Eurotrash Motorsports - B4 20VTQ Avant - v2.0

[NiTeC]

did some investigative work in the quattro swap direction...

1. the shocks mounting is identical between the FWD and quattro chassis
2. looks like the shocks themselves are identical as well - the quattro version has them slightly twisted but the setup looks the same - this makes things very easy because it looks like when it comes to shocks and springs a FWD and quattro cars have identical setups...this also means I can now use springs off a quattro car...the "FWD" version is not available in NA
3. there are 4 attachment points to the 'quattro' part of the equation - you all knew that already...the question was whether everything quattro will swap directly over...after a good hour of staring at the four bolts it looks to me that 2/4 bolts match...the back two holes need to be drilled/tapped into the frame...everything else looks identical
4. can't see much with the fuel tank in but looking from the top the floor plans look the same so i`ll assume attaching the back end of the quattro should be rather trivial

here are some pictures (it was very tight under there...i`ll def undo both back ends and at least mock up a swap...

FWD - passenger side - looking from the back towards the front - this is where the back quattro bolt should be..I was hoping the bolt holding the exhaust hanger will match up but no dice...the diff mount sits forwards of this bolt...


couple of shots of the front subframe mount on the FWD...there are 3 bolts holding it to the chassis...the bolt on the left matches the front diff mount bolt...looks like this one will be plug and pay...



the quattro front bolt:


same bracket on the passenger side:


and the quattro version:


the quattro setup is very 'busy' making it hard to take good shots and measurements...it will be easier to just drop everything down and mount it up on the FWD to see how things look...I am guessing that will be done next week at some point...

meanwhile got some shocks installed while I was under there...everything off:


the back installed:


the front will need a few parts - most bolts were seized and I had to cut a few things off...I`ll be needing new sway bar links and I figured I`ll change the tie rods while I`m in there...it also looks like the shock bearings up top are in need of refreshment...

overall - good work today

[NiTeC]

well....this was a busy day got lots done and lots more to go...

as promised this weekend was devoted to the quattro swap so here we go...

8am...."ahhhhh shit...the shock mounts are different..."




well this project ended up quite quickly...

wait...what's this?



looks like Audi in their infinite wisdom decided to put the holes just in case so I have a 'universal' bolt pattern meaning I can put in the FWD rear shocks or the quattro rear shocks...


k...the shocks are out...clearly different even though they looked pretty close while installed on the cars...


what's next...well let's drop it all down...


you can kind of see where the front diff mounts align with...


it's the right hole here:


these holes are already there...the back I thought was going to be a little different, however I tried the screwdriver trick again and guess what - the holes are there




all right - let's sum this up....the shocks mount 100%...the two front diff mounts bolt directly to the body...the two back diff mount holes are there but there's no thread...it looks like the floor is right above that which means we'll need to cut the floor up a little bit to get access to the top of the holes...I'm thinking of simply welding a nut there or something...

here are the two floors:
Quattro:

FWD:


here are the two tanks:
Quattro:

FWD:


some minor differences:
Quattro:

FWD:


Quattro:

FWD:


and mandatory quattro shots:



still to do:
1. fab up mounts for the front diff support - not existent on the FWD floor plan
2. fab up mounts for the drive axle bearing
3. swap the transmission
4. enjoy quattro

I`ll have to source out the tank supports for the quattro - the ones from the sedan were completely rusted through...also I've have to refresh everything up at the back...perhaps a sway bar that's thicker than a pencil...

so there you have it folks...quattro swaps - no big deal...

[NiTeC]

some engine work...




I`ll try to finish most of it by the end of the week...still stuck with the head issue...waiting for a call from the shop today...got the call that the turbo was refinished at GPopShop - picking it up on tuesday...

[NiTeC]

mmmm spare parts




do you think my mom will flip when she sees the driveway?


and thumbs way up for the work Jim and Gary at GPopShop did...






let me remind you how it left my house:

[John Powell]

Mothers are nothing, wait 'till you get a ... wife!

[NiTeC]

the shop asked me to get the tranny to them so they can make sure everything is aligned properly...so I took it out



let's play a game I like to call 'what did this tranny come from'





some more work:

waiting on a gasket or two to finish the bottom end completely...



meanwhile got the wastegate off the manifold and managed to clean everything up...

everything was insanely rusted...I wonder if I can still use this diaphragm...


some parts ready to go - just need the head now...




I`ll try to get the gaskets tomorrow...as soon as I mount them up, I`ll get the clutch on and mount the tranny...then I`ll have to wait for the welding to finish for the quattro and then everything is going in...my hope is to have everything finished by the end of June except the head...waiting on a quote from Sam@034 for a complete rebuild and 7A->AAN conversion...I`m done playing around with this - not much time left - I still need to test this car out before we head to Targa...

