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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
 
#302 ·
Gonna try and make Motorstadt-- would be nice to catch-up with people I haven't seen for a while.

Everything is going well-- staying busy. My second son is due April 4, and the other little monster is getting bigger by the day. Helping out with a bunch of cars around here, and working on the Rabbit when I can. Got it out last year for Waterfest. If you want to read the whole adventure, you can check it out here:

http://forum.vwsport.com/viewtopic.php?t=24832

How is the 5000 doing?
 
#303 ·
Work continues...

New 034 efi silicone hose kit installed.

Throttle body hose:
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Crankcase hose:
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3way valve cover hose:
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Picture's for the hell of it:
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Next week the headliner gets replaced. I'm tired of the sag.
 
#305 ·
More progress from the last month:

New OEM windshield scored for $50:
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Getting ready to pull the windshield:
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Watching the guy pull the windshield made me cringe:
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New windshield installed. So nice and clear:
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Black trim instead of chrome:
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Woot!
 
#307 ·
Redid the front and rear brakes also. Figured it was time to throw the bigger 20v rear rotors/calipers on:

Box of assorted brake goodies:
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Studs and 5mm spacers for later:
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91 200 20v vented rear rotors vs 10v solid rotors:
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Installed with used V8q calipers:
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Steve
 
#309 ·
I also installed this used TAP strut bar I bought from Jeff(birdmanmt) last winter.

I've always thought it was a very nice piece. It's very lightweight and seems to stiffened things up nicely.

I'll probably powder coat it black later. Or maybe I'll leave it silver. What do you guys think?

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Steve
 
#311 ·
a_CQ said:
That looks Great!! I almost forgot about your car, you don't drive it much, do you? (judging by the pristine clean coolant bottle;-))

But did you get those studs in? They look awfully short!
It's my current daily driver.

Yeah, the studs turned out to be duds...too short. I bought them in a group buy 2-3 years back and that was the size suggested I should use.

Meh, I was looking forward to having studs.

Steve
 
#316 ·
cuatrokoop said:
Steve, you about finished with the WBO2? Is the sensor still alive?

Car looks great though!
No, not done actually. PM coming your way.

Steve
 
#318 ·
Mark Morris said:
Looks great Steve. I'll be in Kalamazoo for a week around July 4-- maybe we can get together sometime while I'm there.
I'd like to meet up if I can get some time away from work. I haven't seen any of the K-zoo guys in a long time. Hell I don'tt even see the GR guys much anymore.

The Waterfest adventure with the Rabbit looked like a good time. :p

Take care Mark.

Steve
 
#319 ·
cuatrokoop said:
No worries! Just like to know it's whereabouts :)

You never notice the chrome trim around the windshield until you remove it. The black just looks, almost weird! You just get used to seeing something...
Cool, cool. Give me a heads up when you need it back.

I really like the black trim instead of the chrome. It almost makes me want to black out all the trim but it's too much work.

I wish all the trim pieces were metal so I could just powder coat everything and be done with it.

Steve
 
#321 ·
SteveAngry said:
I'd like to meet up if I can get some time away from work. I haven't seen any of the K-zoo guys in a long time.
The Waterfest adventure with the Rabbit looked like a good time. :p
We'll make it happen. Email me your number: mmorris@chainconnection.net

Waterfest was an adventure-- I'll be there again crewing for a different car-- look for me in the pits if you make it out to NJ.
 
#326 ·
cuatrokoop said:
I think he did replace it, otherwise you can use straight Simple Green and make them look nearly new (95% or better).
Yep, replaced it about a year ago or so.

Minor update: I picked these wheels up a couple of years ago with intentions to use them on the 5000 one day.

These Are Zender Challenger wheels 17x7 with a 45mm offset. I was thinking of powdercoating them black...or maybe leaving them silver???

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What do you guys think? Hit it or keep the current RS4 wheels?

Steve