uRS6+ Build

[jolio1994]

Hey guys, me again...

A few months ago I made the mistake of buying a '95 Avant. It's became apparent that one or the other needs to go and I can't quite sell the URS6... so with that said I'm going to go for best of both worlds if you will. I think you know where this is going.

105,xxx BCY engine w/ custom frame rail mounting brackets
Stock Motronic 7.1.1 and Engine Harness Integrated into the C4 chassis
Custom Tubular headers with a top mounted Precision 6766 Turbo
SteveKen Manual Trans Adapter Kit
Ringer Racing Stage 4+ Clutch (I really love the feel of mine however, this time I will properly break it in) Haha
HPX MAF

I've posted this on a few older chassis forums, but this is where I need your BCY expertise as the goal is 700-800hp. Here's what I'm iffy about and maybe you guys can give me some feedback.

Twin Walbro 450 Fuel Pumps
1000cc injectors
Stock fuel rail
For a journal bearing 6766, will an oil reducer be necessary?

I plan on having the power delivery coming on smoothly on the right end of the power curve to help prevent not throwing a rod. Feedback is greatly appreciated.


I pulled the stock AAN out of the URS6 last Sunday.
On Monday I dove 7 hours to Pennsylvania to pick up the engine, harness, and ECU

Removed the flex plate and crank plug, and set it up on the engine stand to perform some timing maintenance. Next on the list is I need to get another adapter plate so I can bolt it up to the 01e in the car, and get it mounted. This will happen after I sell the RS6.
And yes, the turbo will be sticking out of the hood...

Look at all that room in the engine bay!!!


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[nubcake]

Custom Tubular headers with a top mounted Precision 6766 Turbo

If you want the thing to be remotely reliable - do yourself a favor and pick up a set of S6/S8/A8 NA exhast manifolds and just elbow off of that. Custom made tubular stuff tends to crack really quickly and doesn't give any real benefit.


For a journal bearing 6766, will an oil reducer be necessary?

No, if you feed with AN3 from a stock banjo. Maybe even AN4 can work as is.


I plan on having the power delivery coming on smoothly on the right end of the power curve to help prevent not throwing a rod. Feedback is greatly appreciated.

Stock rods live just fine at 25+ psi on small peaky hybrids. You'll be fine with any power delivery with a big turbo (it's naturally smoother acting), as long as it's properly tuned (and fueled!) and doesn't knock. Talking gasoline ofc.


Twin Walbro 450 Fuel Pumps

Twins = overkill, unless you go E85.


yes, the turbo will be sticking out of the hood...

I don't like this. :)
Comes down to personal preference ofc, and you're free to do whatever as it's your car. But to me the whole idea of such build is to have a "sleeper", that can surprise everyone with sudden 700+hp.

[jolio1994]

Hey man, thanks for the info. Other than the sound difference by going Tubular I cant really think of a need for it aswell. It was just something I considered, as I wasnt 100% sure on the flow limitations of those manifolds... I like the idea of running the cast manifolds and running an up-pipe similar to the B5 S4 034 Motorsports STK kit.

Very happy to hear I can get away with 1 450 pump, if e85 was readily available, I'd go that route in a heartbeat... for now I will stick with 93 oct.

Assuming the remainder of my questions that didnt get answered are all spot on and right where I need to be?

[nistah]

Wow super cool, I just saw your RS6 6 speed build thread on Audizine, looks like you're persistent & mean business! So I understand correctly you are planning on installing the RS6 BCY mated up to very large turbos into the C4 Avant shell? If I understand correctly that sounds awesome I've always liked the C4 platform & keep an eye open for them for sale online .

I do agree w/ nubcake on the stealth mode benefit of not having the turbo popping out of the hood tho, can you engineer it to blow out the bottom or even sides and make modifications to fenders if necessary?

Finally once you pull it off & I have full faith invested in you, can you build this one for me using a BCY core:revs:?

https://www.audizine.com/forum/showthread.php/870590-1995-5-Audi-S-6-for-sale

[nubcake]

Assuming the remainder of my questions that didnt get answered are all spot on and right where I need to be?

Didn't notice many questions, rather just statements of what you'll be using. :)

No experience with the clutch, so no comments there.
1000cc injectors are overkill for pump, but will work fine.
Stock rails should be just fine.
Never used HPX either, so can't say much either. Stock setup uses twins, as you know - so your tuner has to be able to account for twins -> single. Same goes for fueling, need to disable fuel pump controller. Also single lambda conversion, fans etc.

[jolio1994]

Thanks Nub,

I really appreciate the input, that's why I posted this here in the first place!

For me it's going to come down to heat extraction. I will be running a single radiator up front with a few fans, and want to get as much heat out of the bay as possible. Having the turbo sitting up higher and 1/2 out the hood seems like a great way to do this, but we'll see! It looks like the V8 will sit substantially lower than the 5 cylinder did so I may have more room to work with than I think ATM.

