The last of the hardware arrived yesterday, so it's time for reassembly using the new parts.

First part of the rebuild focuses on the bottom end. The OEM pistons were freshened up and mated to the new Integrated Engineering connecting rods, new rings and rod bearings were installed, clearances were checked, and then everything was reassembled back into the block. The head was cleaned to remove a few thousand miles of road and oil grime build up and also prepped for a tight seal to the block. Due to space constraints, the exhaust manifold and turbo were assembled to the head before putting the head back in its place.

Reinstalling the head, a new OEM head gasket as well as OEM stretch bolts were used. After the head bolts were torqued to spec, a new valve cover gasket and a freshly cleaned valve cover were used to literally top off the engine build. Next, the turbo compressor housing as well as the center section were clocked for correct location of the coolant and oil ports. Stainless steel lines coupled with AN fittings completed the cleanliness of the V-band manifold option. With the turbo securely in place, oil and coolant lines installed, wastegate fitted to the manifold, and intake pipe test fitted, we're that much closer to firing it up.

After all of the VR6 projects that have recently passed through the shop, it's about time the 1.8T showed its face!

This 1.8T project came to us in the form of a 2001 Audi TT 1.8T 225hp quattro owned by a customer from Coconut Creek, FL. We spoke for over a month with him via email and phone before we finally met face to face.

The plan for this TT involves just what we like - something different. Our customer is looking to drastically increase his TT’s power output but he's looking to accomplish this without taking the normal routes. He has researched all of the “off the shelf� kits and quickly realized they are not for him. The customer contacted us after he had decided on a few basic components and has now put it upon us to make his plan a reality.

We wonder if this TT is aware of its fate? If so, it should know it will soon be receiving a Garrett dual ball-bearing GT3076R turbocharger, but again, there's a twist! No T25 or T3 flanged turbos here; our customer has chosen something different - a Tial V-band exhaust housing mated to a Pag Parts V-band manifold. With the turbo and manifold components chosen, our customer is requesting we make this more of a “one of a kind� setup by fabricating our own fifteen52 front mount intercooler system, as well as a 3� stainless steel exhaust. Completing the setup will be a Tial 38mm external wastegate, 630cc injectors, a Tapp Auto Tune, and an inline fuel pump. Since we're headed to a power level that the stock 1.8T rods don't much care for, it's been agreed that a set Integrated Engineering “drop-In� forged rods will offer a welcome extra degree of durability.

While this is a list of the basic plan, we still have a few surprises to offer, so stay tuned.

First up is disassembly. Since we're replacing the rods, we have to remove the cylinder head. With the engine apart to this degree, we can give it a good inspection, and sure enough, everything's in good shape and ready for that massive 3076 turbo.