Audi A4 1,8T B5, Aiming For 450-500hp, Build Thread - Off Topic My Ride - Automation

Audi A4 1,8T B5, aiming for 450-500hp, build t
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Audi A4 1,8T B5, aiming for 450-

500hp, build thread
Off Topic My Ride
hejpadig Feb '13
Hellu!
Posting my car here too.
Audi A4 1.8T ´95.
1.8T 4cyl Turbo engine, AEB.
Bottom end:
ARP main studs
K1 conrods
JE pistons, 81.50mm, 8.5:1 CR (first overbore)
Pro Seal pistonrings
ACL Race-bearings
Balanced and polished crankshaft
Glyco thrust bearings
Topp end:
AEB-head (ofcourse)
Victor Reinz headgasket
ARP headstuds
Supertech Valvesprings with Titanium retainers
Catcams 3658´s
Exhaust/turbo:
3" exhaust from turbo to back
Catless
3" straight through muffler
Precision 3431E (coming soon, the end of this month
Homemade exhaust manifold (coming soon…)
External wastegate, 36mm or 40mm.
Air/Fuel:
Autobahn88 Intercooler kit
VAG 115R coilpack
Nira I3+
Precision 990cc @ 3bar injector, low impedence
Deatschwerks DW300 fuelpump
Driveline:
Sachs PCS pressure plate
DLI-Teknik, singelmass flywheel, ~4,2kg
Balanced flywheel
Sachs PCS 4 puck solid disc
ARP bolts to flywheel
Autobahn 88 Shortshift
Chassi:
D2 coilovers, sport modified
Front strutbrace
034motorsport, front engine bushing with holder
034motorsport, engine mounts and tranny mounts
Weight: ~1140kg without driver (70kg) and with only
~10-15liter of fuel
Wheels:
IA B9 18x8" (BBS LeMans replica)
15mm spacers in the front
20mm spacers in the rear
Falken 215/40/18 ZE-912 WR tires
Brakesystem:
Goodridge steel braided brake hoses
Ferodo brake pads
Ferodo brake discs
Interior:
Autometer Sport-Comp - Bosst pressure
AEM - broadband lambda
Autogauge Black - oil pressure
Autogauge Black - oil temp
Sparco Sprint V seats
Exterior:
Stock, clean look… Un-riced.
Audi RS4 grill
Seibon hood
Goal is to make around 450-engine horsepower, and

maybe more.
It´s FWD though… hehe, highway killer?
And ofcourse… The car:
www1.garaget.org/archive/139/138112/194648/1946
48-2882682.jpg 268
48-2875981.jpg 26
48-2988225.jpg 9
48-3014746.jpg 8
www1.garaget.org/gallery/images/139/138112/13811
2-ce5c875e82bd03206e1ab55c349c7b3f.jpg 13
2-675f66b7940dc06ffaf979a00914a38d.jpg 14
Some enginebuild photo´s:
2-3a2c3003f27dc22c534103434ea66a15.jpg 68
2-195d9d1346eb00829636cedf21db80c7.jpg 6
2-c4d73b1072ab55a67412f1711ddaabc4.jpg 4
2-65fa3f293e423ff2b826bc016fa8dcbc.jpg 6
2-a91a379b43248f77cc58e751b7ba830e.jpg 3 ¨’
2-1c17aff9f75b59cdfa8680177d3d90b4.jpg 5
2-5d3e61d243fa18d76e826f065df3bd47.jpg 18
Exhaust cam. Catcams Vs Stock
2-a3ce06215a65826e9d972e55af514973.jpg 23
Intake cam. Catcams Vs Stock
2-4d21b1e947127a97b6e663c33a3c825e.jpg 49
This is where I am today.
Have fun!
created last reply 20

Feb '13 Sep '13 replies
22 days later
hejpadig Mar '13
Hellu
A small update.
I´ve now put off the cylinderhead again, I thought the
company who resurfaced my head had cleaned it
after, but they had not…
Thankfully I´m using ARP headstuds so I don´t have
to replace them.
So I need to clean the head and pick my valves. I´m
just waiting for my friend to get his tools back so I
can compress the valvesprings and pick them of
again. New headgasket again (OEM Elring) and
valvesteams being changed aswell.
Got a few parts for the engine and car, few more
things to get done befor I can start it.
I also got my package from USA, I finally recived my