First update of the build!



https://www.youtube.com/watch?v=9P2TXkXRW6g

[jolio1994]

Hoping for this, but out the hood and right next to my face
GoPro on my RS6 was a win tonight.

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[jolio1994]

Well this engine was absolutely filthy. Took an air gun and some brake cleaner and hit the valley real quick, will take care of the heavy duty degreaser later on down the road... maybe paint it too? We'll see.


Reason for this post is I need some info so I can start planning some stuff out. 1st'ly the radiator. C5 RS6 radiator uses 3 coolant ports with one port coming from the coolant circulation valve. Is this possible to bypass at the aux water pump I have highlighted? Again, this build is going to have the words "simplicity" thrown around and if I can run an aftermarket 3 row radiator as opposed to the stock 2 row, I'd love it.


2nd'ly (I'm just making these up...) Who here has a pinout of the engine harness to body harness? Gonna need that for sure.... There's this guide -> but is all 7.1.1 the same? Nothing on the chassis deals with boost from the BCY correct? That's about it for now I guess... Still have that damn RS6 so I will continue to wait for now lol


[url=https://flic.kr/p/2hpwYn6]https://live.staticflickr.com/65535/48836723207_f7c56fa0f1_c.jpg (http://https://www.audizine.com/forum/showthread.php/701197-Audi-C5-A6-S6-4-2-V8-40V-ECU-Pin-Outs[/URL)20191003_074911 (https://flic.kr/p/2hpwYn6) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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[nubcake]

Is this possible to bypass at the aux water pump I have highlighted?

Your planned turbo is air cooled, no water.
So you'll have to delete aux pump & afterrun system.
It's sole purpose is to cool the turbos after shut-off to prevent oil coking.

Can't tell you off the top of my head what exactly needs to be deleted/rerouted, but I touched this subject a few times here. Try searching.

[JettaGLi16v]

If you don't go top mount after all, I would love to hear how the BCY sounds on that Stromung exhaust! Those things are absolutely glorious on an AAN, and I can't recall how much, but I know mine was more than $3k, maybe close to $4k.

[nubcake]

how the BCY sounds on that Stromung exhaust

...restricted :hihi:

[jolio1994]

The new owner of the RS6 came by Friday and drove it 3 hours home, he had nothing but great things to say about it; very happy it went to a great home. Now I can dive deeper into the URS6. I already had the Ringer Racing Stage 4+ Clutch come in, so my next purchase will be the Stevenken Adapter Kit; probably later on this week I'll order it.


I did pick up that A6 (Yes, another Blue 2.7T 6sp that'll serve as my donor for the electronic throttle pedal and OBD2 system. My dad is in need of a good 01e for his B5 S4 as well as a spare 2.7t that he can build on the side for when he throws a rod on his K24'd car. I'm going to give him both, but debating if I should pull it and freight it to him or just drive the car down to my parents house in GA and part it out down there, either way I'm hoping to get the "Son of the Year"Award lmao.


Moved the cars around today and pulled my back out trying to get the A6 to move with rusted e brake and a non functioning starter. Bad idea on my part.. but the S6 is in the garage now. Stevenken Adapter -> Bolt up to the 01e in the car -> Make some engine mounts.


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[jolio1994]

The 40v N/A headers aren't going to clear the tie rods.. so I have no choice but to do the top mount with tubular headers.

The question for me now is... steel or stainless steel?

[nubcake]

No easy answer.
Mild steel is significantly cheaper, easier to weld, has better resistance against "temperature-induced" cracking due to lower expansion, but can rot.
Stainless can crack very quickly, especially if not welded properly (or not allowed to expand, or carries a lot of weight, etc).

[jolio1994]

A few fellow enthusiast tagged me in a FB group when this engine was offered for sale. After some talking with the owner I ended up buying the whole car minus fenders, front bumper, seats, brakes, and carbon trim. The rest is still there and aside from the engine/harness/ecu will be for sale in the near future. I'm going to see if a delicately placed cut in the stock RS6 exhaust manifold will allow me to route up the back of the head as a last last resort to clear everything, if not the Stainless will be the direction I go, thanks for the input!

I'll be picking it up this weekend and I swear school seems like it's slowing down, maybe I'll even get the adapter plate in (still lost) and can finally make head-way on this URS6!

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[jolio1994]

Picked up that RS6 last night and pulled the engine out today. URS6 progress is at a standstill until I can get that adapter plate in. Now I have an extra BCY 4.2 for when I blow up the O.G. one! Full partout is in the for sale section.
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[jolio1994]

Adapter plate came in today... I guess I know what I'm doing this weekend!

