Jibberjive's RS6 Build Log

9 minute(s) of a 96 minute read

Pics for the updates from this last weekend. Dowels from ACE hardware that I had to work with to make it fit.

Then I was able to put the FMS and oil pan back on. Then I got the rest of the timing stuff on.

Then I go to bolt on the turbos, and I find that the elbow welded onto the inlet on the passenger side compressor hits a knob on the block, and interferes so I can't bolt the flange all of the way down

I was debating between figuring out what that knub on the block does, and grinding it down if it doesn't do anything, but I ended up reclocking the turbo slightly so that I have a mm or two clearance after bolted up. I've sent an email to Markku at Agtronic to see what he suggests, but I'm hoping that it doesn't interfere with the frame rail or anything else when I go to reinstall the engine. I know it's a tight fit under there.

So, then I go onto making some lines for the oil and coolant to the turbos, since many parts of the ATP turbo line kit were either mis-sized or simply incomplete. I bought these -10 AN adapters from 034 to make the oil return lines, and when I went to fit them into the oil pan, I got yet another awesome surprise. One of the adapters was noticeably different than the other, and it was too large to into the oil pan (in spite of the parts being taken from the same hotdog-link type connected packaging. I've sent an email to Max (since that is who I originally dealt with), and hopefully he is willing to send a replacement asap so that I can potentially install the engine this next weekend.

The good one

The bad one

I used the one that fits to measure some lines, and I'm just waiting on a couple of fittings that will hopefully be here this week.

Coolant line

So, just need to wrap up the turbo lines (which, following suit, were a pretty nagging thing to deal with), then I could potentially do the rest of the big items and get the engine running on a base map!

I'll pull a BigBoost, with a checklist (as much for myself as for the build log). Not necessarily in order.

Checklist:
1. Finish up turbo lines (Get replacement 034 oil pan adapter, get oil inlet lines modified, assemble rest of lines, get fire sleeving)
2. Get flywheel bolts ground down
3. Powerwash engine bay and undercarriage
4. Polish bipipes
5. Assemble rest of engine (serpentine assembly, intake mani, flywheel, tranny, etc)
6. Do 'big 3' wiring upgrade with 0 ga, and wire car for trunk battery relocation, install wideband and sensors (Zeitronix, WB02, EGT, Boost)
7. Reinstall engine
8. Install ER's
8.5. Install HID kit and Depo headlights
9. Startup!
9.5. Install interior
10. Get exhaust installed ('cats' , v-bands, and extra resonator welded in)
11. Break it in and tweak the tune!
12. Finish developing custom intake manifold, custom catch can, and custom dual 044 surge tank and nitrous setup
13. Assemble fuel lines and install new fueling setup (surge tank, pumps, lines, rails, FPR, ethanol content analyzer)
14. Self tune for E85!

I'm sure I'll be adding to this list as I remember more stuff.

11/30/11

I spent a ton of time at the shop this last week, but still have like one more day to get it running (I'll post an update when I get time), but I just got your voicemail and I'll call you. Also, if you need a fast B5 S4, it won't be mine for the first little bit, because I'm going to be running wastegate spring boost (13lbs IIRC) and with the stock fuel pump for the first little while, while I break the motor in and build the surge tank/catch can. So it won't necessarily be fast for a while (probably seem like a Toyota Corolla compared to what you've been driving ha). The stroker getting a little unrealistic for daily duty?

And a teaser pic for everyone

1/2/12

2/25/12

Clutch and motor broken in, approx 1200 mi on the engine. I'm off headed up the canyon right now to hopefully tune/optimize my current setup! I'm not sure how much I'll be able to turn up the boost on the stock fuel pump before I start to lean out, but I assume at least a little bit more than the 15psi I have been running. I've got a wideband and all monitoring set up though, so I should be able to get it pretty decent.

And for reference for people, I just got 27.07 mpg driving 215 miles on the highway the past day and a half. Crazy because I had the windows and/or sunroof down for a bunch and was cruising around 80. I've got some MPG tricks up my sleeve as well, and when I get my tune honed in, panzer plate on, and 2.0t coils in, I'm going to go easy for a tank and see what I get. Kind of interesting I got such good mileage, considering I got my worst tank ever, 12.x MPG, the previous tank (though that was with continual fats testing and lots of parking lot idling to keep warm while I view logs and tune).

I guess I've got other non-fun updates as well: turned my front rotors, replaced my rear pads, got a replacement set of bipipes in but yet to install (I had one of the very first sets from 3 or 4 years ago, and they are oddly shaped). Picked up some Y-pipes to finish development on the catch can. Yeah.

5/9/12

Random quick update. Met up with a buddy (Nvrsummer or something on here) with a VAST stage 3 S4 (~19psi, stock IC's, walbro 255 lemmi-tweaked) to go on a drive this last weekend. My car is currently still on stock fuel pump and ~15 psi boost, I've got a small vacuum leak at the DV, and my 3rd gear synchro is grind-y (these are the facts of the car, not excuses). Over the course of the drive we were able to do a couple of pulls. We did like a rolling 2nd gear and a rolling 1st gear pull for the legit pulls. He probably jumped ahead a hood-length for the first second or two, then it was pretty much dead even til the top of third, then I kept pull-ing a couple of cars by around the top of 4th (maybe even 5th?) before we shut it down. It performed almost exactly where I though it would, just about even with an average stage 3, then maybe pulling a little in the higher gears/higher RPM's. They were really casual runs and completely for fun; I'm sure neither of us had the ideal pull or our cars set up ideally. It was just the two of us, so no videos. Good times though. I can't wait to throw in proper fueling, turn up the boost and refine the tune more!

2/13/13

I haven't hooked up my fuel pressure gauge yet, but I have had a wideband on it since the beginning. I'm fine running on wastegate boost (~15.5psi), but when I increase it even to like 17 or so psi, it starts to lean out. So I've been waiting to install my pumps to push it any further, and I've got a fuel pressure gauge.

8/12/13

 Running good, been my daily driver coming up on 2 years shortly. Yup, still currently on the stock fuel pump while I finish up testing on the fuel lines/pumps setup I'm developing. Because of the stock fuel pump I'm only able to run wastegate pressure, which is around 16psi (probably around 375-400whp up here at elevation). Just loving driving it around daily at the ~stage 3 level for now, though I'm going to be cranking the wick up shortly as I have my fueling setup getting close to going in, 5 bar map sensor, and pretty much everything ready to rock and roll (other than a tranny that desparately needs to be rebuilt).

I really will update this thread in the next couple of days to show the finish of the build from 2012 and up til now.