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Thread: Milka Build thread

  1. #1
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    Milka Build thread

    As a few people have asked for this, I am going to do a mini build thread on here. Please if you have any questions or want to see and modifications let me know and I will post pics, measurements, logs, etc. My full build thread is here http://www.ozaudi.com/forums/a6-s6-r...-thread-6.html

    So the car started as a 2003 built MY2004 Aus delivered RS6, came with 19' 5 spokes, recaro interior, matt black interior handles etc, carbon trim, etc.

    My current mod list is something close to this: (I will modify as I remember more)
    Hotchkis sways
    KW v3 Coilovers
    Adjustable front upper control arms
    B7 RS4 wheels 265/35/19 Toyo Proxes T1S
    Alcon front brakes, RS6 Plus rear rotors
    Stainless lines brake lines all round
    Twin GTX3071 Turbos, Twin scroll .82 housings
    Tial MV-S external wastegates set to 13 psi base pressure
    Custom exhaust manifold, Twin scroll with single Tial per bank
    Milltek Exhaust with cats and resonators
    Custom 3' dump joined into Milltek cats
    Twin LC-1 wideband 02s
    Twin BMC OTA Carbon airfilters
    Twin A8 MAFs
    Custom intake piping joining the stock air intakes into BMC OTAs then A8 MAFs then into enlarged Y at back of engine
    Re-core'd RS6 intercoolers with Garrett 4.25' thick cores
    Removed additional radiators
    Weldon fuel pressure regulator
    Integrated engineering billet 1.8T rails modified to fit RS6
    -8 teflon fuel lines with speedflow fittings
    Bosch EV14 980cc injectors
    Phenolic Spacers 1.8T port matched to RS6 heads/manifolds
    0A3 B7 RS4 gearbox
    Custom 6mm gearbox spacer
    Modified TDI 6th gear
    B7 RS4 clutch slave
    A6 manual Clutch master
    A6 manual clutch pedal/brake pedal
    ClutchMasters FX850 Twin Plate clutch
    custom front half shafts (using existing stock RS6 CVs)
    custom gearbox mount brackets
    modified tail shaft
    modified oil cooler to be just engine oil no gearbox
    shifter from B5 S4
    W8 ABS controller
    Catch Can with baffles (removed SAI and replaced with catch can)
    Wavetrac LSD
    Self Tuned via TunerPro with the assistance of PRJ ;-)

    Currently working on:
    Twin Walbro 416 E85 intank pumps (with option of going to Radium external surge tank if needed but trying to avoid this)
    E85 Conversion
    Tilton Carbon/Carbon Triple Plate Clutch
    B7 RS4 shifter
    R8 Rims /w 255/35/19 fronts and 295/30/19 rears

    Spare engine being worked on (aiming to run >30psi)
    Heads fully built and ready to rev over 8500 (I will set red line to 8000)
    Pauter rods
    Need to figure out Pistons/rings for spare blocks
    (If anyone knows a company that has done Alusil pistons/rings before please let me know, second option will be to sleave the block)
    Last edited by milka; February 27th, 2014 at 02:29.

  2. #2
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    Car prior to pulling apart for the manual conversion and big turbos, external gates, etc

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    Engine mated to B7 RS4 gearbox

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    Comparing the GTX3071s to stock RS6 turbos

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    Last edited by milka; February 27th, 2014 at 02:44.

  3. #3
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    Manifolds being fabricated

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    Test fitting on engine
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    Test fitting clearances in the engine bay
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    Last edited by milka; February 27th, 2014 at 04:05.

  4. #4
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    Checking Flywheel vs flex plate alignment of the tone ring
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    Now test fitting exhaust manifolds with turbos attached and wastegates attached.

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    Last edited by milka; February 27th, 2014 at 04:11.

  5. #5
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    Fabricating the dump pipes and wastegate piping
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    Full length showing shifter fitted and dump pipes fabricated into existing Milltek downpipes/cats
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    Passenger turbo from the side (yes yes I'm in Australia ;-) )
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    A little bit of customization needed to make the wastegate dump fit past the shift rods. Everything was very tight!
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    Last edited by milka; February 27th, 2014 at 04:16.

  6. #6
    Registered User 4everRS's Avatar
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    Sounds like quite a job.

    In this forum I think you only have a couple hours to edit a post. After that you can't edit or add pics.