Precision Turbo!
Pretty funny to compare the new turbo with the old
stock KKK-K03 turbo.
Enough with this english writing! Another update is

coming soon…
Some pictures:
2-98982de12a6616c24a1696d2a9d5944e.jpg 52
Cylinderhead is now removed again…
2-2a758b1bebf56f123a2da6f486e68091.jpg 4
Also got few parts from a friend. Tial-copy 38mm
external wastegate, woho! Filter and a ?idle-motor?
—> is it right?, from an volvo 940 ´95.
2-58ff915fd88a7be624af151dab55fe47.jpg 5
viscous fan clutch removed, using an electric fan
instead.
2-1c3bb94d7212e522c40e5e23c14cf387.jpg 8
Stock fuelpump removed and a Deatschwerks
DW300 (320 lph) is fitted.
2-7cc831995ce50604e39098f6657941ff.jpg 7
Finally found an magnetic oil plug on ebay in UK.
Was a pain the as to find here in Sweden, M26x1,5.
2-82008ca2b6451c449189df7d5ae5a18c.jpg 1
Nira EGTC
2-6a23b34ec1131841495c03cbf21147a6.jpg 22
Ahh… And the new turbo Precision 3431E ,63
A/R vs stock KKK-K03
2-4df9c7b01313093a3d84a5882aae7fad.jpg 17
2-2d5ab961fc5f82c89d655f1a6128198d.jpg 51
I hope you guys don´t mind that I put up alot of

photos… It´s easier for me to tell and show what is
done instead of writing it all down.
Hejdå, vi hörs lite senare.
Daffyflyer Mar '13

Developer - Lead Artist & Founder
Loving all the photos, and that’s one BIG turbo

upgrade
oxygen Mar '13
I fear that the drivability(?) of this car will downgrade

with turbo that big. Not sure how much though, but
i’m sure the lag will increase greatly. Not being a
judge here, i’m sure you know what you are doing.
LAG LAG LAG OMG SHIFT!
hejpadig Mar '13
[quote=“oxygen”]I fear that the drivability(?) of this

car will downgrade with turbo that big. Not sure how
much though, but i’m sure the lag will increase
greatly. Not being a judge here, i’m sure you know
what you are doing.
LAG LAG LAG OMG SHIFT! [/quote]
hahaha thanks!
Well… it isn’t the smallest nor the biggest. 3431E is
57mm in both the compressor wheel and the turbine
wheel, and I’m using T3 ,63 A/R Turbine Housing,
there is ,48 A/R aswell which would give faster spool,
but i’m afraid that there might be backpressure,
revlimit is going to be set at 7800 or 8000rpm.
The turbo has a horsepower limit or flow limit of
~545hp, according to Precision. If that’s true, i’m
about to find out.
I expect full boost somewhere between 3800-
4500rpm.
I also bought the catcams 3658´s just becouse I want

to get more horsepower like how you tune an N/A
engine. So my point is that if I can make 450hp with
Stock cams and the new turbo on (for an example)
on 2.0bars of boost, I want the cams to help me
reach the same horsepower but I can run 1,5bar
instead, becouse the cam´s are going to help me a
bit. So it doesn’t put so much stress on the motor or
the turbo.
Sorry if my english is bad, hehe but you probably

understand what I mean.
Nevermore1983 Mar '13
Great thread i been really interested in this one
thats one big turbo think i will be going for a hybrid

KKK-K04
hejpadig Mar '13
[quote=“Nevermore1983”]Great thread i been really

interested in this one
thats one big turbo think i will be going for a hybrid

KKK-K04[/quote]
Thanks, it´s great to hear that you like it!
Yepp, hehe. I think it will do the job pretty good. KKK-

K04 sounds nice, I had it last year in mine too!
It made quite a huge different to be honest, of
course… Anything can get better than the boring
K03, backpressure deluxe.
You won´t regret it, I think you´ll like it.
A clip from my Audi when we raced an Saab 9-3
2.8T, chiptuned aswell. It´s my friend´s car. (with the
K04)
youtube.com/watch?v=vwfTUwIyIB4 32
It ran quite ok…, had some problem in the begining

of the summer when I installed the K04. Since I was
running a software (BSR) which was made for the
stock K03, 283cc injectors and stock MAF, it ran
quite rich… We sorted the problem pretty well by
using a broadbandlambda and were using ~60% E85
(ethanol) and ~40% 98octane petrol. Unfortunately, I
didn´t record at the end of the summer when it ran
much better.
Nevermore1983 Mar '13
love Saab’s my dad had a old 99 turbo lag was so

bad every time turbo kick in felt like sum one had
drove in to the back of you. how much has all this
work on your a4 cost so far my s3 will be a very long
project i have very little cash to play with until my
business is off the ground.
hejpadig Mar '13
Nevermore1983:
love Saab’s my dad had a old 99 turbo lag was

so bad every time turbo kick in felt like sum one
had drove in to the back of you. how much has
all this work on your a4 cost so far my s3 will be
a very long project i have very little cash to play
with until my business is off the ground.
Not a big fan of Saab myself…

The k04 itself cost ~400$, it was a chinese-copy.
Total of ~1000$, I got most of the parts from my
friend.
hejpadig Mar '13
Hellu
I have not done so much with the car this week, just
a few things.
Me and buddy was on the scrapyard and got
ourselves a quite nice valve cover. Painted it with
some bodyspray (rust protection) with a very thin
layer, and after that i sprayed it matte black colour.
You get the rough surface.
I was quite puzzled about my clutch… I ran an Sachs

PCS pressure plate which is Reinforced with a 4puck
solid disc. The specs on the Sachs pressure plate
was: 365 lb/ft.
I will probably run a little more so I found a good
clutch kit on Ringer-Racing.com 1 in USA and they
had a Clutch Master FX400 kit for my car. Specs on
that clutch is : 445 lb/ft ~ 610nm.
Some information:
•Heavy-duty street & racing system
•Holding capacity 170% over stock
•Heavy-Duty reinforced pressure plate
•Hi-Leverage pressure ring design
•4-button pad
•Ceramic friction material
•SFI Approved on most race applications
I will soon post another update, my friend got his

tools back so I can pick off my valves again and
clean the head.
Befor:
2-34ae041ccd832c91901c3912226de130.jpg 6
After:
2-e268b0d08a24f1a30a5a46209e72e263.jpg 9
Looks quite good.
So that´s it, vi hörs lite senare. Ha det fint,

haaaaaajjjjjj!
14 days later
hejpadig Apr '13
Hellu!
So it was a while ago last time I posted a new

update… I´ve done a few things to the engine and
also the car.
I finally got the awsome-looking valvecover which is
coming from the AGN-engine. Smooth surface and
looks “clean”.
I got the tools from my friend and I took of the valves
and cleaned the head, the valves was fitted again
with new valvesteams.
The camshaft are set after original markings, I got a

little problem to find out how many degrees they are
going to be set to. Normally you would measure the
lift @ TDC, but it doesnt work cause the camshafts
are in the way, I´ve really tried…
Found a guide when a guy is using a Digital Angle
Finder to set the cams, which i´ve ordered now. Just
waiting for it to come how to its new happy owner.
The clutch isen´t far away now, it´s down in Malmö

