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Thread: Audi A4 B5 Quattro 1.8t GT2860 build

  1. #1

    Default Audi A4 B5 Quattro 1.8t GT2860 build

    Hi All,
    Thought Id show case a Audi A4 1.8T Quattro just got finished building and tuning,
    Beautiful red Duco Pre facelift with only 195k on the clock.

    Build included (Clean this up for starters- YUK)

    bit dirty.jpg
    Full major service- Timing belt/water pump/ thermostat. All aux belts and Cam chain tensioner gasket, cam seals.
    Valvetrain.jpg

    Opened up and ready for WERKS

    build begins.jpg
    '99 Quattro, stroked 2L
    Concept, tune and build by QMS
    EFR 6758, Bosch 1000cc, E85 @7bar, Bosch 413 in 034 surge tank. VVT cam timing upgrade. Controls by Eurodyne boost manager, V8 MAF, LC1, EGT. JE 9:1, 13kg 2L Crank, 475gm rods, Ferrea , Dowel pin crank, IE tensioner, 034 Pheno Spacer, FX400 240mm x6, Apikol SMIC, Miltek 2.75 Koni coils, Stoptech BB, Powerslot Rear, SS lines, 034 G/b, Apikol Diff mounts, APR snub mount.



  2. #2

    Default

    Ringer racing stage 3 with 240mm flywheel going in, This clutch is full face which means long lasting and smooth,
    its also cerametalic one side and organic the other- what this means is HOLDING POWER at 528 ftlbs rating the rods will bend like twizzle sticks before this clutch lets go!

    RingerRacing stage 3.jpg

    clutch in.jpg

    Attachment 31567
    Last edited by rockersteady; August 1st, 2020 at 09:46 PM.
    '99 Quattro, stroked 2L
    Concept, tune and build by QMS
    EFR 6758, Bosch 1000cc, E85 @7bar, Bosch 413 in 034 surge tank. VVT cam timing upgrade. Controls by Eurodyne boost manager, V8 MAF, LC1, EGT. JE 9:1, 13kg 2L Crank, 475gm rods, Ferrea , Dowel pin crank, IE tensioner, 034 Pheno Spacer, FX400 240mm x6, Apikol SMIC, Miltek 2.75 Koni coils, Stoptech BB, Powerslot Rear, SS lines, 034 G/b, Apikol Diff mounts, APR snub mount.



  3. #3

    Default Turbo Mock up and clocking

    The supplied Mamba GT2860 turbo and side mount manifold is a generic kit, it needs a lot of twiddling to get everything lined up the right way-
    turbo outlet headed down towards original hard charge piping, wastegate actuator pointing towards wastegate and clearing oil drain line and coolant inlet, so exhaust and compressor housings had to be fine tuned to get it right.

    turbo clocking.jpg

    Vband turbo dump bolted on after a whole bunch of fiddling and grinding to get it to fit and run the nuts on in the right order

    IMG_0129.jpg

    Turbo is fitted to exhaust manifold after several mock-ups
    exhaust manifold.jpg turbo mount.jpg
    Now that's sorted have to figure out a way to hook up the turbo inlet and all the attachments like Dv return, Breather, N75 and fuel tank venting...
    So the charge pipe is connected and the dv release nipple added to it
    IMG_0131.jpg

    Turbo coolant supply line from block fitted and mock up air intake /maf fitting and air filter location- being a side mount turbo means factory air box has to go...


    Turbo coolant inlet.jpg IMG_0130.jpg
    Attached Images Attached Images
    '99 Quattro, stroked 2L
    Concept, tune and build by QMS
    EFR 6758, Bosch 1000cc, E85 @7bar, Bosch 413 in 034 surge tank. VVT cam timing upgrade. Controls by Eurodyne boost manager, V8 MAF, LC1, EGT. JE 9:1, 13kg 2L Crank, 475gm rods, Ferrea , Dowel pin crank, IE tensioner, 034 Pheno Spacer, FX400 240mm x6, Apikol SMIC, Miltek 2.75 Koni coils, Stoptech BB, Powerslot Rear, SS lines, 034 G/b, Apikol Diff mounts, APR snub mount.



  4. #4

    Default relocate Starter supply cable and fabricate the turbo intake pipe with attachments

    Starter power supply cable well and truely in a bad spot- direcly in line of fire of the turbo dump
    20200618_140446.jpg

    A little massaging of the cable and tucked it under the heat shield following the frame rail sorted that out

    relocated Starter cable.jpg


    Now getting all the attachments to the turbo intake pipe figured out.... I relocated the PCV pipe from the block that runs arund above exhaust manifold to the Left side of engine now and along front of engine to hook up to turbo intake with the pancake

    IMG_0134.jpg IMG_0135.jpg IMG_0136.jpg IMG_0137.jpg intake finished.jpg
    '99 Quattro, stroked 2L
    Concept, tune and build by QMS
    EFR 6758, Bosch 1000cc, E85 @7bar, Bosch 413 in 034 surge tank. VVT cam timing upgrade. Controls by Eurodyne boost manager, V8 MAF, LC1, EGT. JE 9:1, 13kg 2L Crank, 475gm rods, Ferrea , Dowel pin crank, IE tensioner, 034 Pheno Spacer, FX400 240mm x6, Apikol SMIC, Miltek 2.75 Koni coils, Stoptech BB, Powerslot Rear, SS lines, 034 G/b, Apikol Diff mounts, APR snub mount.



