackforestindustries.com/whlugboall1.html I have not purchased from them but saved the link a while back after doing some research. Also, I have some 10mm H&R spacers I'm not using right now if you want them sent to you for testing. Perfectly fine to hang on to them for as long as you need. your call.

SteveKen

September 3rd, 2014, 20:09

I ended up going with some 5mm long lug bolts instead of the studs, which I thought might stick out too far. I got a set of black ones, rather than the normal silver ones.

Another question for someone out there.....

Can anyone look at the P/N on the power steering reservoir cover? I bought one brand new and it doesn't seem to fit. The ABS unit bracket that the cover mounts to is not rectangular, but has a bend in it. I wonder if this is normal? Anyone have a picture of the brake boost pump without the cover over it?

EDIT: I figured it out it I think. I bought the wrong part. RS6 needs 4B0422569D and I bought Rev A.

MaxRS6

September 3rd, 2014, 20:37

http://www.kendrish.com/galleries/blackS6/RS6_Conversion/1_Sept_2014/rear_pass_side.JPG

I think I'm going to need to use those 5mm spacers on the front........

I think you are gonna need a stronger seat belt....

Awesome!!

AussieDan

September 4th, 2014, 12:51

Great looking project!

Codinc

September 8th, 2014, 02:09

Subscribed. Great job on all of your hard work. Car looks awesome!

SteveKen

October 3rd, 2014, 22:02

Does anyone have a spare ECU that I could borrow for a week or two?

alrightroad

October 5th, 2014, 00:16

I've got one. Will send you email...

SteveKen

October 14th, 2014, 15:10

Little update. Everything is mechanically sound and I need to replace some misc items, like trans mounts, rear diff mounts, maybe engine mounts.

I'm pleased with things thus far and am waiting for the finalized ECU from AMD. Thanks to allrightroad for the loaner ECU.

Sorry for crappy pics and dirty car.

http://www.kendrish.com/galleries/blackS6/misc/14_Oct_14a.jpg

http://www.kendrish.com/galleries/blackS6/misc/14_Oct_14b.jpg

It's headed to the tint shop for 30% all around today (sans front of course).

I'll get it inspected once the AMD ECU returns.

It probably might look better a bit lower, but I need to be practical driving on the roads that I travel around here.

It still needs a full detail and the rear spoiler needs to be affixed and some other minor details to complete the assembly. I'm having front bumper fitment issues after I installed the IC ducting so I need to remove the bumper and trim the ducts and possibly tweak the length of the bumper shocks.

I'm going to try and refinish the headlights, clay bar it and start paint correction this weekend if I have time.

I'm also debating on whether to have the whole thing painted over winter, too.

It did pretty well on some back roads when I was running late to the local Oktoberfest car show on Sunday. And when the roads are smooth, it's nice on the highway, too.

lswing

October 14th, 2014, 15:21

Awesome to see it's on the road! Looks more like an Allroad with that ride height and wide wheel offset:)

RS2racer

October 14th, 2014, 15:28

Outstanding as usual Steve ! let me know next time you come thru Albany, I know we missed each other last time, but I'm around for a bit.

Cheers,

Mike L

Dmb408

October 14th, 2014, 16:13

Looks gorgeous.

Mr. Rictus

October 14th, 2014, 17:08

Awesome. Glad to see it all came together!

Turbowned

October 15th, 2014, 00:41

Looks fantastic; can't wait to see it after it's detailed and running 100%!

SteveKen

December 5th, 2014, 15:01

Another update and some questions.

The car is all PA legal now with the AMD 6MT Stage 1 tune flashed. Passed state safety and emissions.

My Milltek knock-off downpipes arrive today. I'll report on whether I can swap them out without disturbing (dropping) the engine.

I also have a coolant leak from the dreaded coolant pipe that I had in my hands and inspected prior to doing this build. It had no deterioration so I can only imagine that the o-ring has failed. I did proactively replace all the poop low head socket head cap screws with normal ones, so removing the bolts holding the cooler should be manageable, but I'm not 100% that I still will not need to drop the engine.

When I upped the boost on the car, I also experienced something that I'm trying to figure out.

The best way I can describe it as that the car feels like it occasionally/intermittently skips or flutters under heavy acceleration/boost. Almost like the clutch is slipping/jerking, but I'm certain it's not the clutch since it's some super duper AMD/CM setup good for gobs of torque.