[NiTeC]

here's today's progress:

took the 7A pan off and cleaned it up as much as I could...


added the AAN baffle...



mounted on the engine:

block->gasket->baffle->gasket->pan (a little bit of a weird design IMO)


worked on the 01A from the A4...took the shifter off, swapped the plastic clutch slave cylinder with the metal one off the V6, got the new bearing in there....




got working on the engine side of things:



had to stop because I needed some help with aligning the tranny and stuff...so I decided to take apart the extra bits I got off the V6...

oh look at this - brakes are 2 piston vs. my tiny 2.0E brakes...nice!


the calipers haven't been used in a while so it will take a little bit of elbow grease but I think it will be a nice upgrade to what's on the car right now...also took the shocks off to start rebuilding with the Billsteins but decided to wait for the car and see which ones are in better shape...

shipped the head out to 034....hopefully it will be back by mid July....I should have done this a long time ago...who would have thought nobody would want to do this locally...60.9lbs shipping weight - should be even higher when they ship it back to me...

hmmm...just realized Dave suggested using the 7A oil pickup tube - I have already closed everything up with the AAN tube - what's the problem? everything lined up fine...

[NiTeC]

all right...let's see...




noticed something rather 'odd'...mounted the B4 tranny mounts to the A4 01A - they are offset a bit weird...the holes align fine but if you tighten one of the bolts the rest of them are off by about 2-3mm...you can see it here...



nothing to be worried about - a few spacers will fix this up but I wonder why that is...should I get a set of A4 mounts? will they line up with the subframe? we`ll have to wait and see

oh and the calipers cleaned up nice...the holders are fubered up but they look identical to the ones on the car - again we`ll have to wait and see....

[XR4Ti]

Awesome thread. Great pics detailing the swap and nice job on finding all those hidden holes!

Engine and turbo are lookin fast, good luck with the rest of your build.

[NiTeC]

I'm getting dangerously efficient at destroying cars



a shot of the ABS...


notice - no prop valve as this is FWD and the prop valve is mounted to the rear sub frame...


the fan...I`ll try to use the same rad-fan setup if possible...


the ABK - pretty sure the engine's been swapped at some point...the odo reads 400+ km...




weird (different) driver side tranny mount...


results in the following difference in subframes...



dirty:


clean:


ABS completely out...didn't cut a single wire - very proud of myself


wiring mess in:


wiring mess out:


I wonder if the 01A will have issues with this extra bit?


mandatory quattro shots:




the quattro work the shop had to do was fairly straight forward...nothing crazy...i`ll drop it down tomorrow to get better shots....

and got the heater out:



tomorrow is a short day but I still hope to drop the rear end, clean it, clean the interior, put apart the heater and remove all AC shit, figure out the clearance issues with the 01A and mount everything up...sounds like something I can do by lunch right?

all of this was performed at 30+ degree sunshine....I need beer...bad!!!

[NiTeC]

short but insanely hot day today...

dropped the rear diff to take some shots of the mounts...

rear subframe bolt mounts:


front diff mounts:



central bearing mounts:


and yeah...mounted the engine...WTF!!!!



I sat there staring at it for a few minutes freaking out...luckily I had the 7A mount to try...


phew...I`ll source out the passenger side as well...looks like the UrS4 mounts aren't a good fit...I should have expected that...

[NiTeC]

silly photobucket....thinks it can slow me down

started mocking stuff up in wait for the head....


tried to figure out what bumper to use...I gotta hang a pretty big IC (Greddy 28r off my old Mk4) and was thinking it has to fit the rad as well...the V6 rebar seems to work (without the dampers)...I`ll have to drill some holes...


here's the front done...


interior is ready for some cables:


hey look what I found at the local junk yard...


all of my problems are solved lovin the price list too: rad 40$, alu head with cams - 40$...gotta put apart a whole lot of it to get to the passenger side engine mount though - pain in my a**...

oh wait - I was wrong...the rad won't work



sigh....

[NiTeC]

yey pics are back up...holy shit - I ran out of 10GB of picture bandwidth...at 200k a picture that's a LOT of viewing...

here's some more

drivetrain is complete - everything is installed...had a little problem with the front diff supports - the shop welded the plates with the thought of using nuts on top - super hard when the gas tank is in to get nuts on top of the diff nose....might have been better if I had the gas tank in place when they were doing the brackets...



also got the passenger side engine mount on - needed a little trimming to the mount but get everything nice and tight at the end...had to figure out the rad and the intercooler today so I mocked it all up...installed the TB to see how things will line up with the side rad...




yeah...that's not gonna work...so let's see what else can be done here...



I`m liking this - OEM rad from this car...it will need to be moved a little forward to clear the accessory belt...I haven't decided whether I`m using the UrS4 setup or the 7A stuff yet...i`m doing the brakes tomorrow and the rad and IC will be done right after...the dash and electrical are next...if all goes well everything will be done by the time the head comes back....