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[jolio1994]

It kinda fits! Had to cut out the subframe, but it's in there! Practiced making an engine mount bracket and it came out pretty damn good I think. Full penetration on the first practice piece, it's solid as a rock. Yes I know I need more practice, but hey this entire project is a first for me. I'll be moving the plate down 2" on the final piece to add a bushing but:
A. I'm still looking for something suitable (Any mounts that would work given the clearance would be greatly appreciated)
B. I just need something to begin tubular header and turbo mock-up.


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[jolio1994]

I finished up the passenger side mount, and the engine is all bolted down and what not. Now to wait for Black Friday turbo sales and hopefully even an exhaust manifold kit sale.

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[jolio1994]

Little small kinda big update, but will add when I get everything in; Black Friday was very kind to me.


Two Mishimoto 12" Slim fans
Mishimoto 19 Row Oil-Cooler
Mishimoto R-Line Intercooler (Big Boy)
Tial 44mm MVR Wastegate
Tial Sport Q BOV
Stainless 304 Audi 4.2 Exhaust Turbo Header Kit
Dual Ball Bearing Billet T76 T4 .81 A/R Turbo



https://www.youtube.com/watch?v=4sq2S5jda-I

[JettaGLi16v]

I love your updates, man. You're absolutely mad, and it's absolutely awesome! Keep us updated!

[jolio1994]

Haha thanks man. Turbo, wastegate, bov, and exhaust piping are all in so I'll start fabrication of the exhaust manifolds very soon.

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[jolio1994]

Mini update.

Driverside manifold is tact'd up. If the passenger side comes out any better I may end up redoing it. It's a step in the right direction.

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[jolio1994]

Someone needs to do this to their C5 please! That'd be ever sweeter!


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[jolio1994]

So... some more progress! Rolled the car out for the sake of the wheel bearings and brakes and decided why not put the turbo on it.
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The driverside manifold is welded save the collector star and a little bit more of the collector I couldn't reach. Passenger side is 1/2 done, but I ran out of gas. I'm thinking maybe I'll MIG what I can't get with the TIG? I also need to get some steel plate to weld the flanges, but no gas, no rush...
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https://www.youtube.com/watch?v=l9D9YKZbWNY&t=

[jolio1994]

Starting to get somewhere now and I love it haha. Probably weld everything up tomorrow and then I don't know what to do after that... I didn't think I'd make it this far.


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[jolio1994]

The front end is on and it looks like I'll be needing a new radiator with 29"x19"x2" dimensions along with the inlet and outlets on the passenger side. I'll try and find a suitable one tomorrow, but in the meantime it's onto the intercooler piping


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https://www.youtube.com/watch?v=m5ZNhKxm4NQ

[jolio1994]

So I think I've got this cooling system ironed out, using the stock URS4/6 expansion tank. The stock URS4/6 radiator is 29" in length and the standard S6/RS6 radiator is 32". A bit too long. I'll be using this guy right here https://www.summitracing.com/parts/bci-35024 from Summit which should fit in rather nicely.


Here's what I have to deal with and how I plan on setting up the cooling system using resources I found online thanks to SteveKen. I'll have to make my own shroud, but there is about 5" between where the radiator sits to the serpentine belt. Plenty of room to work with; after all the name of the game is ease of serviceability.


(I'm a visual person so until I see it layed out, I can't really picture it in my head)


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[redwoodkiwi]

Huge respect for you taking this project on. Enjoying your posts and amazed with your progress given the limited resources you have at your disposal.

I had thought, though, that the snail placement you've chosen was just for proof of concept. But, it looks like you are committing to it. I'm sure you considered every possibility - but is that really the only place it can go? Kills any prospect of being a sleeper (not that that is what you are necessarily going for). Although, on the flip-side, it does immediately offer a great statement piece and an interesting view from the cockpit.

I've read about rear installed turbos (a lot of plumbing is required, but a positive is that it eliminates the need for an intercooler due to the ambient cooling that occurs naturally by distance). Wondering if that might have been a possibility for you (turbo installed in spare wheel wheel)?

[nubcake]

Huge respect for you taking this project on. Enjoying your posts and amazed with your progress given the limited resources you have at your disposal.

I had thought, though, that the snail placement you've chosen was just for proof of concept. But, it looks like you are committing to it. I'm sure you considered every possibility - but is that really the only place it can go? Kills any prospect of being a sleeper (not that that is what you are necessarily going for). Although, on the flip-side, it does immediately offer a great statement piece and an interesting view from the cockpit.

I've read about rear installed turbos (a lot of plumbing is required, but a positive is that it eliminates the need for an intercooler due to the ambient cooling that occurs naturally by distance). Wondering if that might have been a possibility for you (turbo installed in spare wheel wheel)?

There's plenty of room in the engine bay.
This design decision was deliberate, I think.