It also feels like it slips/flutters immediately when I let off the gas when under load/boost.

Has anyone else experienced this or something similar?

Right now I'm looking at the MAF seals between the MAF and turbos. I removed the MAFs from the airbox and placed them over the inlets and the fit is really sloppy and I'm not sure that the seals are doing their job and I've probably got lots of 'un-metered' air entering the system under load. I've made the decision to remove the seals and adhere the MAFs to the inlets with some type of adhesive. On the short list is just black RTV. Has anyone done this? If so what did you use to glue them in? Any suggestions? I thought some others on the forum were doing this but my search skills are not so good, I guess.

After this, my next step will be testing the bypass valves. Then the N75... Then the wastegates... Then the turbos...

Aside from this, the car is nuts on how it pulls. I've retained the S6's servotronic circuitry and rack and it seems like a RWD car under hard acceleration. I'm most likely going to pull the servotronic relay or make a switch to defeat it when desired. Maybe VIA a FUNK button.

The PC 680 battery seems to be holding up well, too.

Other than that, it's still some cosmetic stuff. I'm thinking of having the car painted over winter (wife wants a color change but I'm hesitant).

I still need to play with the ride height, install the rear spoiler and misc new interior bits.

I've not had a chance to clean it up lately, so a crappy butt pic will have to do for now. Had the windows tinted, too.
http://kendrish.com/galleries/blacks6/misc/17_Oct_14.jpg

Dmb408

December 5th, 2014, 15:14

Awesome work Steve! On the battery, have you had many super cold starts with it? How did it do?

Mr. Rictus

December 5th, 2014, 15:35

Your fluttering issue sounds a lot like what you think it is, unmetered air. Good luck with getting that sorted.

Got a pic of the spoiler? I'm still thinking of getting one for my Avant.

Bigglezworth

December 5th, 2014, 15:55

I also have a coolant leak from the dreaded coolant pipe that I had in my hands and inspected prior to doing this build. It had no deterioration so I can only imagine that the o-ring has failed. I did proactively replace all the poop low head socket head cap screws with normal ones, so removing the bolts holding the cooler should be manageable, but I'm not 100% that I still will not need to drop the engine.Can be done w/o removing engine, but it's a bear. Given that you are one of the few on this forum that has removed a 5Tip from below with car on axle stands, I think you will find this significantly easier....

When I upped the boost on the car, I also experienced something that I'm trying to figure out.

The best way I can describe it as that the car feels like it occasionally/intermittently skips or flutters under heavy acceleration/boost. Almost like the clutch is slipping/jerking, but I'm certain it's not the clutch since it's some super duper AMD/CM setup good for gobs of torque.

It also feels like it slips/flutters immediately when I let off the gas when under load/boost.

Has anyone else experienced this or something similar?Yes. My 2nd beast with Marc's tune did this all the time. It was like a 'hiccup' and I was never able to figure it out.

Right now I'm looking at the MAF seals between the MAF and turbos. I removed the MAFs from the airbox and placed them over the inlets and the fit is really sloppy and I'm not sure that the seals are doing their job and I've probably got lots of 'un-metered' air entering the system under load. I've made the decision to remove the seals and adhere the MAFs to the inlets with some type of adhesive. On the short list is just black RTV. Has anyone done this? If so what did you use to glue them in? Any suggestions? I thought some others on the forum were doing this but my search skills are not so good, I guess.I did a redneck fix for this specific item. 3-4 wraps of electrical tape around the base of the MAF made the friction fit with existing seals sufficient to hold the MAF's solidly in place. Can drive without the aircleaner housing and perform quick review for leaks, testing, etc., this way. I'm contemplating removing the rubber seals all together and adding a velcro wrap to the outside of the MAF that will provide a friction fit without letting air bypass. Haven't tested this to guarantee it works, but I would find it hard to believe that any measurable quantity of air would bleed past the outside of a 3" hole directly next to it...

SteveKen

December 5th, 2014, 17:08

Yes. My 2nd beast with Marc's tune did this all the time. It was like a 'hiccup' and I was never able to figure it out.

Makes me wonder if it's tuning related or related to higher than stock boost?

Hopefully it's not tuning related.

I've got spare MAFs, diverter valves and N75 valves. No spare turbos, though.

Bigglezworth

December 5th, 2014, 18:14

Makes me wonder if it's tuning related or related to higher than stock boost?

Hopefully it's not tuning related.

