Project S4-MH500

[confusionhunter]

For those of you who wondered what happened to fade2greys car

Ok so if youve read my post in 2006 which Ive resposted you'll know Ive dabbled before....
http://www.rs246.com/index.php?name=PNp ... +road+trip


Anyway I always wanted to do another.... but better.. so up came an opportunity of a good nick car with a snapped timing belt.... I bought it and started work.... Ive got a fair way through the project but need some motivation to push on.... Now I have a real deadline, I need to be able to drive it away on the 6th of june when I move house! so that include fresh MOT and insurance tax etc! I need a kick up the arse!!!!

Its a Red S4 avant and it was delivered to me in December. Nice full Black nappa leather interior with carbon trim. Even came with a load liner and a dog guard!!! Its got some nice features like Bose stereo(which while still not brilliant is miles better than crap audi std effort) cruise control and a nokia bluetooth kit too....Bonus!!





Ive been collecting bits as they’ve come up second hand so already had some nice bits before I even had the car!!!

lol, I stole this pic as I havent taken a pic of my own one!!

and some big port NA heads
a pair of RS4 KO4s,
6 x 630ccm injectors with a kind map from Doug @ MRC to get me running
RS4 clutch
also ordered a new fuel pump...
another custom exhaust is on the cards again…..
I came across a total bargain for suspension once again from Grizz on RS246…. Fully adjustable stasis kit and some Porsche Cayanne brakes. Using RS6 discs….. biggest damn brakes I’ve ever laid eyes one!!
Got some H&R anti roll bars to compliment the set up…..
I also decided to get hold of SSW mesh wheels, may need some matching tyres for this fella though, I tried them on the car before I started all the work and took a couple of piccies:





anyway
Soooooo had to take apart the engine: found some mangled heads! 3 valves per cylinder were bent! But I have a spare engine so no big deal….






found some mangled heads! 3 valves per cylinder were bent! But I have a spare engine so no big deal….


the rest of the engine was in great nick, later I’ll give it a fresh timing belt kit and Ive got some good condition std heads to put on it so al in all that will be a nice 90k miler engine when its done….. BUT I had a spare engine from when I did terrys car that in even better nick, but after lying around in the garage for over a year it needed some help:
so on with striping and rebuilding the spare engine:


After some care and elbow grease…..



On to the bottom end….. drained the oil and took the sump off to inspect the general condition:



looked good! I wanted to clean the upper sump and get a proper look at the crank so didn’t stop there:



All looks good so I didn’t go any further…. I ordered the parts I needed, gaskets and such like (low compression fellas for some nice high boost)…..
heres one of the nice high flow heads to go on:



That’s as far as Ive got….. need a kick up the arse so I’ll put the core engine together tomorrow night as the wife is out…..

oh and incase you havent noticed as the name suggests the target is 500bhp....

[Doug_S2]

you only have 1 days work left to do!

[redrod]

what a wonderful thread, very nice...... please keep the spec and pictures flowing

RR

[derdle]

Target date of 6th June...what's wrong with 17th May...pull yer finger out!

[spen]

Nice work

[AdamS4]

Nice work... how did the engine pull take you ? 1st time ?

[mikeyquattro]

Target date of 6th June...what's wrong with 17th May...pull yer finger out!

I'l agree with derdle. Get on with it man! Bring it down to RS246 Live! and kick some serious butt!

[confusionhunter]

yes, I actually have a little plan to make it for thr 17th, but there is various dependancies etc etc....

Adam, no Ive done an engine pull before on my old black one which I sold to my brother in law.... I played with that one too...
Check it out:
http://www.rs246.com/index.php?name=PNp ... +road+trip
The pull took 3 nights mainly fannying about with the gearbox bits. The last time I did a pull I left the gearbox in.... this time I pulled it out with the engine.....

[Soupie69uk]

Good work Mark!!

Hopefully will get a spin in this one sometime.

[DavidT]

Mark, if you pay for your RS246 Live! entry, you'll have plenty of motivation to get the car finished

[matias]

Bought the tubolar manifold from Ebay?