(Malmo for you who don´t have the letter: ÅÄÖ…).
when the clutch has arrived I can finally put the
engine in the car
I also freshened up some parts of the car, painted
some brakedetails, drew new brake lines to the rear
calipers and next i´m going to remove the fuellines
because I need to go a little bigger. I need to go 8mm
all the way from the fueltank to the fuelrail. Stock is
(strangely) 8mm from the tank but under the floor it
runs down to 5,5mm. 450-480hp DOES need some
fuel, especially with E85.
Some pictures ofcourse!:
2-91e94f89f7e5a326c792e3f0edd8452d.jpg 7
More fun to work with when it´s fresh.
2-192a2d4d9cb71b307953bcbb0b4c4d66.jpg 3
2-547abb7d480e2a5cf7506eecfdc0e1cf.jpg 1
2-61b7b3e6471bdb4fbe41be312ce8cece.jpg 1
Supertech dual exhaust springs, titanium retainers.
Lovely <3 (Had it befor but got a picture of them
when I took the valves of again)
2-bddc48a5bb5b633d1dcdcfcae8bbe14c.jpg 1
Supertech intake spring, titanium retainers. (Had it
befor but got a picture of them when I took the valves
of again)
2-3195e5c7a028231a7a8b5429539808ee.jpg
Starting to look an engine again, some plastic covers
got cleaned after the pic.
2-8c84f817455429e254ca14cbb936499a.jpg
If you don´t have an exhaust manifold, you´ll have to
hold it like this…
2-65784238ae02edf93f8aa052e42e3d71.jpg 5
Finally found an AGN valvecover! Look awsome.
Det var det, uppdaterar så fort jag fått hem eller fått
gjort något skoj! Hejsvejs!
21 days later
hejpadig Apr '13
Hellu
Finished some more work with the audi. I´ve put new
fuel lines from the fueltank to fuelrail, 8mm inner
diamater and is supposed to work well with e85.
The engine is in the car now, finally. There´s some
small things I need to fix befor I can start it…
Starting to look like a car again.

Had a used trunk laying in my wardrob for about a
year, it was also red but it was in quite bad condition.
But my “original” trunk was rusty and I hate rust, so I
took it off… threw it away and plastidip´ed the other
trunk matte black and put it on. Looks good.
More updates is coming soon when i´ve finished

building a new exhast manifold and some other parts
Some pictures:
48-3079831.jpg 7
48-3090170.jpg 1
2-7e63f5ffcba1f6d2f91c57189f7cf9f8.jpg
2-c8bc65fbe06d890e6e472e44c05bb23d.jpg
2-b6b0cd3dd192ab8947f9f26bd6382b07.jpg
2-5d7c09781ff78a88e94975b545d132be.jpg
2-e3c1f3ce1a736bf18411fcb8c1374fb0.jpg
(The engine is not running, there´s no oil, coolant,
fuel, intake nor exhaust manifold)
2-a55dfa9b29da716f0cc9edf6b040c62a.jpg 1
I hope I wont use it…
2-f405ada5dbafee423435e67a4155294e.jpg 2
First time plastidipin´
And ofcourse… My daily driven car, though a 1.8 N/A

´97 with only 54725 miles on it and is like 100%
clean from rust. Was supposed to buy it from my
moms husbands´s mom which passed away a while
ago. He was going to sell and knew I was going to
take good care of it, I could only pay 250$ at the time
for it but got it instead as a gift on my 20years
birthday last year
Just one picture I got on it when I polished and

waxed it yesterday.
2-5e52c863629ee3ab128255ae22efd2c9.jpg 3
I know… I need some coilovers.
Hejsvejs era korvar!
13 days later
hejpadig May '13
Hellu
The project is moving on.
I have painted the intake manifold silver and I have

installed the fuelrail with injectors.
2-170c467cf3036ae2e6f8a80bbc3ec5fb.jpg 3
I have also started to build a exhaust manifold with

my friend. He is welding the pieces together.
2-e1f5482a5e3ab82e8c81a0dd5e97bef4.jpg
Started like this, I need to know where it would fit. It

was quite tricky to build it.
2-31808f0e77dc7862fce0916272318d01.jpg
How it looks like, just the 2nd and 3rd cylinderpipe

which is welded together to hold it in place so we
could check the clearence.
2-14d4d9fcf34e02d003c4905aae33426a.jpg 1
2-75b57ae9f6e66516f126bac756c8b1d2.jpg
All the cylinderpipes is done, I need to make an hole

for the NIRA EGTC sensor and weld on a pipe for the
external wastegate
2-967ade4dfcd404ee2d4096485ddce24a.jpg 2
Not the best picture taken…
I got some small things to do untill I can start it up.

