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Steve's Megasquirted Audi...*mulling over 20v ghetto motor *

100K views 394 replies 64 participants last post by  cuatrokoop  
#1 ·
Hey guys. Thought I'd add my car to the project page.

Nothing really major being done to it at the moment.

I thought it'd be nice to have a section where I can keep track of the cars progress so here goes:

I bought this car 3 years ago from a guy named Todd W. who worked at APR in Alabama.

I took the bus down to Atlanta to meetup with Steve Jensen and he drove me to Birmingham to Todds parents house to pick up the car. Thanks Steve!

Here's the car pictured shortly after I got it back to Michigan:

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Car needed some serious attention to the paint as it was peeling in a bunch of different spots.

There were also a couple of dents. You can see in the second picture where the sheetmetal had sucked in when he rolled the rear fenders. Also the passenger door was a different color.

It also needed some suspension work, a headliner, the dash reassembled, a headlight, a new pressure plate, new drivers seat, hard start problem, new motor mounts, new turbo coolant return line,etc.

I had some work cut out for me.

It's wasn't all bad though. The car came with alot of parts and some interesting mods already done to it. It had a Intended Acceleration Stage 1 chip, Schrick 272 cam, A8 style 5 spoke rims, urS6 Eibachs, Boge TG shocks, upgraded turbo, stainless brake lines, etc.

It also had a fairly brand new out of the crate tranny and cylinder head which was good.

I had the car for a about a month when I had a engine problem creep up on a high speed jaunt on the highway.

I took the car over to Jim Bushs house for further investigation.

I lost the number 1 exhaust valve.
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I bought a new exhaust valve and took it to the local machine shop for testing, cleaning and repair for $80. Total damage was around $200 with all the gaskets, timing belt, etc I put on at the sametime. Not bad.

It was time for some more performance mods. First up I did a BPV. I used the TAP Samco hose with a Bosch 710 valve(know using a Forge valve)

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I the went ahead and put on some Bilstein sports in place of the Boge TG's. Instant difference in feel. The Bilstein sports with the Eibachs is a good combo IMHO.

Next up I had a Sach sport clutch kit installed.

Then I sourced a Euro spec 1B/2B single pass intercooler from Audi5turbotech.

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Here is a comparison pic of the 1B/2B and the stock dual pass IC.

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Installation was fairly straight forward. The only thing that needs to be modified to make the 1B/2B IC fit is some trimming of the front cross support.

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Here is a pic of the IC installed.

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A little later I upgraded the snub mount and snub mount bracket(not pictured)

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It was time to address the interior.

I replaced the tan comfort seats with some black sport seats from a 200. I also replaced the headliner and dash. I also added a Grant steering wheel, A4 knob and Autometer gauges.

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I then dyed my door panels from tan to black:

Before:
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After:
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I think they came out ok but are a little too shiny for my taste. I'll probably replace them at some point with some black OEM ones.

Anyways here's how the cockpit turned out:
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The paint was really getting on my nerves and my friend Dan knew a guy who paints cars on the side. He said he could do it for $600-700. I figured why not.

The car being reassembled after being painted by me, Jim Bush, Greg Jacobs and Dan Adams.

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The car with fresh Alpine White paint:
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It's not perfect but it looks good. Someday maybe I'll paint it again.

The car needed some different wheels so I bought these:
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RS4 reps in 16x7 35mm offset. I think they fit the car nicely.
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So thats how the car looked as of Summer 04.

During the fall I added a custom made strut brace:
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This helped tighten up the steering feel alot. I was skeptical but it works.

I then had to tackle a leaky gastank. The car had developed a small leak and I had to let it sit all winter into late spring.

I bought a used gastank from Chris at Force5. I took the tank to a local radiator shop that is a franchise for Gas Tank Renu.

They sandblast the tank inside and out and then coat it and bake it. Turned out pretty good and cost $300.

Recoated tank:
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Tank was installed and harmony returned to the universe. lol

Harmony was shattered about 2 months ago when I hit a huge piece of metal on the highway.

Bent rim:
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Everything turned out ok. I found a wheel shop not far from work who fixed the wheel for $75. Not bad.

I also bought new tires since the old ones were getting pretty old.

Thats it for now. More to come.

Steve
 
#2 ·
very nice, I really like all the detail touches here and there to get it to the car you really want. :woowoo:
 
#6 ·
newt said:
very nice, I really like all the detail touches here and there to get it to the car you really want. :woowoo:
Thanks Newt.

It's been a lot of hard work.

Steve
 
#7 ·
875ktq said:
Said to before, but really nice car Stephen! You bringing it to Carlisle this year?
Thanks Chris.

I'm gonna try to bring it out to Carlilse this year. It's not as nice as some of the cars that show up but what the heck.

Steve
 
#8 ·
scottmandu said:
I know that car! Me and Todd Williams ? Romped around Big D in the "Beast" he bought the new 200q transmission from me when I had a stockpile of them. Glad to see the car went to an enthusiast.
Yep, it used to be his car.