I've got spare MAFs, diverter valves and N75 valves. No spare turbos, though.Marc's tune has less max boost than a number of the other tunes out there so I don't believe that was the issue. Further, I run that same tune in two different cars now and neither have the 'hiccup' I experienced and to which you sort of describe. Challenges with complex EMS like the one on this engine - difficult to pinpoint the exact problem many times.

fbatwork

December 5th, 2014, 18:38

I'm running Marc's tune as well - no issues on my car.

SteveKen

December 8th, 2014, 11:08

Got these on Saturday.

Fit and finish seems pretty good.

http://kendrish.com/galleries/blacks6/misc/ko_dps.jpg

I'll report back with fitment after install.

bmlee007

December 8th, 2014, 19:37

Those are sexy. I'm interested.

alrightroad

December 9th, 2014, 01:28

DP's look nice. Hopefully you get the skipping sorted. Marc's tune didn't give me those issues when I was running it. FWIW.

SteveKen

March 26th, 2015, 19:15

Little update. Ive got a new clutch installed, bufkin pipe on deck and hope to have it buttoned up and on the road in a week or so. Maybe I'll post some pictures when I get it ready to go back in.

I'm anxious to see if the custom downpipes make any difference over the gutted precat stockers. Mainly sound I'm guessing.

Next week will be the first time in a long time that I will have two running Audi's at once. D2 S8 fuel pump and new filter goes in this weekend, too.

SteveKen

April 24th, 2015, 16:07

Just got back from a business road trip. Black is hard to keep clean.

I'm having it professionally detailed prior to Carlisle in mid May.

http://kendrish.com/galleries/blacks6/RS6_Conversion/2014_04_23_dirty.jpg

It's just about done and I'm liking the new clutch. No complaints on the downpipes, too.

I can spin all four wheels, too.

RS2racer

April 24th, 2015, 16:45

Yeah... I'm going to have to buy it from you one day Ken... hopefully sooner than later.Mike

s8prtotype

April 24th, 2015, 17:59

Downpipe source?

Bigglezworth

April 24th, 2015, 18:50

Yeah... I'm going to have to buy it from you one day Ken... hopefully sooner than later.MikeMove to Canada, enjoy clean air and water, and import a 2002 from Europe in 18 months....

SteveKen

April 24th, 2015, 19:22

Move to Canada, enjoy clean air and water, and import a 2002 from Europe in 18 months....

Good luck finding a clean one at a decent price...

Downpipe source?

http://www.fahrzeugtechnik-zinram.de/

Bigglezworth

April 24th, 2015, 20:36

Good luck finding a clean one at a decent price...They exist....
http://www.ebay.de/itm/Limitieter-Audi-RS6-4B-plus-Avant-Nr-288-von-999-mit-650PS-LOBA-Motorsport-/141643559759?pt=LH_DefaultDomain_77&hash=item20fa9d334f

SteveKen

May 19th, 2015, 04:56

Now that this project is reaching the drive and enjoy stage, I really need to get some photos.

Here's one I stole from a fellow who was at Carlisle over the weekend.

http://www.kendrish.com/galleries/blackS6/misc/carlisle_2015.jpg

RS2racer

May 19th, 2015, 14:18

Noice !! ^ ^ ^ ^

SteveKen

May 19th, 2015, 21:21

I found another pic from a different source

https://lh4.googleusercontent.com/-4LB042UcDnU/VVn50vae2pI/AAAAAAAACLY/tiBVJ9elaIM/w904-h678-no/IMG_3800.JPG

Bdubs

May 19th, 2015, 21:25

how much? lol. just kidding. kinda. not really...how much?

:rs6kiss:

BuffaloRS6

June 4th, 2015, 16:26

I was lucky enough to see this beast in the 'flesh' so to speak. @ Black Forest Motorsport in Buffalo, where it was getting a thorough detail by Mike of Auto Aesthetica who does incredible work. I can't wait to see pics of it all shined up. Steve, please take some time to enjoy this badass ride. Haha. For whatever reason I feel proud that a part of my RS6 (SE exhaust) made it onto this gorgeous car. Best of luck on whatever your plans are for it. Mine is still for sale, but with summer pretty much here, I'm getting closer and closer to putting the plates back on it and driving her like she should be.

kruat

June 4th, 2015, 17:50

I'm really considering building one of these in the next few years. S6 prices are getting pretty reasonable, and it seems there's always a rs6 or two with a bad title for sale.