[confusionhunter]

Hey phil, yes I have been talking to MarkB and andiroo, but unfortunataly there are too many "other" people involved in getting this thing off the ground, mainly the exhaust place, and how well the fluke the downpipes first time round.... Having just bought a new house too 150 is too much to gamble o things going smoothly.... plus my track record of completing my car projects is pretty crap as the fall to the bottom of the priorities if other things happen.....

Yep... cheapo manifold! just got them back from my fabricator to make some modifications.... I'll post the details in the manifold section once i have them fitted...

[confusionhunter]

Managed to get my finger out and finish the bottom end...
Upper sump resealed and torqued up, one of the two m10 allen headed bolts at the gearbox end snapped!!! Thankfully I was able to get it out other wise I would of had to take it off clean it up and reseal it again...!!


Cleaned the bottom part of he sump:

New bolts all round....


Also had the inside of the manifold welded, Im gonna flow then with my carbide bit to make sure it nice and even and free flowing.

[Blue_Thunder]

It's pics like these which sadly remind me why I have to fork out good money to get anything done on my car.

Looking good though Mark. Your garage looks cleaner than my kitchen.

[confusionhunter]

Next installment!
OK, I bashed on a little more with the bottom end, New water pump, new thermostat , new timing belt pulleys.... just about ready for the heads to go on... All torqued up exactly after my lucky ascape a while ago!! See here:
http://www.rs246.com/index.php?name=PNp ... cky+escape
how bottom end is looking:

So then... time to bash on with the heads... theres 2 outstanding things before the heads go on and thats make the manifolds fit as best as they can be and block off the extra ports that the NA and RS4 heads use but the S4s dont....
So manifold first, not quite done them both but just about there. I sent them back to my welding genius and he tigged the inside of the runners to the inside of the flange so thatthe welds are double up. However that leave a flow restriction so I started flowing them back...

So after welding (before they were welded they were just ends of the tubing exposed, not great for flow...)


So got out my flowing kit!!! stuck on some music.... then put my ear defenders on (good job I put the music on!)... and got cracking.

end result:


quite pleased with that....
now the NA heads have larger ports than the RS4 heads but even with that I think that I could in theory flow the heads a little but Im not going to as the heads are clean and ready to go on.... seee check the gasket out:

See how the ports are smaller than the gasket?
Now on the manifold:

difficult to see but the ports on the manifold are larger than the gasket.... better than the ridiculous restrictions that the standard manifold are!

Ive flowed a few bits and peices mainly alu and steel, but stainless is a lot harder and made short work of my trusty carbide bit!! ah well all in a good cause!!!


Anyway, I fitted the manifold up to the head and it wasnt a great fit. I needed to chamfer the edges of the manifold so there was adequate clearance from the head castings, it might be an NA head thing as the castings are different to the S4 heads....

crap pic, sorry bout that but you can see where I took the angle grinder too...


so was happy with that...


So on with the Head port blocking...
I was going thinking of using the audi technique of ramming a ball bearing in but wanted to get the right size.....
see the issue, std s4 on the right, NA on the left:

can you tell what going to happen with this somewhat "well used" s4 head and the suspicious looking angle grinder???


You guessed it!

So got the bearing out, measured it up at 11.3mm... can I find 11.3mm ball bearing anywhere?? nope... 11.1mm and 7/16 inch bearings but both too small by 0.2mm... hmm might need to hack the other head up or makea blanking plate.... still undecided on that....not sure I fancy taking a large hammer to my newly rebuild na heads!!!

so thats it for now, I also received some more goodies for the project....
A bosch motorsport fuel pump thats up to the job with appropriate basket and strainer (cheers to doug at MRC tuning for that!)


And some nice new bits from Liam/Kylie at ESP engineering, all looks pretty damn good to me!
Brace bar:

and I got the knob enscribed with the audisport symbol BEFORE the titanium plating for the super subtle.... I quite like it...(I should have dusted it before I took the pics tho!!)



Well thats me for now.... hope to do more one night this week.... and at the weekend.... k: