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URS6 + 4.2T Now Running

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 Post subject: URS6 + 4.2T Now Running
PostPosted: Sun Sep 15, 2019 8:14 pm 
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Not too long ago I finished my 6sp RS6 and filled with boredom I bought a URS6 to build... It's became apparent I need to sell one or the other, and for some reason I just can't let the wagon go, so.. I'm going for best of both worlds if you will. Here's the game plan.

BCY Engine w/ custom frame rail mounts.
Custom headers + 6766 top mount turbo
SteveKen Manual Trans Adapter kit
Ringer Racing Stage 4+ / Ringer Racing Twin Disk (Undecided)
Twin Walbro 450 Fuel Pumps
1000cc injectors
Stock Motronic 7.1.1 / Engine harness

Goal is 700-850hp on the stock RS6 engine, fueling and turbo may change down the road but this is what I'm planning for #'s wise.

Tonight I went ahead and pulled the AAN engine, and I will update as I go along.
This isn't going to be another forum usual "This is the plan", then you guys reply "It's stupid, you won't follow through", and then you guys never hear from me again type of thing... That being said, college is in full swing and work has my balls tied up right now, so it will probably be a while before I get down to the nitty gritty of it all.

AAN came out tonight... already spoken for, but I will have the engine harness and MTM Stage 1+ ECU for sale.

Image20190623_212831 by Joel Francisco
Image20190914_164726 by Joel Francisco
Image20190914_164715 by Joel Francisco
Image20190915_194829 by Joel Francisco
Image20190915_194838 by Joel Francisco
Image20190915_194852 by Joel Francisco

So much room for activities!

Image20190915_201407 by Joel Francisco

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Last edited by jolio1994 on Tue Mar 31, 2020 1:13 am, edited 1 time in total.

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Sep 16, 2019 7:26 am 
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This is nuts, looking forward to your progress.


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 Post subject: URS6 + 4.2T Now Running
PostPosted: Mon Sep 16, 2019 7:40 pm 
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So I went on a 7 hour adventure to Pennsylvania today to pick up this bad boy.

105,xxx miles with harness and ecu. Will need the timing belt serviced which I am no stranger to. Next on the list is the SteveKen Adapter Kit and I can start mocking everything up.
Baby steps

Image20190916_165154 by Joel Francisco

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Last edited by jolio1994 on Sun Mar 29, 2020 6:14 pm, edited 1 time in total.

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Sep 16, 2019 8:28 pm 
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Damn Joel, where in PA did your u go for that?

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Sep 16, 2019 9:54 pm 
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Dave, it was all the way out in Hershey, PA! Philly traffic didnt help one bit man! Hopefully this is the last of the whole "Day tripping it to pick up car parts".

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Sep 16, 2019 9:59 pm 
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Haha, I was there too today! Had to take Mom to the Penn State Hershey medical center. Spent way too much time nearly falling asleep in the waiting room! If you ever come out this way again, hit me up!

Oh, and yes! Philly traffic can really suck!

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Dallastown, PA
1991 Audi 80 quattro (10vt project)
1991 Audi Coupe Quattro (my first 20v)
2007 Mitsubishi Raider(Dakota in disguise)
2019 Chevy Cruse Hatchback RS (wife's new ride)


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 Post subject: Re: uRS6+ Build
PostPosted: Wed Sep 18, 2019 6:10 am 
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Well. This isn't going to suck.

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 Post subject: Re: uRS6+ Build
PostPosted: Wed Sep 18, 2019 7:28 pm 
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Interested in seeing your progress with this.

I've not heard of anyone putting a rs6 engine in a urs6, normal v8's yes. Have you thought about remote turbo's like 'project judas'

not sure on the power of the urs6 5 speed box but a 01e 6 speed should hold the power. Been a while since I had my urs6.


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 Post subject: Re: uRS6+ Build
PostPosted: Wed Sep 18, 2019 7:42 pm 
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It will be the first Single turbo BCY swapped into the chassis let alone the first on stock Motronic and ECU. I considered two top mounts, but decided on the single top mount to keep everything as simple as possible.