  5. #5

    Default Exhaust

    Exhaust
    I had an 2.5' Exhaust laying around from a very well known Audi Performance Race shop in Good old USA that I chucked on minus turbo dump/cat
    exhaust 1a.jpg exhaust 2a.jpg exhaust welding.jpg

    100cell race cat fitted, a bit further back to help the turbo spool
    Last edited by rockersteady; August 1st, 2020 at 10:54 PM.
    '99 Quattro, stroked 2L
    Concept, tune and build by QMS
    EFR 6758, Bosch 1000cc, E85 @7bar, Bosch 413 in 034 surge tank. VVT cam timing upgrade. Controls by Eurodyne boost manager, V8 MAF, LC1, EGT. JE 9:1, 13kg 2L Crank, 475gm rods, Ferrea , Dowel pin crank, IE tensioner, 034 Pheno Spacer, FX400 240mm x6, Apikol SMIC, Miltek 2.75 Koni coils, Stoptech BB, Powerslot Rear, SS lines, 034 G/b, Apikol Diff mounts, APR snub mount.



  6. #6

    Default

    Tuning
    Airbox.jpg
    Airbox made up (Keep it all legal... cant have a open pod filter.....!)


    Chuck a quick tune at it- tuned the factory ecu, running 500cc, VR6 maf housing and 98ron, 20psi will do - not too much boost to keep intake and cylinder temps low enough amp torque with timing
    Last edited by rockersteady; August 1st, 2020 at 11:24 PM.
    '99 Quattro, stroked 2L
    Concept, tune and build by QMS
    EFR 6758, Bosch 1000cc, E85 @7bar, Bosch 413 in 034 surge tank. VVT cam timing upgrade. Controls by Eurodyne boost manager, V8 MAF, LC1, EGT. JE 9:1, 13kg 2L Crank, 475gm rods, Ferrea , Dowel pin crank, IE tensioner, 034 Pheno Spacer, FX400 240mm x6, Apikol SMIC, Miltek 2.75 Koni coils, Stoptech BB, Powerslot Rear, SS lines, 034 G/b, Apikol Diff mounts, APR snub mount.



  7. #7

    Default factory rod safe Max ouput tune

    Metric
    Andre A4 B5 1.8t Quattro GT2860 20PSI 98Ron QMS tuned.jpg 193awkw

    Ole Skool

    Andre GT2860 V6A HP_FTLBS 1.jpg 259awhp

    222FT/LBS at all wheels = 297 ft/lbs at crank. Pretty much spot on 300ft/lbs rod safe max torque.

    job done.!
    '99 Quattro, stroked 2L
    Concept, tune and build by QMS
    EFR 6758, Bosch 1000cc, E85 @7bar, Bosch 413 in 034 surge tank. VVT cam timing upgrade. Controls by Eurodyne boost manager, V8 MAF, LC1, EGT. JE 9:1, 13kg 2L Crank, 475gm rods, Ferrea , Dowel pin crank, IE tensioner, 034 Pheno Spacer, FX400 240mm x6, Apikol SMIC, Miltek 2.75 Koni coils, Stoptech BB, Powerslot Rear, SS lines, 034 G/b, Apikol Diff mounts, APR snub mount.



  8. The Following User Says Thank You to rockersteady For This Useful Post:

    Gbomer (August 2nd, 2020)

  9. #8
    Join Date
    Sep 2006
    Location
    Fairfield Sydney
    Posts
    1,330
    Thanked: 8

    Default

    How is that full face stage 3 clutch . Once my organic is done for. Ill need something like this or the stage 4

    Is it sticky and really grabby like the 6 puck ?

    Sent from my SM-G965F using Tapatalk
    Now > 99 A4 1.8TQ (silver)
    Handling
    KW V3's | Hotchkies Front and Rear Sways | 320mm Brembo BBK |
    Power
    Garrett GT3076r 52 Trim 0.63 A/R| Haltech PS1000 (custom harness PNP) | Piper Ultimate Road Cams | Scat Rods | JE Pistons | Supertech Valve Set | IE Springs Set | Full Race Ex Mani | Custom Enlarged Intake Mani | 1000cc Inj | Zietronix Flex Fuel Sensor | Treadstone TR18 FMIC

    R.I.P > 98 A4 1.8TQ (cactus green)

  10. #9

    Default

    The 240mm (stage 3) clutch in this car drives smooth!! feels like factory- but the owner stalled it several times getting used to where it bites on the pedal (he was used to his mushy stock engaging high) so it will BITE if quick release- which is fantastic for soft launch (Hard launches really only on high torque setups and a hard launch - button clutch) yes please , switch to (a) stage 4 type full FACE cerametalic clutch

    I have a stage 4, 240mm in a (GTX2860R with rods and E85) clients B6 avant and it was a long break-in till it smoothed out (chatters in first gear engage a bit ) but its easy to drive and doesnt make the driver look like a novice when parking LOL.
    The stage 3 is smoother-
    but I also run them with a Dual mass flywheel (same material) but unsprung and its grabby (chatters a bit), the stage 4 on a dual mass is smoother!

    Most are still driving Audiis, only when you strip out the sound deadening and switch to a race seat should you ditch the DUAL MASS (all the r series Audiis run them)

    Ive run huge power clutches on the dual mass, its not the torque that kills them its the driver who inadvertently overheats it doing drag style launch attempts which spin the clutch and not the wheels lol.

    cheers,
    Ed
    '99 Quattro, stroked 2L
    Concept, tune and build by QMS
    EFR 6758, Bosch 1000cc, E85 @7bar, Bosch 413 in 034 surge tank. VVT cam timing upgrade. Controls by Eurodyne boost manager, V8 MAF, LC1, EGT. JE 9:1, 13kg 2L Crank, 475gm rods, Ferrea , Dowel pin crank, IE tensioner, 034 Pheno Spacer, FX400 240mm x6, Apikol SMIC, Miltek 2.75 Koni coils, Stoptech BB, Powerslot Rear, SS lines, 034 G/b, Apikol Diff mounts, APR snub mount.



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