[jolio1994]

I considered a lot of different turbo locations. In fact, Nubcake's original post to use the 40v NA manifolds for simplicity and keeping the turbo under the hood similar to the B5 S4 Single Turbo Kits was by far the smartest thing I could've done. Unfortunately with the C4 chassis, an up-pipe would've immediately hit the tie rods, so that idea was scrapped.

Like you said, I'm very limited on resources; the main of which being skill and knowledge so I chose for the next easiest thing which was to just run a collector on either side and a y pipe to the turbo on top. The main goal of this project was to revolve around serviceability and ease to work on. It's sitting about 2" higher than I originally planned, but that's because I decided to reduce the piping down from 3" to 2.5" immediately after the collector to reduce turbo lag.

Had I ran twins there would've been plenty of room on either side for smaller snails, but with this 76mm, there would've been very limited room and I would have had to relocate the fuel filter and severely modify the headlight. Doing a remote setup would've been possible, but would've required a lot more fabrication than I had originally opted for.

While it's not in everybodies best taste, it's what I have to work with and I enjoy the view. And I'll drop a picture of the NA manifolds so you know this was my best option haha

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[redwoodkiwi]

Totally understand. Loving that you are embracing it and loving watching your build unfold.

[jolio1994]

Got in the Dual Pass Radiator so I went ahead and made some brakes to fit in the stock location as well as the bracket for the intercooler. Coupe more small things to order in the meantime such as coupling reducers for the intake, and power steering / oil / coolant AN lines + fittings. I'm super stoked to begin the harness integration for the ECU, OBD2, and the throttle pedal; wiring fun -> fabricating not.


https://live.staticflickr.com/65535/49364142978_4e990e46f4_h.jpg (https://flic.kr/p/2id98Tq)20200110_150700 (https://flic.kr/p/2id98Tq) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)

[JettaGLi16v]

Coming together for sure!
What are your plans for a hood?

[jolio1994]

Not sure yet. I'm going over a few things in my head right now. Not sure if I want to use the stock brackets to open and close the hood or have 4 hood pins on either corner. That later would mean less cutting as it'd simply drop down straight on top of everything.

[jolio1994]

Been a little lazy lately. The build is starting to take a toll on me as I've been slowing down; I've been looking at R32 GTS-T's as a fun car to have in between, but we both know if that happens, I'll never finish this. So, pushing ahead. Intercooler piping is done. Engine's back out so I can make some adjustments to the engine bay. Things to do with the engine out:


-Cut/adjust the motor mount brackets to allow 2" of hockey-pucks
-Relocate ABS controller about 4" lower and make a bracket to hold it
-Reinforce subframe
-Finish welding exhaust Y-Pipe, including wastegate provision.
-Install flywheel, clutch, and pressure plate


Then I'll get the engine back in the car. From there there's not a whole lot I have to do before I can test fire:


-Run the oil lines and oil cooler
-Integrate the stock 7.1.1 ECU and harness with electronic throttle and OBD2
-Mount the throttle pedal


Then I can make some loud noises.


https://live.staticflickr.com/65535/49410593723_a6e68909dd_c.jpg (https://flic.kr/p/2ihfd5k)20200119_154426 (https://flic.kr/p/2ihfd5k) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
https://live.staticflickr.com/65535/49411269542_e458281ecf_c.jpg (https://flic.kr/p/2ihiEYo)20200119_154442 (https://flic.kr/p/2ihiEYo) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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[JettaGLi16v]

WE'RE ALL COUNTING ON YOU!!! YOU MUST PRESS ON!!!

Also, that IC piping is freakin beautiful! Polished aluminum?

[jolio1994]

Haha, it's getting there man! The pre turbo exhaust is fully welded including the Tial 44mm MVR wastegate I did yesterday. Still need to make the dump pipe for turbo and wastegate, but it's not a priority at the moment.

On the intake side I need to weld the Tial Blow off valve, HPX MAF sensor, and MAP sensor flanges to the Intercooler piping.

Oil cooler needs to be mounted and oil lines ran...

I need to weld a -16AN bung to the coolant crossover pipe to go to the radiator...

Radiator fan shroud is done, just need to cut out the 2 holes for it..

I should be pulling the engine out today so I can mount the flywheel, clutch, and pp and after that I'll be ready to start wiring and hopefully get it started. A lot done, but still so much to do. I'm just thankful I dont have to touch the transmission, suspension, and anything else on the car once it's running. Just go straight to driving and street tuning.


https://live.staticflickr.com/65535/49470999946_46fb099e7e_c.jpg (https://flic.kr/p/2inzNJW)20200131_154726 (https://flic.kr/p/2inzNJW) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
https://live.staticflickr.com/65535/49470999941_2f606d93a8_c.jpg (https://flic.kr/p/2inzNJR)20200131_220729 (https://flic.kr/p/2inzNJR) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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[JettaGLi16v]

Not bad at all to be working on details that fine after 4 months of doing it on the side!

You said BOV, but I thought you were running the RS6 ECU? You are planning on coding out the DV, i guess?

A thought I just had (but it could be a bad one, it's barely formed), as I know you mentioned you were dreading the wiring harness integration, have you considered a standalone like VEMS (I know that one is the primary one used on the C4 cars)? Also, you could probably call Marc at EFI Express. He is crazy good on the C4 chassis ECU / Tuning side (He wrote me the chip for my RS2 injectors in my C4 S6), and might be able to assist. He does a lot of custom VEMS installations. I imagine the wiring / ecu part will involve equal assistance from the BCY & C4 communities, have you considered a dual thread on like motorgeek.com or theprojectpad.com?

[jolio1994]

Not bad at all to be working on details that fine after 4 months of doing it on the side!

You said BOV, but I thought you were running the RS6 ECU? You are planning on coding out the DV, i guess?

A thought I just had (but it could be a bad one, it's barely formed), as I know you mentioned you were dreading the wiring harness integration, have you considered a standalone like VEMS (I know that one is the primary one used on the C4 cars)? Also, you could probably call Marc at EFI Express. He is crazy good on the C4 chassis ECU / Tuning side (He wrote me the chip for my RS2 injectors in my C4 S6), and might be able to assist. He does a lot of custom VEMS installations. I imagine the wiring / ecu part will involve equal assistance from the BCY & C4 communities, have you considered a dual thread on like motorgeek.com or theprojectpad.com?

Generally having everything before started and not having to wait on parts has been great so far!

I will be running the BOV in conjunction with the RS6 ECU with the help of the HPX Blow Thru MAF. Another advantage of the HPX MAF is that it's routed between the turbo and the throttle body (Instead of our traditional pre-turbo MAF.

The wiring really isn't too difficult for me; I've just been saying it's going to suck... OBD2 might be challenging since I won't have the same modules as the C5, but I have 2 full RS6 harnesses and the entire RS6 chassis harness from the one I parted out. Shouldn't be too difficult. VEMS would be great, but I already have a very competent tuner when it comes to the stock motronic. Plus I have 2 ECU's...

Funny, I started this thread on Rs6.com to help with the BCY end of things... MotorGeek.com to help with the C4 side... and the ProjectPad as a combination of both and fabrication...
Each kinda serve their own purpose.

Thanks for the support, the next update will be dope.

[jolio1994]

Busy Monday, wrapping it up before I head to work tonight. Pulled the motor and installed the Steveken Flywheel + Ringer Racing Stage 4+ Clutch. Went on like clockwork...

https://live.staticflickr.com/65535/49485052951_1d65fa08d6_c.jpg (https://flic.kr/p/2ioPQd8)20200203_123908 (https://flic.kr/p/2ioPQd8) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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Since I'm running an oil cooled turbo, I don't need all the extra coolant lines under the intake manifold. The driver side cam gear has to come out which means taking the belt off. I wasn't going to do the timing belt, but it'd be stupid not to at this point.

https://live.staticflickr.com/65535/49484561828_7bf6ab180e_c.jpg (https://flic.kr/p/2ioMjdu)20200203_133904 (https://flic.kr/p/2ioMjdu) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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I have a -16AN going into the radiator so I figured putting one of the crossover pipe out simplify things. Exhaust manifold next to the valve cover meant it had to be modified. I'll run a 90 off of it and wrap it over to the passenger side fender, then back to the radiator.

https://live.staticflickr.com/65535/49484560608_82a1e4b911_c.jpg (https://flic.kr/p/2ioMiRs)20200203_151800 (https://flic.kr/p/2ioMiRs) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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After the last fit up I found a few things that won't work. I'll need to run an 8" fan instead of the 12" for the passenger side. The main 12" fan will open at 180 degree's and the 8" fan will open at 210 degrees. I think that wraps up the cooling. Just need to cut and rotate the radiator outlet to clear the alternator and bing bang done. I have some cleaning up to do in the meantime...
https://live.staticflickr.com/65535/49485050121_c818079311_c.jpg (https://flic.kr/p/2ioPPnk)20200203_170624 (https://flic.kr/p/2ioPPnk) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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From yesterday. I through it together for the Gram! Fitment... is not on point. Haha

https://live.staticflickr.com/65535/49485144641_e9a158e3ea_c.jpg (https://flic.kr/p/2ioQisZ)2020-02-03_05-59-03 (https://flic.kr/p/2ioQisZ) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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[jolio1994]

Replaced only the necessity in regards to the timing belt. Also opt'd for an 80° thermostat instead of the 87° in hopes to keep this beast cool... Hocky puck motor mounts are done as well. They are literally rocks; should be great for my back.