You must be Scott from Corpus Christi, TX?

Todd said he bought some parts off of you for the car. Tranny, V8Q rear diff, etc?

Steve
 
#12 ·
scottmandu said:
That would be me! How is Todd doing is he still at APR? Was the car perl white originally, or was it alpine?
I don't know. I lost contact with him. The last couple emails went unreplied and then I lost his email addy.

Last I knew he wasn't at APR anymore and was floating around Europe somewhere.

It used to be Pearl.

Steve
 
#13 ·
Dont let Steve fool ya, he keeps his car CLEAN! Whenever I see it or ride in it Im always impressed. He made me drive it over a year ago while coming back from the Mid Ohio ALMS race. All I remember him saying is "comon, punch it!" when I was too scared to :p .

And yes Steve, bring that thing to Carlisle this year, its gonna beee funnnnn. We will all have to get ice cream again, like last year.
 
#14 ·
Small update:

Installed some European H3/H4 headlights along with relays. It's nice to be able to see at night again.

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I also installed this Audi Sport steering wheel from the mid 80's. I've always wanted this wheel and found one for $50. Good deal.

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Steve
 
#19 ·
SteveAngry said:
Small update:

Installed some European H3/H4 headlights along with relays. It's nice to be able to see at night again.

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I also installed this Audi Sport steering wheel from the mid 80's. I've always wanted this wheel and found one for $50. Good deal.

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Nice car Steve! Looks great. And $50 for a Sport Wheel? bastard. Market price is like $300+

Good job-

Brandon

Steve
 
#24 ·
UPDATE:

Well the time has come. I'm finally ditching the CIS.

We pulled all the CIS stuff out last night. Suprisingly it only took about an hour.

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The only problem we ran into was when we removed the fuel injector inserts only the brass threaded part came out. The brown plastic pieces are still stuck in the head. Anyone have any good ideas on how to remove them without removing the intake manifold?

As for parts, the MS computer, Relay board, etc are already built. I still need to have the case cut for the LED's, etc...

These parts will be ordered tomorrow:

EFI bungs x 5
034 fuel rail kit
034 fuel line kit
Racetronix 42# injectors
Universal MS wiring kit
intake and coolant sensor
intake and coolant connectors
Bosch EFI connectors x 5
Braided wire shielding

I will still need to order a TPS, 02, and FPR. Anything else I'm missing?

I think I'll use a 7A FPR. Any problems or BTDT?

TPS: I might look for something in the local junkyard. Any BTDT.

02: I really want to go wideband. Most likely with a gauge similar to Innovatives or AEM's. Any BTDT?

Also, has anyone used 034's fuel line kit on a 5000/200? Does it have the correct fitting at the fuel filter and return? What are the sizes for each, anyone know off the top of thier head?

All BTDT appreciated.

Steve
 
#25 ·
SteveAngry said:
The only problem we ran into was when we removed the fuel injector inserts only the brass threaded part came out. The brown plastic pieces are still stuck in the head. Anyone have any good ideas on how to remove them without removing the intake manifold?
Nope, same thing happened to me, I popped them out when I pulled the head....but your probably going to pull off the IM to tap an IAT anyway?
 
#26 ·
SteveAngry said:
The only problem we ran into was when we removed the fuel injector inserts only the brass threaded part came out. The brown plastic pieces are still stuck in the head. Anyone have any good ideas on how to remove them without removing the intake manifold?
yes. take a coat hanger, cut it, fold it in a "U" shape. then turn the ends out, or also into "u"'s the other way. stick it down in there, hope the ends catch, pull like HELL!

SteveAngry said:
I will still need to order a TPS, 02, and FPR. Anything else I'm missing?

I think I'll use a 7A FPR. Any problems or BTDT?

TPS: I might look for something in the local junkyard. Any BTDT.

02: I really want to go wideband. Most likely with a gauge similar to Innovatives or AEM's. Any BTDT?
Ok for TPS, find something off of a 3b, aan, v8, 12v v6 etc...it will bolt up to the MC throttle body. get the wiring. all the saab and volvo's one's i've ever checked look the same and are only switches.

7a FPR will work fine, what size injectors are you using? you will have to have custom lines crimped using audi fittings off of an 80 or similar(7a). then the other side can go to AN for the fuel rail and you can get the fittings from summit to adapt the hard lines. 5/16th inch should work. about $10 each, you need to that have something that converts to -6an. Honestly it's almost easier to spend the 150 and get something that's AN for a FPR. then it's "done".

oh shoot, you only need 1 of those. there's an AN fitting that's 12x1.5mm and adapts to -6an that will thread into your fuel filter with a crush washer.

for 02, you can't just use a wideband sensor, you need a controller for it. your stock 02 will work fine for megasquirt in the mena time, cut the wire at the mac11 run it to the MS. be sure not to solder to the shielding.

are you doing squirt only? or spark too......this could greatly lengthen my list of answers! if squirt only, you can cut the fuel pump wire on the mac11 too and just run that to MS.

hth, i'm sure i'll think of more! 8)