DHall1

June 4th, 2015, 18:33

When I had my perfect S6 for 2 years....there were no wrecked RS6s avail

I hated driving the S6 so i finally got rid of it.

Now i have the wrecked RS6 and S6 prices have jumped along with almost no low mileage examples left.

Damn

I'm really considering building one of these in the next few years. S6 prices are getting pretty reasonable, and it seems there's always a rs6 or two with a bad title for sale.

BuffaloRS6

June 4th, 2015, 18:46

Any interest in a non-wrecked RS6??? Haha.

SteveKen

August 28th, 2015, 18:36

FYI, the avant walks on the GT4 from a 75 to 150+

Didn't even take it out of 6th gear. Just hit the gas pedal. GT4 went down to 4th and shifted near redline.

Pics since it did happen.
http://kendrish.com/galleries/blacks6/misc/GT4_RS6.jpg

The sounds of the GT4 and the rev matching feature during downshifts sounds glorious, btw. I want one....

Turbowned

August 28th, 2015, 18:55

GT4, droooool

More pics of your car, please!

lswing

August 28th, 2015, 23:48

FYI, the avant walks on the GT4 from a 75 to 150+

Should I just send you a GoPro to record these events?

Thanks for sharing. The pull in 5th when boost comes on around 100mph is impressive:)

SteveKen

August 29th, 2015, 04:45

GT4, droooool

More pics of your car, please!

I'll get more pics when I quit tinkering with it. I'm now having a legit OEM RS6 avant rear spoiler being painted prior to installation.

Thanks for sharing. The pull in 5th when boost comes on around 100mph is impressive:)

Don't forget that I've also got less drivetrain loss with the clutch & flywheel, too.

Wonder what would have happened if I'd downshifted to 4th.

bethridg

August 30th, 2015, 03:46

I dream of owning a 6MT RS Avant but don't think I have it in me to go thru another conversion. And the one that was for sale (did it sell?) is too rich for my blood.

Gosh, I hate waiting for parts to arrive....

DHall1

August 30th, 2015, 05:09

Im going to look at a S6 avant on Monday. Time to get this show on the road

ttboost

August 30th, 2015, 12:14

You need another project and you definitely need another Audi.

MaxRS6

August 30th, 2015, 13:24

Im going to look at a S6 avant on Monday. Time to get this show on the road

You need another project and you definitely need another Audi.

..and we all need More Cow Bell- Go Dave!

DHall1

August 30th, 2015, 16:32

Papadocs old car was talking to me this week. She wants to get back on the road. I have the tcu coming back and just got the ecu immobilizer defeated thanks to Yokust. Then I see a S6 close by and....well this could be time.

lswing

September 1st, 2015, 00:38

Can you use a '99? http://portland.craigslist.org/clk/cto/5198050310.html

Bigglezworth

September 1st, 2015, 02:49

Can you use a '99? http://portland.craigslist.org/clk/cto/5198050310.htmlNope. Even though the chassis is a C5 also, there are far too many parts that don't match. Biggest one is that it's not a 'wide body' so you could never get the suspension and tires inside the shallower wheel wells. That along with the fact that the 4.2 models for the C5 chassis have aluminum uprights, aluminum fenders & hood, different frame rails, different headlights/front bumper, etc. The list goes on.

C300

September 6th, 2015, 05:46

So do the S6 C5's have the same aluminum front end? Every thing forward of the firewall? and wider front and rear wheel arches ?

DHall1

September 6th, 2015, 06:24

Same, same

So do the S6 C5's have the same aluminum front end? Every thing forward of the firewall? and wider front and rear wheel arches ?

C300

September 6th, 2015, 07:02

I was told that the sub frame clip on S6 and A6 were steel. Not aluminum. Also, seems like it would take more than its worth to get all the same part's to copy the RS6. Even the wipers ! Maybe I'm just not informed. Still, a fast and fun can is still a fast and fun car !

lswing

September 6th, 2015, 11:26

Bigglezworth

September 6th, 2015, 14:54

You take all parts off an RS6 donor, even the wipers, then post the scraps for sale.....and when you do go to list the hulk for sale, take a few seconds to indicate it's a hulk from a swap effort so that people know that all the RS6 specific parts - except for perhaps the spoiler - are not available. That would have greatly assisted the seller on this listing who is undertaking an RS6 Sedan to an S6 Avant swap, but didn't state such so many believed the RS6 specific parts they want for maintenance or a rainy day might be available - which of course they weren't. lol

http://www.rs6.com/showthread.php/32309-FS-2003-RS6-Part-Out

lswing

September 6th, 2015, 15:05

^^^Hehe, that's what I was referring to...can't list the RS6 parts since they've all been plundered.