All that's left to do now is wrap the manifolds and toss the engine in for the final time

https://live.staticflickr.com/65535/49500113977_bbe62150fc_c.jpg (https://flic.kr/p/2iqa2jZ)2020-02-06_11-59-54 (https://flic.kr/p/2iqa2jZ) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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[jolio1994]

Been busy doing nothing lately. Got the engine back in with the flywheel + clutch kit and tested it to make sure I wasnt going to have the same hang-up as my first BCY 01e swap I did a year ago. Wheels are turning while moving the crank in gear and, yet stationary when out of gear... perfect.


Made a big giant to do list, and going one by one knocking everything out. Aside from making a new oil feed line to the 76mm turbo and a drain line, I'm ready to start wiring in the harness, which aside from a spanner check is the last thing on my list...


Spent all of today redoing the throttle body piping and radiator shroud clearancing among a few other stuff, and I'm able to get the front end on beautifully. [wrench][wrench]


https://live.staticflickr.com/65535/49598328127_eaf31deaf6_c.jpg (https://flic.kr/p/2iyQoYp)2020-02-28_08-07-07 (https://flic.kr/p/2iyQoYp) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)

[jolio1994]

Front end/engine bay is 95% sorted.


Time to start wiring the RS6 ME7.1.1 ECU and OBD2 into the C4 S6


https://live.staticflickr.com/65535/49628452657_8817e83fc6_c.jpg (https://flic.kr/p/2iBuMWR)20200306_163812 (https://flic.kr/p/2iBuMWR) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)

[jolio1994]

First start:


https://www.youtube.com/watch?v=5gGYkYMGu-A

[jolio1994]

Almost there guys!

Running the stock ME 7.1.1 with a Blake Beadle base tune, using 1 HPX MAF sensor. Very smooth and I cant wait to bleed the coolant and start getting some miles on it!


https://www.youtube.com/watch?v=QcxgmYswlZI

[JettaGLi16v]

Freakin awesome! Sounds great! Can't wait for the first AWD drift / burnout video!

[jolio1994]

First shakedown today and to say the car runs like a beast would be an understatement! Coolant temp gauge won't work, but I've been using a Bluetooth OBD2 scanner to keep an eye on it with my phone. Something I will need to address sooner or later... I'll also need to either find a way to integrate the oil pressure warning and coolant warning into the cluster so it stops beeping or bypass it all together, but she runs... drives... and builds boost...Oh yea, and it sounds tits too!


Enjoy

https://www.youtube.com/watch?v=b9pP7wruyXs

[papadoc]

Well this brought a nice smile to my face today! Amazing patience to put this together, and I loved your wife calling "where are you?!". And treat her well, few wives would put up with this. :bow::applause:

[jolio1994]

Haha, she's been great through this whole thing. She begged me to install the passenger seat today to go for a trip to the beach. Even caught a glorious acceleration. The car sounds awesome and I couldn't be happier (for now...)


https://www.youtube.com/watch?v=Ji3ZUZQHzZg
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[jolio1994]

Photo dump of this crazy build on a beautiful Sunday. I got about 200 miles on today: ears still ringing, but man what a day!

https://live.staticflickr.com/65535/49852491298_7157661234_b.jpg (https://flic.kr/p/2iXi3Q3)20200503_191907 (https://flic.kr/p/2iXi3Q3) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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https://live.staticflickr.com/65535/49852490713_a26280292d_b.jpg (https://flic.kr/p/2iXi3DX)20200503_192938 (https://flic.kr/p/2iXi3DX) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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I'm going to fabricate the wastegate up pipe so it sit's flush with the "exhaust". Then it's time to start adding boost. I just want to thank Steve for the incredible adapter plate he's came up with and perfected over the years; I honestly don't know if I would've been able to it without that piece.


https://www.youtube.com/watch?v=CNPos-7rhNk

[jolio1994]

It's a little more "sensible" now.

https://live.staticflickr.com/65535/50045145728_e13328c68b_c.jpg (https://flic.kr/p/2jfjsh9)20200618_172105 (https://flic.kr/p/2jfjsh9) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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[JettaGLi16v]

Holy shit, man!!

With the turbo tucked in there you will friggin surprise soooooo many people!

I love it! Why did you switch from out through the hood to tucking it in behind the headlight?

[AudiPilot]

Looks really awesome. Is there any concern with intercooler blanking from the bumper? I’d buy that! One-of-a-kind.

[nubcake]

I like the new location much more.
In fact, I'm running a very similar setup in my RS6. Only a bit bigger turbo. ;)

[jolio1994]

Going to need pics of that nubby!

So, been busy with it, here's a small update...


Took the engine out. I sent the flywheel off to ClutchMasters for a new tone ring and ordered a new starter from Summit Racing. While I was waiting I put the engine back in and tried to tackle some others stuff...


Made a full 3" turbo back with 2.5" tips.


https://live.staticflickr.com/65535/50035002786_ac5cb378dd_h.jpg (https://flic.kr/p/2jeqt8Q)20200622_150641 (https://flic.kr/p/2jeqt8Q) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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Got the flywheel back so I took the engine back out... reversed the coolant flow to exit the driverside instead of the passengerside and bolted everything up; put it back in the car.


https://live.staticflickr.com/65535/50121742528_859fce8aa9_h.jpg (https://flic.kr/p/2jn62QC)20200326_031021 (https://flic.kr/p/2jn62QC) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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Finished installing everything today with hopes to make it out the the cruise in PA this Sunday, but that's not going to happen; mainly in part to what I think it a bad CPS. Cranks but no start; nothing changed wiring wise, and I'm not getting any movement on the tach when cranking. Guess it'll sit til I can get a new one in.
DAMN IT LOOKS GOOD...


https://live.staticflickr.com/65535/50124375997_c3da8cf86c_h.jpg (https://flic.kr/p/2jnjwFg)2020-07-17_07-46-12 (https://flic.kr/p/2jnjwFg) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)

[nubcake]

Going to need pics of that nubby!

I've been planning to do a build thread, once it's really ready.
But the progress is super slow.

Here's one of the older pics I have on hand.
https://www.rs6.com/attachment.php?attachmentid=19276&stc=1

Basically it's running and driving at this point, and I'm dailying it (one of the reasons progress had slowed down). Maybe 5-8k miles on this setup so far. Makes around 600 at the crank. Clutch slipped at 650, so I toned it down a bit.

Stock ECU, speed-density (2xMAF converted to MAP), 2 wideband lambdas pre-turbo actually doing fuel trims yadda yadda.
Definitely not fast by today's standards, but very fun, when the boost hits.

Anyway, this thread is about your car. :)
Your exhaust might be a bit restrictive, especially for big numbers. To give you some perspective - there's like 4psi of backpressure after the turbo on a 900hp V10 with 3" downpipes. Essentially, 450hp thru a single 3".

[jolio1994]

Damn that is really crammed in there, but I'm sure it's a hoot! I'm hoping the 3" turboback is enough for me to see 600hp. I've thought it over long and hard and I don't want to set records, just to have a nice reliable V8T. Realistically, I want ~500 reliable horsepower; not crazy, but again I just want it reliable at this point.

Both plastic cam tensioner guides broke on the driverside head so I'm fixing the 4 intake valves it bent up. Trying to do everything else in the meantime like rewiring the radiator fan relay harness and installing the aerocatch hood pins.

I should hopefully have the valves in later this week...

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[jolio1994]

Alright alright, I know it's not a C5 RS6 Avant, but it is the C4 S6 with the BCY so close enough I suppose. I've been pouring the miles on since I last got it back together last week.

Been pedaling it at about 1/4 throttle trying not to build boost or go over 4,000 rpm since the HPX Maf isn't tuned/scaled yet. More on that this week...
I will be adding a resonator and mid muffler to help make it not sound like an old Ford truck..

https://live.staticflickr.com/65535/50207741773_53e9ad3b49_k.jpg (https://flic.kr/p/2juFNqe)2020-08-09_07-50-12 (https://flic.kr/p/2juFNqe) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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https://www.youtube.com/watch?v=l8IYTnWm0-w

[jolio1994]

I'm running a single HPX Maf in place of the stock 2x Bosch units for my single turbo setup (Currently wired for G70 MAF). The HPX pigtail is wired as it should and I'm getting +12v at the green/yellow wire, engine/chassis ground at the green/back wire, and have tested and read continuity between the green signal wire on the MAF to pin 29 on the ECU connector.

VCDS (https://www.ross-tech.com/) still reads signal too low and measuring blocks 2 and 3 both show no activity for the MAF's. Also having fault codes for o2's and n75 signal too low as well... my tuner and I are stumped.

Fuses are out of the question since I'm getting power to the MAF, no short to grounds or anything weird aswell.

And help or suggestions are appreciated, I need to open this wastegate up!

[jolio1994]

Car's running great. This is still the first revision, but so far so good. Almost stock RS6 power with 5psi and little timing. Also only at 68% duty cycle on the stock injectors so well see how far they take me.


https://www.youtube.com/watch?v=-A7aMt79BvE

https://live.staticflickr.com/65535/50265303186_2e2d6687de_k.jpg (https://flic.kr/p/2jzLPqo)Capture (https://flic.kr/p/2jzLPqo) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)

[JettaGLi16v]

Killer video man! Sounds like she's running pretty good. Sounds awesome!