    Edit: I see pics are coming.
    Avus Silver RS6 - Viper Stage 2 ECU/TCU - Water/Meth Injection - Frozen Rotors - Hbars - clear corners - Hella smoked tails - gutted precats

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  8. #8
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    Quote Originally Posted by 4everRS View Post
    Sounds like quite a job.

    In this forum I think you only have a couple hours to edit a post. After that you can't edit or add pics.

    Edit: I see pics are coming.
    Thanks for letting me know, I just filled the posts with some pics that will show how big everything is, and how little room there is to put the larger turbos in..... It does fit just!

  9. #9
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    Looks like a great build. how was the B7 trans mate complication? Straight forward with a custom plate?
    03 RS6 :: 01 allroad

  10. #10
    Registered User lswing's Avatar
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    Wonderful fabrication work and photos, thanks for sharing!
    Ace/Edge TC - Tozo Trans - MTM TCU - REVO/ME7 tune - Wagner IC's w/ Venair Hoses - Aux Radiator delete - Hotchkis Sways - Hawk HPS Pads - Koni Sport Struts - Scroll KO4 Turbos - Devil's Own WM - 421whp/452wtq on Mustang Dyno - http://www.audirssix.com

  11. #11
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    Thank you.

  12. #12
    Registered User MaxRS6's Avatar
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    Wowza- +1- Thanks for sharing your work product!
    201K miles rolled

  13. #13
    Registered User ben916's Avatar
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    Nice work and ambitious project!!!

    Are you planning on ceramic coating of the manifold and piping?
    Probably will help keep some of the heat down.
    SOLD - 03 RS6 Avus (905355)
    Current - 03 Toyota Tacoma 4x4 double cab - the YETI, lifted, winched, snorkeled, lockered, skidded, geared

  14. #14
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    Quote Originally Posted by ben916 View Post
    Nice work and ambitious project!!!

    Are you planning on ceramic coating of the manifold and piping?
    Probably will help keep some of the heat down.

    Nice thinking ;-) , this was all about 1 1/2 years ago at this point, I'm just catch up posting pics so people can see what was done
    OZ RS6, 0A3 manual, Tilton Carbon/Carbon Triple Plate, twin GTX3071s, twin Tial mv-s gates, Custom ICs, BMC OTA filters, A8 MAFs, 980cc injectors, etc

  15. #15
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    FX850 clutch

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    Individual pieces laid out
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    Test fitting on the engine
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    Attaching tone ring in the right orientation, also had to machine a channel behind the tone ring as there was not one when it arrived, fine for Alu but not good for Steel
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    OZ RS6, 0A3 manual, Tilton Carbon/Carbon Triple Plate, twin GTX3071s, twin Tial mv-s gates, Custom ICs, BMC OTA filters, A8 MAFs, 980cc injectors, etc

  16. #16
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    Clutch hit the gearbox when first fitted...... :-(
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    Spacer for the crank angle sensor
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    Fabricators comments about the flywheel pre getting it machined to fit.
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    Pic of the channel that was cut behind the tone ring to get clean readings
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    OZ RS6, 0A3 manual, Tilton Carbon/Carbon Triple Plate, twin GTX3071s, twin Tial mv-s gates, Custom ICs, BMC OTA filters, A8 MAFs, 980cc injectors, etc

  17. #17
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    Modifying the Intake MAF pipe, this was modified to accept R32/B5 S4 MAFs but also the tiny diameter to the turbos was enlarged to nearly twice the diameter. And then Coated

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    Downpipes finished and ceramic coated
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    Other components coated and nearly ready to put back in, after a little cleaning up of the ports
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    Tailshaft length modified, rebalanced and ready to go
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    B7 RS4 starter motor vs stock RS6 on the left
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    Starting to put titanium heat wrap on exhaust manifolds
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    OZ RS6, 0A3 manual, Tilton Carbon/Carbon Triple Plate, twin GTX3071s, twin Tial mv-s gates, Custom ICs, BMC OTA filters, A8 MAFs, 980cc injectors, etc

  18. #18
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    Manifold wrapped and test fitted
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    Some custom fittings machined up to get all the dash fittings to connect to engine, clutch, etc
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    New machined connection to the clutch slave, still uses the stock plastic fitting but allows dash teflon lines to be used, also created a dash fitting on the bleed for a remote bleed in the top of the engine bay, no need to get under the car to bleed the clutch!
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    OZ RS6, 0A3 manual, Tilton Carbon/Carbon Triple Plate, twin GTX3071s, twin Tial mv-s gates, Custom ICs, BMC OTA filters, A8 MAFs, 980cc injectors, etc

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