x Build a new downpipe
x Draw new intercooler pipes from the turbo to ic
x Put on some vacuum hoses
x Fix some stuff with the electric
x Fit the airfilter somewhere…
And then I should be done to actually start it. Should

be done in 2-3weeks
Hejsvejs era luder! <3
21 days later
hejpadig May '13
Hellu!
Another small update.
Things is going quite well with the car now, just need
to finish with my downpipe and then I will put on the
front bumber and the headlights.
I have to finish some work with the electric aswell
befor I can start it, but maybe next weekend.
Some pictures:
48-3115052.jpg 3
I have moved over to new garage, a better one.
2-519cbf679da903a8d4b22f9358525500.jpg
I got a used steering wheel from my buddy, which he
had in his 200sx s13, garaget.org/?car=219130.
2-44d3523f4c7cb88d6bc04bea82462316.jpg 1
Tight fit in these nasty 1.8t´s …
2-310a2e3e2b9e0f93502ce41250f811a2.jpg 1
Everything is fitted just for the look, welding and
cutting a new downpipe…
2-589fea75087c13603f337fb39e5d20dc.jpg
Also welded and painted a new intercooler pipe.
2-d5ed19750c34a30506bfab1f453e0fa9.jpg
Lovely screampipe!
2-fc9bc9dbe7953b059c89aaa7216912e9.jpg 3
exhaust manifold is finished.
Tack för idag, hejsvejs
oxygen Jun '13
This is going to be MAD
hejpadig Jun '13
oxygen:
This is going to be MAD
haha thanks!
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Audi A4 1,8T B5, aiming for 450-500hp, build t

Off Topic My Ride

Automation Forum Rules

The rules below have been compiled by the

Audi A4 1,8T B5, aiming for 450-

hejpadig Feb '13

Posting my car here too.

Audi A4 1.8T ´95.

1.8T 4cyl Turbo engine, AEB.

Goal is to make around 450-engine horsepower, and

And ofcourse… The car:

Some enginebuild photo´s:

created last reply 20

hejpadig Mar '13

I also got my package from USA, I finally recived my

Enough with this english writing! Another update is

I hope you guys don´t mind that I put up alot of

Hejdå, vi hörs lite senare.

Daffyflyer Mar '13

Loving all the photos, and that’s one BIG turbo

oxygen Mar '13

I fear that the drivability(?) of this car will downgrade

LAG LAG LAG OMG SHIFT!

hejpadig Mar '13

[quote=“oxygen”]I fear that the drivability(?) of this

LAG LAG LAG OMG SHIFT! [/quote]

I also bought the catcams 3658´s just becouse I want

Sorry if my english is bad, hehe but you probably

Nevermore1983 Mar '13

Great thread i been really interested in this one

thats one big turbo think i will be going for a hybrid

hejpadig Mar '13

[quote=“Nevermore1983”]Great thread i been really

thats one big turbo think i will be going for a hybrid

Thanks, it´s great to hear that you like it!

Yepp, hehe. I think it will do the job pretty good. KKK-

It ran quite ok…, had some problem in the begining

Nevermore1983 Mar '13

love Saab’s my dad had a old 99 turbo lag was so

hejpadig Mar '13

love Saab’s my dad had a old 99 turbo lag was

Not a big fan of Saab myself…

hejpadig Mar '13

I was quite puzzled about my clutch… I ran an Sachs

I will soon post another update, my friend got his

So that´s it, vi hörs lite senare. Ha det fint,

hejpadig Apr '13

So it was a while ago last time I posted a new

The camshaft are set after original markings, I got a

The clutch isen´t far away now, it´s down in Malmö

Some pictures ofcourse!:

hejpadig Apr '13

Starting to look like a car again.

More updates is coming soon when i´ve finished

And ofcourse… My daily driven car, though a 1.8 N/A

Just one picture I got on it when I polished and

Hejsvejs era korvar!

hejpadig May '13

The project is moving on.

I have painted the intake manifold silver and I have

I have also started to build a exhaust manifold with

Started like this, I need to know where it would fit. It