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

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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
 
#178 ·
SteveAngry said:
That port looks factory. I have no idea why it's there. It's sure not there for the CO reading, since the OEM downpipe has the CO tube. Perfect location for a EGT...

Steve
Am I the only one that had my stock O2 sensor located there? Thats where I'm running my WB. (Yeah I know the life of the sensor will be degraded by placing it in a hot spot like that).

DP looks nice btw!
 
#179 ·
Ok update time, lots going on with the car...

Finally got the 3" downpipe to fit. We had to do some modifications to it for it to clear and added a extra 02 bung for a wideband guage. Here's what it looks like uninstalled:
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Also been working on the 3" exhaust I sourced from Hayden. Here it is cleaned up. We have since modified it to meet up with the downpipe. Still needs some tweaking. Better pics later:
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After some problems with oil consumption and smoking I've come to the conclusion it's time to swap all the old engine parts out and go with new/rebuilt stuff. So out comes the engine:
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The cylinder head. Some heavy carbon build up and oil. Gonna take it to the machine shop tomorrow to have it tested and priced out for rebuild:
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The stocker MC bottom end with 300+k miles. Still some cross hatching and a small ridge at top. It's getting tossed so I'm not gonna bother checking it out. I might pull the crank and pistons for the hell of it:
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I'll update later when the parts start rolling in and I zero in on what motor/turbo combo to use.

Steve
 
#181 ·
hey theremy name is Corey. ive got the same car except mine is a 1988 and is stock expect for the sound system and racing harness for safety reasons in regaurds to the lack of airbags. Im living in New York on Long Island and want to know if you can point me in any directions of where to get started with this car. I have done buisness with Chris at Force 5 for replacements parts. I have three main issues that must be fixed with the car first the electical system that seems to drain everytime i use the heat of rear defroster, the paint b/c its on its last leg, and of cousre the head lights b/c i want to see at night. HELP please!!!

BTW you have very clean ride. (id take it any day of the week)
 
#183 ·
#187 ·
FYI regarding that mc2 short block you have with pistons that are a bit TOO proud, the last time i talked with scott mockery about squish clearance, we were thinking maybe a diesel head gasket could be used to dial in clearance since they can be bought in different thicknesses. i never looked into it but if the bore diameter is right and the other stuff lines up maybe it would be perfect for you.
 
#188 ·
I just noticed this the other day. Runner #2 is totally caked with a black film. I can't tell if it's oil or carbon.

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My first thought was maybe a injector was stuck on but the manifold is before the injector so that can't be it. Could it be a leaky valve seal that caused this?

For those you haven't been following my soap opera, I was having very bad oil smoking at idle. Any BTDT?

I did recently have the head tested and new valve seals put in. The guides and valves speced out.

Steve
 
#190 ·
Something maybe warped. even if the seals are new, the part that is warped maybe letting oil through

so heres what im thinking when the engine is cold the metal is contracted and any spaces are or gaps are open. when the engine warms up the spaces and gaps close creating a good seal.

What i need to know is this only happening at idle at start up before the engine is warm and did you use that red die to check for cracking.
 
#191 ·
is not there an emission related hose or something the plugs into the manifold about right in line with number 2 cyl? i would guess that is causing this tracing and i would guess everybodies engine looks the same way or there is an issue related to that hose and that is your oil consumption problem. i am just throwing ideas out there :) but this is off the top of my head so check it out for yourself to confirm.
 
#192 ·
Update time...

Drove out to Ohio and picked up Eric's freshly honed and tanked MC short block:
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Cleaned up and freshly ringed pistons:
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Dropping the pistons in:
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Pistons in:
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Box of powdercoated goodness:
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Got parts?
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New oil switches, thermostat, idler, water pump, etc...
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More later...

Steve
 
#200 ·
cuatrokoop said:
Hey Steve, the one pressure switch you replaced drives a VDO oil pressure gauge...I'd run a gauge if you aren't, especially on a fresh rebuild...That's why I gave it to you instead of keeping it as a spare :wink:
Yeah, I wasn't sure if it worked or not.

I had new switches anyways and figured I'd throw them in for now and shop for a gauge in the meantime.

If you're sure it worked, then I'll most likely look for a used VDO gauge from a B3 or something and use that to monitor oil pressure during break in.

Steve