[Connell]

it honestly blows my mind that those things ever passed a crash test with what can only be described as NO crumple zone!!!! iirc, isn't there some IM for that engine that the S2 guys use whose tb mounting point is somewhere closer to cyl 1 so you could use the side mount rad? mind you, methinks that's probably cost prohibitive eh?

[NiTeC]

yeah there's a Wagner IM that can be used but there's no need...plenty of alternatives

bled the brakes and the clutch although the clutch took a little while....it looks to me like the clutch has discovered the secret to anti-gravity...the liquid was NOT flowing down that's for sure...the most exciting part of the brakes:



the rad and intercooler were finalized and I cleaned and painted the rebar...the pictures are a little dark but I`m happy with the result...



it ain't easy bein cheesy let me tell ya certainly did wonders for boostin my enthusiasm



busted out a box of goodies that I've been itching to get my hands on for over 5 months...




got everything mounted up and came up with 2 acc. belt setups
1. tightened using the alternator and a custom bracket i`m about to fab up

2. conventional belt tensioner


about an inch difference between the two....notice I`m not using the fan pulley

this is where I`m going to put the bracket for the alternator if I go that route....


hydraulic pump issue solved - V6 pump swapped over..you can see the differences here - the AAN pump has an 'add-on' that is basically that third port...


the ABK pump is actually the same but uses different mounting so can't use it...


actually so is the Eurovan one anyways...the alternator is in a rough condition - been sitting around for a while but the damn thing is 200$...it's the same as the V6 one but my V6 alternator is completely seized...


the Eurovan one is different...I can probably make it work but won't try until I've made sure I can't find a V6 one...


belt's done...46" using the conventional tensioner and no fan pulley...it's pretty solid...


ready for battle


well...not exactly but def ready for exhaust and IC piping...


proper wheel gap...and it will only get bigger with the Kumho tires


hmm...I noticed today the bumper is a little short with the IC installed...i`ll have to come up with a creative bumper extension...

mmmm clean....




straight 2.5" pipe, used the Urs4 downpipe but modified to fit the B4 chassis + added an extra 02 bung for the wideband sensor...3" hi-flow cat, no muffler or resonator...this will be LOUD!


stainless steel piping for the IC - next time it will be done with thinner walled alu but for now this will do...the MAF is mounted just before the TB - I was going to put the whole thing together but couldn't get those damn silicone couplers over the MAF....any ideas how to 'soften' them up a little?


picked up some goodies...



that helmet is BADASS!!!! gotta take some better pics of it on my heat...the intercom is also Stilo WRC and it's amazing...

also managed to get the couplers loosened up - used a bottle of Baileys and a heat gun - worked like a charm...so here's the finished setup...







swapped on my R615s so I can bring the rims over to get the Kumhos mounted....205/50/15 - this is what the actual wheel gap will be...I`m wondering why the front wheels are seeing a bigger gap than the back - I would have expected the opposite...




overnight from Japan - Mishimoto low profile fan....nice and snug..




and this is where I`m going to mount the battery...it would be good to get something a little thinner so it fits in the floorpan better...

[PMcD]

That things too big. Go over to Total Battery on Newmaarket Street and pick up an Odyssey for $110.00. Half the size, 15 pounds, and you'll be very surprised at the cranking amps it has.

[NiTeC]

hmmm - I could argue both sides...I was going to swap in a Miata battery for it's size but I want something sturdy in case I lose the belt/alternator...the weight savings aren't worth much considering all the rest of the junk in the car + this will offset the weight of the fuel tank on the other side...haven't finalized it yet - we`ll see what happens...also if I get a dry battery (the Odyssey for example) I can skip getting a battery box...

[sb_600]

Looking REALLY good dude! Keep it up.

Are you going to do something to "protect" the intercooler in case of an incident? It looks pretty vulnerable sitting out front there!

[NiTeC]

not much that can be done really...I still gotta figure out how to mount the bumper - it looks like i`ll have to cut 2 bumpers and try and make one BIG one

[Connell]

just throwing it out there because i have no idea about capacity etc... but doesn't the S2 or RS2 sport a fancy dancy IC that is incorportated into the front cross member?? yep, it's require some very dangerous (for me anyways ) ebay.de action but it'd certainly solve the IC vulnerability issue. having said that, with targa a month away, i can see how that option is no longer viable for ya.

[NiTeC]

hahh...the S2/RS2 piece is the same - perhaps a little smaller and the flow is wrong for this head but it's just as vulnerable and sits at about the same spot...if god forbid I take the IC out I`ll just swap out a 2.5" pipe and call it a day

[Connell]

that low? meh, it's been a while since i've looked at one...

regardless, looks good man.

[NiTeC]

http://youtu.be/ocomIqsKZeg

[GoesFilled]

FYI - It's been the worst, rainiest summer in Nfld that anyone I know can remember... on the Avalon Peninsula anyway.

Looks like the Quattro might come in handy.

[NiTeC]

took it for a drive yesterday...got some high rpm/boost misfiring situation but other than that feels pretty solid...track day this Saturday...should be fun...