1552 v.2 blog #29: Audi B7 A4 Shop Demo

Apr 4, 2009 - "Out Back" Photoshoot

noreply@blogger.com (fifteen52) — Fri, 03 Apr 2009 19:00:00 +0000

It's nice to attach catchy phrases to photoshoot opportunities, but this one, however, is merely titled "Out Back", as in out back behind the shop. Basically, we wanted to offer quick view of how our A4 currently sits after the most recent round of upgrades.

Mar 31, 2009 - Minor Details

noreply@blogger.com (fifteen52) — Tue, 31 Mar 2009 19:00:00 +0000

While we are still awaiting our base tune, we took the opportunity to go over a few minor details which can and do change the overall look of a custom setup. As minimal as they may be, and as picky as we are about small details like this, attention to such things is just up our alley!

Rather than using the typical silicone vacuum lines for the BOV and wastegate connections, we decided to swap them out for Goodridge 3AN SS lines w/anodized blue AN fittings. Odd sizes were needed for the dual wastegates and EBC connections, and therefore needed to be special ordered. While we await their arrival, the BOV used a more standard size and can give an idea of what small changes like this can do to the overall look of the setup.

Mar 30, 2009 - Bumper Fitment

noreply@blogger.com (fifteen52) — Tue, 31 Mar 2009 00:00:00 +0000

When adding a FMIC to any car, fitment is always a consideration. Luckily, even with our choice for larger FMIC (Precison 750hp core with dimensions 31.5" x 12" x 3.5"), the B7 S-line bumper has a rather large nose and only requires minimal trimming for it to swallow up the new intercooler and snuggle back in place. Before the bumper was mounted tightly, we took the opportunity to apply some of the skills acquired from building our VW MK5 GTI prototype flares to change the front look of our B7. Using a combination of 1/8" MDF wrapped in fiberglass, the A4 now has a much more aggressive look with the addition of this one-of-a-kind splitter.

Mar 28, 2009 - Turbo Hardware Install Completed

noreply@blogger.com (fifteen52) — Sat, 28 Mar 2009 17:00:00 +0000

The first stage of the build and fabrication is completed and we're happy to say the car started up with little hassle. While we are still awaiting our base tune, and therefore waiting to install the upgraded high pressure fuel pump and larger injectors, starting the car even in this form allows to be sure we are free of any oil or coolant leaks with the rather complex run of lines due to the location of the turbo.

Mar 27, 2009 - Bigger IS Better!

noreply@blogger.com (fifteen52) — Fri, 27 Mar 2009 21:00:00 +0000

Before we confuse anyone thinking we are forgetting or skipping a step, engine internals, we have decided to get the turbo setup fabrication completed prior to touching the internal workings of our 2.0T. While boost and power will surely be limited on the stock internals, following this path will allow us to quantify any changes in spool and power (on low boost) due to the planned drop in compression. We'll also admit we are a little impatient in wanting to turn the key and hear the car come to life with the monstrous GT35R under the hood!

Mar 26, 2009 - Getting Started

noreply@blogger.com (fifteen52) — Thu, 26 Mar 2009 18:00:00 +0000

The physical start to any build is always the worst part; that is removing all of the small and insufficient OEM parts! Luckily we are rather familar with the 2.0T so removal of the factory turbo hardware occurs in short order. Once the turbo/manifold combo, oil and coolant lines, and twin side mount intercoolers are removed, we can go forward with the fitting of our new, much larger, replacements.

Mar 24, 2009 - Manifold Arrival

noreply@blogger.com (fifteen52) — Tue, 24 Mar 2009 16:00:00 +0000

As mentioned in a previous update, we were waiting on one last piece in order to get started with the project. Well, our manifold from Jay @ JRP has just walked in the door and we are now able to go forward with the build.

Mar 6, 2009 - Exhaust Fabrication

noreply@blogger.com (fifteen52) — Sat, 07 Mar 2009 03:40:00 +0000

While we are waiting on a few remaining parts, we've chosen to get started on a few things and get them out of the way. First is the fabrication of the exhaust utilizing stainless steel mandrel bent piping, Magnaflow mufflers, and V-band clamps and flanges at all joints. To best expel the exhaust gases from the GT35R, we've chosen to use a full 3" setup with a 3" downpipe from the turbo to the rear axle, then into 3" splits out the back of the car. While the piping diameter is a bit large for the typical A4, once completed our A4 should be far from typical!

Mar 4, 2009 - Hardware List

noreply@blogger.com (fifteen52) — Wed, 04 Mar 2009 19:50:00 +0000

The start to any project is choosing a hardware list that not only fits the platform properly, but also one that meets goals and expectations after the project is completed. Our previous A4 build-up using the B6 platform in its final stage used a GT3076R turbo, so we knew for this one we wanted to go bigger. As with any turbo project, there are sacrifices for choosing either too small or too large a turbo. This car will typically be daily driven, so a smooth, well rounded powerband was extremely important, yet it will occasionally see track time and a large peak number was also important. To achieve those goals the infamous Garrett dual ball bearing GT3582R was chosen.