[jolio1994]

Thanks man! She's a hoot!!!


C4 chassis feels way too over powered for the torque it puts out. The brakes are inadequate and the interior feels dated; but that why I absolutely love this thing! Its a blast to drive... definitely needs a bigger rear sway bar and lsd though!

I'm about 1000 miles into my trip, I'm about to drive back up to NJ for the last 1000 mile leg in an hour or two. Heres something to enjoy in the meantime from my dad and I having fun.


https://www.youtube.com/watch?v=hdbKyiA8KVg

[AudiPilot]

For those of us who’ve followed your conversion... what happened!? Saw your part-out on the For Sale page... very sorry to see that.

[jolio1994]

Not sure; I'm leaning towards gas. I had the tank filled by the attendant last week when I was en route to the EuropaParts Fall Foilage Cruise in NJ. On the way back home the car started misfiring really bad. I got it home and 4 of the 8 spark plugs had really bad pitting due to detonation. I replaced the plugs and it destroyed the new ones as soon as i went into boost to test.

I emptied the tank out and put in a fresh 5 gallons of 93 octane + octane booster as well as another fresh set of plugs. It drive so much better now but #5 and #8 keep going. I had a look at piston #8 today (which is the worse) and it looks l ike the lunar surface.

Car still drives great with new plugs and no boost. It ran awesome for 7,000 miles up until that fill-up last week... I'll be selling the old setup in the near future though.

https://live.staticflickr.com/65535/50557010036_94b11cc5ba_b.jpg (https://flic.kr/p/2k2xTGQ)2020-11-01_07-15-06 (https://flic.kr/p/2k2xTGQ) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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[nubcake]

That's very unfortunate...

Looks like detonation destroyed the spark plug porcelain & that did all the mechanical damage bouncing around in that hole.
However, if it was just one bank - I'm inclined to think, that something else happened. Either fuel starvation, or exhaust restriction. Possibly, fuel pump or FPR line. Off the top of my head, bank2 is the last to receive fuel through the stock rail setup (not 100% on that).

[AudiPilot]

I read this sort of thread with the awe of someone who has nowhere near the expertise to undertake such an awesome project myself... so in that light, it’s a sad day to see the first (known) C4 RS6 Avant come and go.

[jolio1994]

It was a super fun run spoiled by some bad luck. I always like to look at the positives in life and this is no different. Now there's going to be a first ever 5.2 V10 URS6

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[jolio1994]

Can't count how many times this engine has been in and out in the past 2 months, but figured it's a great time to post a small update as I near the first start-up.

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[fukinavit]

[QUOTE=jolio1994;294202]Can't count how many times this engine has been in and out in the past 2 months, but figured it's a great time to post a small update as I near the first start-up.

I (https://flic.kr/p/2kjhkTZ) Love your passion man, if there were more people in the world like you then it would be a better place for sure!!

I hope you have more luck with this one, looking forward to seeing and hearing what its like.

Keep with the updates, i love to see what crazy stuff you have been up to!!

[AudiPilot]

Keep with the updates, i love to see what crazy stuff you have been up to!!

+1 here!

[jolio1994]

I went back to work last night, but I'm not quite sure my wife was ready for me to leave yet. With being a full time student, 40+ hours a week 3rd shift mechanic, and a newborn it quickly became apparent that the cars not going to get done anytime soon...

So I'm taking another month off to free up some time so I can finish this thing.

I quickly threw a dual 3" to single 4" exhaust together which should suffice until if and when I decide I need a muffler. It came out decent for a day and a half build which tacking the pipes on the car with a tig torch and foot pedal... Yikes! It fits great and shouldn't pose any issues down the road.

I also started to work on the wiring harness since it's really the only thing stopping me at this point from loud V10 exhaust sounds. The ECU's and cover on the passenger side fit like a glove, the driver side might take a little extra work.

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[jolio1994]

So it's been a minute... But here's a little something to keep it up to date as well as first start-up!

Radiator is finished and mounted as well as the inlet and outlet hoses. Just need to connect the heater core lines.
Power steering is being looped until I can replace the steering rack (Can't find them!)
Waiting on C4 V8 tie rods so they clear the coolant crossover pipe in the rear.

Will finish wiring everything up in the meantime

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https://www.youtube.com/watch?v=pM7WKPh7Gk4

[jolio1994]

1000 mile break in update. The Ringer Racing Stage 5 should be broken in by now so I think we're ready to start making some power. I installed a 4" Vibrant muffler as it was unbearably loud on the highway... much better now!

https://live.staticflickr.com/65535/50987636671_c5105619bc_b.jpg (https://flic.kr/p/2kFAXZZ)20210226_072816 (https://flic.kr/p/2kFAXZZ) by Joel Francisco (https://www.flickr.com/photos/150736981@N05/)
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