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Pops' 1997 S6 2.5L Stroker - RESURRECTION BEGINS

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 Post subject: Pops' 1997 S6 2.5L Stroker - RESURRECTION BEGINS
PostPosted: Sun Dec 19, 2010 10:53 am 
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First off we'd like to thank the following people for their input/help so far: Marc Swanson, Dave Jones, 034, Eurospec (see post), [email protected], and Mike in Buffalo

I'll be adding more to this later (with pictures of progress and more deets), but for now a quick history:

My dad has owned URS cars since 2004, when he picked up a bone stock 96 Europa/Ecru sedan. From there he bought a 95.5 Green/black sedan with an RS2 6 speed, MTM 2+ (chip, 3bar MAP, RS2 mani), suspension, and brakes. We swapped all the goodies to the 96, and then he sold the green car. Things were fine for a while, but then my little sister crashed the 96. Thankfully it was a low speed crash, but still needed a bumper and some other front end stuff. The car has been patiently waiting (as have I, as I'm inheriting it). Then he picked up a 1997 S6 which was owned by the owner of Competition Motors in Belleville, Ontario. The car was fairly heavily modded by Dave Jones and Autosport Werks, using an ITS T04E/K26 46 trim turbo. Dad took the car and added VEMS, larger injectors, and the plan was an FMIC before //S-Fest last year (specs in sig here). The FMIC didn't arrive in time, and on the way home from //S-Fest he lost cylinder 3. Made it home fine, just slowly. Just before //S-fest, he picked up a spare motor which had a basically brand new head on it - less than 500km on it, was replaced by dealer for $3800 by the PO. Then he crashed the car.

The plan:

Full boost at 3800rpm was okay, but dad wanted the car to be a bit more street friendly. And he likes the idea of having something unique. So, the hunt for a 92.8mm crank began (after doing quite a bit of reading we decided it would be the best and easiest solution for a stroker). Finally, one was acquired through Eurospec after a huge runaround of "no we don't have any 92.8s" and "yeah, we have one. We'll ship it out" and "no we don't have any cranks, we swear!" - just crazy stuff. Got the crank shipped to Mike in Buffalo who picked up lowlyoilburner's GT42R'd 550whp S6. That was a fun ride! Anyway, the plan is to build the spare motor to the same spec as the one in his 97 now, but as a stroker and then swap it in.

Specs:

VEMS
92.8mm stroke crank
SCAT rods (moving to a new set of 160mm rods)
83mm coated pistons (moving to Weisco)
copper 83mm head gasket (moving to bored MLS)
ringed block (moving to tall block)
Wagner Sport Quattro exhaust manifold (moving to Hank's)
Comp Turbo CT3-6465 triple ball bearing/billet turbo w/ v-band outlet, 1.0AR (swapped to .82A/R)
N75 operated Sound Performance Quickspool valve
AEM dryflow air filter
ARP head/main studs with new bearings
ID1000CC injectors
044 fuel pump
7A cams
NEW head with lightweight lifters (less than 500km on it, PO then totaled car)
ported head head/intake mani
custom 3" downpipe (moving to Hank's)
034 phenolic spacer
big FMIC
South Bend stage 4 clutch w/ 7A flywheel - 900ftlb!
034 catch can
entire build cryo-treated
AEM water/methanol injection

Won't be high revving so valvetrain stuff isn't needed.

Comments and suggestions welcome!

Album of pictures of work completed on 97 pre-//S-Fest: linky
Album of pictures dedicated to stroker build (only "joke" pix so far): linky

_________________
Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


Last edited by chaloux on Wed Dec 05, 2012 10:08 pm, edited 31 times in total.

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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 10:53 am 
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Update on the cause of no cyl 3, some more turbo info, and pics of build bits :)

when we pulled the head, this is what we found:
Image

Image

brutal. Not sure exactly how it fried, a few things were suggested on QW, one of them being a crap injector. Those will be tested/balanced before the rebuild. Now onto the GOOD stuff :)

JE 83mm pistons, coated obviously
Image

The lifters out of the "old" head and the new one - both ended up weighing around 67 grams with oil. 034 says lightweight are 63 grams and normal are 85. Nice that these were free!
Image

Ahem... hard to admit this one. Note: shaft threads MAY be reverse. Do not talk about stuff while taking apart. do not assume it's a locking nut. Lastly, check the dang threads!
Image

Other than that, we found some interesting info on the coldside after measuring:

inducer: 50.8mm
exducer: 74.9
trim: 46

Based on this site, it is a T04E 46 trim (map link). Anyone have any experience with these/know what they're capable of? I found one site that said 300-420whp... great. lol.

Current status of the build is: block being sandblasted, then everything goes off for cryo treatment! Then the block should be bored/skimmed soon after.

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


Last edited by chaloux on Mon Jan 10, 2011 8:25 pm, edited 1 time in total.

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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 10:53 am 
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kickin' tires'n lightin fires
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*reserved*

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 10:53 am 
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*reserved*

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 10:53 am 
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*reserved*

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 10:53 am 
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*reserved*

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 10:54 am 
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kickin' tires'n lightin fires
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*reserved*

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 10:54 am 
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kickin' tires'n lightin fires
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*reserved*

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 10:58 am 
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Location: Lee, NH
box of goodies for the build shipped yesterday, BTW :)

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90 CQ 4.2 V8TT
83 UrQ
95.5 //S6 Avant
93 //S4
97 F250 Diesel
Can you tell I like turbos?


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 11:01 am 
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Thank you Marc, I'm sure we'll be sending you an email or two. And thanks for the consulting w/ VEMS and everything else thus far. It seems like it's been taking forever, but hopefully it'll all be wrapped up quickly now that the parts are starting to come together :)

_________________
Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 11:44 am 
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I am following this build! Major S6 fan here.

Why is there so much rust?

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96 Audi S6 20vt sedan auto, PRJ chipped.
95 Audi 80 converted to Quattro + AEB.


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 12:37 pm 
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ChrisAudi80 wrote:
Why is there so much rust?


96 and 97's are normally from Canada IIRC...

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Build Thread Here


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 1:16 pm 
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Mmmmmmmmmmm salty Ontario.

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Dec 19, 2010 2:45 pm 
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Joined: Tue Jan 13, 2009 8:51 pm
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Location: Ottawa, ON
sweet!!!

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95.5 S6 - 160000mi - 3071R
94 S4 - 352000Km - soon to be in pieces
85.5 944 - spun bearing = slow
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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Sun Jan 02, 2011 10:04 am 
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Made some headway with cylinder 3 yesterday and this morning. We changed the batteries in the fiber optic scope and took another look at the cylinder and top of the piston. On the exhaust side it looks like there's some deformation. We hooked some air up and can feel air coming out of the exhaust. We're pretty sure without absolutely knowing that it's an exhaust valve that burnt up, but we're going to be taking the head off tomorrow to find out. Tomorrow we also plan on prepping the block (sandblast, POR20, skim). Pictures to follow!

_________________
Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Thu Jan 06, 2011 5:11 pm 
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Whats the update Matt? Seen the shots of the valve on qw. When do you two plan to assemble the motor?


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Mon Jan 10, 2011 8:26 pm 
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Not exactly sure what happened with the valve. Right now the block is being blasted, then everything will be cryo treated, then painted/assembled after the block goes for boring/skimming. See post up there for pics!

_________________
Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Mon Jan 10, 2011 10:07 pm 
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where do you get the cryo done? and is it a euro van crank?


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Tue Jan 11, 2011 7:12 am 
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We have two options for cryo in Ontario, but I forget what they are off the top of my head. One is in Toronto and one is near Niagara. I think for the entire engine in pieces - everything we can throw in there - it's $850.

_________________
Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Tue Jan 25, 2011 12:24 pm 
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Just a small update... currently talking with Marc about going with Comp Turbo, the SQ manifold, and a quickspool valve. We'll see how everything turns out :)

Block is now bored and ready to build.

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Tue Jan 25, 2011 1:13 pm 
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Awesome... soo looking forward to the build

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Build Thread Here


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Tue Jan 25, 2011 1:25 pm 
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quickspool valve 8) very cool, will be watching this!

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Current Attire:
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Past Affairs:
-1991 Audi 200 20vt - GT35 and 24psi
-1991 Audi 90 20v
-1985 Audi 4000CS quattro
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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Wed Jan 26, 2011 9:49 pm 
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build specs updated above... :)
Image

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Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Mon Feb 21, 2011 9:16 am 
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Just a quick update - Marc finally has all of our stuff to ship to us! Except for one little thing... Comp sent the turbo with a divided T4 housing. LOL - of COURSE they did!

So the entire order will probably ship to us by mid week. I asked Marc for a pic of the turbo... we'll see if he can find some time to take one :)

Also, dad's been busy getting a Saab 9-3 ready for my mom to drive will the rest of the build is finished. This is why there's been no progress on the stroker. Soon there will be pics of the head porting and intake manifold cleaning out. Also of the block once it finally gets o-ringed, as that's all it needs before it can be rebuilt.

_________________
Matt

04 Jetta TDI - DC stag I clutch/14lb fw
96 Audi A6 Avant 2.5l TDI - RocketChip tuned
SOLD :( - 87 4ktq - 4 FOX SNAKES
DEAD :( - 1996 S6 mit TDI
Image


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 Post subject: Re: Pops' 1997 S6 2.5L Stroker build
PostPosted: Mon Feb 21, 2011 9:43 am 
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Location: by the lakeshore, mi
Sweet! Cant wait to see everything come together.


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