SteveKen

September 6th, 2015, 17:25

I sourced both my bumpers and the sideskirts from Germany.

Thus the reason for the (albeit non-op) parktronic sensors on my front bumper.

Benefit of the company having an office there.....

You can buy an S6 and spend more on the RS6 body pieces.

Btw, that rear avant bumper is quite spendy if you get someone in the US to get you a new one and import it.

SteveKen

September 9th, 2015, 21:01

I finally sucked it up and decided to pull the trigger on a new belly pan and rear mounting brackets.

It's a huge chunk of change on something that I've been going without for such a long time.

Almost a bigger shame to immediately cut holes in it doing the Sportec Gurney flap mod, too, but I did it on my previous RS6 and will most likely do it again but I can't seem to find the link with the cutout template.

Can any one think of any reason why I shouldn't do it?

If the car starts to run hot, I'll be pissed....

PS: Finally getting my legit RS6 Avant rear spoiler painted this week. Then maybe I'll take some pictures.

PPS: My D2 S8 snapped a timing belt on Sunday and I'm in the middle of an autopsy. Passenger side head cam adjuster guides had disintegrated and the chain must have caught and locked up the intake cam. At least that's what I think happened. Leakdown on 3 cylinders on this head were within spec before I jacked up my leakdown fitting on the 4th cylinder. Fingers crossed that I'm only replacing a few valves at worst. At least I know that 9 intake and 6 exhaust are good. Had to leave on a business trip and will get back at it this weekend I guess.

SteveKen

September 9th, 2015, 21:03

Pics of said D2 S8:

http://kendrish.com/galleries/S8/T_Belt_Break/tbelt_break_1.jpg
The pass side head is still in time (via the belt) with the crank even though the exhaust cam was totally locked via a broken chain.

I'm thinking that the driver's side head is the one I need to worry about....

http://kendrish.com/galleries/S8/T_Belt_Break/tbelt_break_2.jpg

BTW, did I mention that I purchased new guides and a timing belt kit a few months ago. Still in the box. I was driving the car to make sure that the slushbox was good before doing the PM stuff.

Bigglezworth

September 9th, 2015, 21:08

Yuckeroo...

SteveKen

February 3rd, 2016, 22:07

Well it's the end of an era for now...

http://kendrish.com/galleries/blacks6/misc/feb_03_2016_lastday.jpg

I sold the beast to a local enthusiast (via a semi-unsolicited offer) and I'm starting to get a little sad. Hopefully he can take better pictures than me and I can share them one day.

Also, it's for the best as I had some many other things I would have liked to do to it that kept it always 'unfinished' in my eyes even though it's probably the most well sorted 6MT as well as Avant conversion out there. Nothing was spared primarily on the things that couldn't be seen.

SteveKen

February 3rd, 2016, 22:09

Last picture taken was of the modification I did to the climate control unit. I replaced the worn tacky buttons with the pre-tacky ones. The results surprised me, as I thought that it's would be negatively noticeable.

Not bad, however.

http://kendrish.com/galleries/blacks6/misc/cc_buttons.jpg

SteveKen

February 3rd, 2016, 22:12

Also, I'm compiling a detailed list of mods performed, components and stats, etc. that I hope to post up here once I've finished it.

Bigglezworth

February 4th, 2016, 03:15

Wow. Tough move. I don't know if I could put that much "love" in to a ride and then part with it shortly afterwards. What's on the bucket list next?

Fast Co

February 4th, 2016, 16:17

Hi guys, I bought Steve's car yesterday. I will post an introduction thread and take some pictures when I have more time. I am a long time Audi enthusiast, this is my 10th quattro. A couple of years ago I bought a C5 S6, which replaced a '95.5 C4 S6 avant. I liked it so much that I wanted a manual version. I have known Steve for a few years, checked out the black car last year at Carlisle, never thought I'd be in a position to eventually own it. I asked Steve about doing a conversion, then we discussed the RS6A. I test drove it in December and we agreed on a price. Steve then continued to fine tune it to the point where he was happy. He obviously put his heart and soul into this car, I hope to be a worthy caretaker.