I have a wide 1st in my 01e, and I fully intend to run the stock 5sp as is. I have a stock 6sp 01e in my RS6 and it's amazing the difference/feel the linkage and shift box alone can make between the two.

My RS6 breaks traction in 2nd gear with 255 Conti S tires and that's at a modest ~500hp, I'm curious to see what happens with a 225 at 750hp. Something I will need to address later.

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 Post subject: Re: uRS6+ Build
PostPosted: Thu Sep 19, 2019 7:05 pm 
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Got it on the stand today. Timing appears to be perfect with the cams and crank locking together. Now I get to take everything off.

After that I guess next on the list is to get the SteveKen adapter, and bolt it up to the car/make some mounts. Gotta sell the RS6 first...

Image20190919_174938 by Joel Francisco

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Sep 23, 2019 3:50 pm 
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First update of the build!

https://www.youtube.com/watch?v=9P2TXkXRW6g

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Sep 23, 2019 10:49 pm 
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Gotta love the safety mandles...

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2007 Mitsubishi Raider(Dakota in disguise)
2019 Chevy Cruse Hatchback RS (wife's new ride)


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 Post subject: Re: uRS6+ Build
PostPosted: Thu Sep 26, 2019 7:38 pm 
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So one of the biggest issues I see myself facing with the swap is that our cars use a throttle cable rather than the 4.2 BCY engine which uses drive by wire.

I want to keep everything on the engine side of things as factory as possible so, I guess I'll need to buy an entire C5 A6 (again) to aid in the swap.

Has anybody ever tried this before? I know I'll need the C5 pedal assembly, master cylinder, brake booster, and everything in between them. Furthermore, I'll be swapping over the entire gas pedal + OBD2 wiring assembly to try and make everything work.

This should(not) be fun at all... lol

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 Post subject: Re: uRS6+ Build
PostPosted: Thu Sep 26, 2019 10:45 pm 
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D2 uses a potentiometer that converts a cable pedal to electronic throttle. Could possibly use that to keep the C4 pedal and use the C5 ECU.

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Oct 21, 2019 8:01 pm 
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The new owner of the RS6 came by Friday and drove it 3 hours home, he had nothing but great things to say about it; very happy it went to a great home. Now I can dive deeper into the URS6. I already had the Ringer Racing Stage 4+ Clutch come in, so my next purchase will be the Stevenken Adapter Kit; probably later on this week I'll order it.

I did pick up that A6 (Yes, another Blue 2.7T 6sp that'll serve as my donor for the electronic throttle pedal and OBD2 system. My dad is in need of a good 01e for his B5 S4 as well as a spare 2.7t that he can build on the side for when he throws a rod on his K24'd car. I'm going to give him both, but debating if I should pull it and freight it to him or just drive the car down to my parents house in GA and part it out down there, either way I'm hoping to get the "Son of the Year"Award lmao.

Moved the cars around today and pulled my back out trying to get the A6 to move with rusted e brake and a non functioning starter. Bad idea on my part.. but the S6 is in the garage now. Stevenken Adapter -> Bolt up to the 01e in the car -> Make some engine mounts.

Image20191021_102640 by Joel Francisco

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Nov 04, 2019 2:45 pm 
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The adapter plate has been lost in shipping (thanks UPS), all you had to do was ship it from Pennsylvania to New Jersey and you f*cked it up. Still trying to push ahead to get a better understanding of what I need.
-Those 40v NA headers I bought aren't going to work so It'll have to be tubular coming up from the side of the heads into a 4-1 collector on either side.
-Going to need some really really small engine mounts and while I'll be using the stock engine mount bracket points on the chassis, they're pretty much going to be laying on the subframe above the swaybar.
-Coolant crossover needs to be cut so I can route it away from where the exhaust manifold will come up.

Placement isn't finalized and will change slightly, but this is where I stand (for the most part)

Image20191104_150947 by Joel Francisco
Image20191104_151027 by Joel Francisco
Image20191104_150812 by Joel Francisco
Image20191104_150804 by Joel Francisco
Image20191104_150840 by Joel Francisco
Image20191104_150852 by Joel Francisco
Image20191104_151600 by Joel Francisco
Image20191104_151122 by Joel Francisco

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 Post subject: Re: uRS6+ Build
PostPosted: Tue Nov 19, 2019 4:36 pm 
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Adapter plate came in today... I guess I know what I'm doing this weekend!

Image20191119_181022 by Joel Francisco

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 Post subject: Re: uRS6+ Build
PostPosted: Wed Nov 20, 2019 7:39 pm 
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this should be interesting!

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 Post subject: Re: uRS6+ Build
PostPosted: Sun Nov 24, 2019 7:28 pm 
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It kinda fits! Had to cut out the subframe, but it's in there! Practiced making an engine mount bracket and it came out pretty damn good I think. Full penetration on the first practice piece, it's solid as a rock. Yes I know I need more practice, but hey this entire project is a first for me. I'll be moving the plate down 2" on the final piece to add a bushing but:
A. I'm still looking for something suitable (Any mounts that would work given the clearance would be greatly appreciated)
B. I just need something to begin tubular header and turbo mock-up.

Image20191124_115220 by Joel Francisco
Image20191124_134355 by Joel Francisco
Image2019-11-24_09-18-54 by Joel Francisco
Image20191124_200702 by Joel Francisco
Image20191124_200714 by Joel Francisco
Image20191124_201253 by Joel Francisco

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 Post subject: Re: uRS6+ Build
PostPosted: Mon Nov 25, 2019 9:51 pm 
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I finished up the passenger side mount, and the engine is all bolted down and what not. Now to wait for Black Friday turbo sales and hopefully even an exhaust manifold kit sale.

Image2019-11-25_10-40-31 by Joel Francisco

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 Post subject: Re: uRS6+ Build
PostPosted: Wed Nov 27, 2019 1:38 pm 
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Holy cow this is a wicked project and I can't wait to see it done!

Did you reinforce the subframe that you cut out for clearance for the engine?


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 Post subject: Re: uRS6+ Build
PostPosted: Sun Dec 01, 2019 3:17 pm 
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Haven't done it yet, but to reinforce it I will most likely cut the whole section out... weld end plates to either side, and then a 2 1/2" Steel Tube in between it.

Little small kinda big update, but will add when I get everything in; Black Friday was very kind to me.


Two Mishimoto 12" Slim fans
Mishimoto 19 Row Oil-Cooler
Mishimoto R-Line Intercooler (Big Boy)
Tial 44mm MVR Wastegate
Tial Sport Q BOV
Stainless 304 Audi 4.2 Exhaust Turbo Header Kit
Dual Ball Bearing Billet T76 T4 .81 A/R Turbo

https://www.youtube.com/watch?v=4sq2S5jda-I

Image20191201_155331 by Joel Francisco, on Flickr

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 Post subject: Re: uRS6+ Build
PostPosted: Tue Dec 03, 2019 7:36 pm 
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Cant wait to start making the manifolds!

Image2019-12-03_09-33-02 by Joel Francisco

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 Post subject: Re: uRS6+ Build
PostPosted: Wed Dec 04, 2019 6:31 pm 
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kickin' tires'n lightin fires

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jolio1994 wrote:
Haven't done it yet, but to reinforce it I will most likely cut the whole section out... weld end plates to either side, and then a 2 1/2" Steel Tube in between it.

Ah ok.

Oh wow that's a huge snail :woowoo: I'm very curious how your going to fit the turbo under the hood especially as a top mount setup.


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 Post subject: Re: uRS6+ Build
PostPosted: Wed Dec 04, 2019 9:59 pm 
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Under the hood?! You crazy?

It's going to be completely out of the hood because quite frankly... theres no room and why not! Haha. But in all honestly theres just really no room.

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