To help with spooling the GT35R on the 2.0l 4cyl, we opted to go away from the "norm" and go forward with a twin-scroll setup. A correctly done twin-scroll setup will allow quicker spool-up from a normally laggy sized turbo for the app. As premade twin scroll manifolds are not available for our platform, we put the task of building a tubular twin scroll manifold on the shoulders of our friend Jay Thornton of JRP (Johnson Research & Performance). To keep exhaust gas pressues separate on the paired cylinders and control boost pressure, twin Tial 38mm V-band wastegates best fit the requirements. Sincet the turbo setup by far exceeds the capabilities of the internals of the FSI block, we've selected to use a set of JE 82.5mm 8.5:1 compression pistons connected to the already OEM forged crank via a set of Integrated Engineering 144x20 rods. Since the FSI motor is fairly new, other engine hardware is limited, however, we managed to get our hands on one of the first sets of Supertech intake and exhaust valves to add a bit more safety to the internal workings of the motor.

The hardware list in its entirety:

GT3582R, twin-scroll, .78 a/r, 4" anti-surge inlet, 3" V-band exhaust
Jay Thornton custom tubular twin-scroll manifold
Tial 38mm V-band wastegate x 2
JE 82.5mm 8.5:1 pistons
Integrated Engineering 144x20 rods
Supertech inconel exhaust valves
Supertech SS/nitride intake valves
ARP head bolts
Tial Q BOV
Precision 750 FMIC core
2.75" IC plumbing
Full SS 3" exhaust w/ 3" splits & Magnaflow mufflers
Snow Stage 2 W/M injection
RS4 injectors
AWE HPFP upgrade
BSH PCV blockoff plate
Clutchmasters FX500, 6 puck, unsprung, Power Plus II pressure plate
Cluchmasters 16lb steel flywheel
Turbosmart Eboost2 EBC
Innovate XD16 w/ LC1 wideband controller

With any build of this nature, collecting all of the proper parts and in a timely manner is a mean feat all in itself. As nothing of this sort has yet to be completed with the longitudinally mounted 2.0T (as situated in the A4), we have had to perform some extensive research and planning when it came to quite a few of even the smallest parts which brings a project like this together. And we should add that our fueling solution is still in the hush-hush phase, so that's why it's not currently listed above.

As the "pile" of parts required for the build has been increasing significantly over the last few weeks, we finally have a majority of what's needed to get started! Our custom manifold is due to be delivered shortly and at that point we can really begin the build.

Feb 28, 2009 - Suspension, Brakes & Wheels

noreply@blogger.com (fifteen52) — Tue, 03 Mar 2009 17:43:00 +0000

If you'll notice the date of this update you'll see it's the same as assigned to the project intro.

As we mentioned in the intro, we wasted no time in getting the B7 A4 into a more appropriate condition. Fortunately, we kept some of the hardware from our project B6 A4 and those components will work just as nicely here as before.

A set of Tein adjustable coil-overs help bring down the ride height and firm up the damping and rebound. A somewhat unusual choice in the Audi aftermarket, Tein is a top suspension manufacturer from Japan and their quality is top-notch.

Considering what is planned for under the hood, we were wise indeed for keeping the Alcon front and rear big brake components used on our B6, and at the end of the day there really is no better caliper available - street or track.

This staggered set of HRE 19" 3-piece wheels will also seem familiar to those who followed our B6, but as nice as they look here, they are up for sale and we plan to use something a bit more motorsport-oriented this time around. We don't want to tip our hand just yet, but the next set of wheels will likely possess the initials B, B & S.

Next update will involve some serious 2.0TFSI massage work.

Feb 28, 2009 - Project Intro

noreply@blogger.com (fifteen52) — Sat, 28 Feb 2009 15:21:00 +0000

Just back from a 700-mile roundtrip, our newly purchased 2008 Audi B7 A4 2.0Tq is finally home.

Purchased from a dealer in GA with a mere 16k miles on the odometer, the A4 has the equipment we've been searching for ever since Shawn sold the B6 A4 1.8T. Wearing Quartz Graphite Metallic paint and black leather, hardware consists of a 2.0TFSI engine mated to a 6-speed manual transmission and Audi's magnificent quattro all-wheel-drive system. Yes, you read that right - this time we have AWD and look to be able to put some really big power to the ground.

Big power? Oh, yes, soon enough you'll see some impressive numbers coming from the 2-liter engine. You see, we intend to make a splash in the B7 2.0TFSI market and a mere 300 or even 400-whp isn't really going to be enough, is it? Stay tuned for details.

The A4 was at the shop a mere 15 minutes before we pulled it in and began taking it apart. We'll follow up with all the details, but in the mean time here are a few real-time progress pics: