2000 A6 4.2 - Project Mayhem

[v8a6]

2000 A6 4.2 - Project Mayhem






Current Upgrades

• H&R coilovers
• H&R rear sway bar
• RS6 side skirts and rear spoiler
• Euro-spec Recaro seats
• 6-speed manual conversion
• Southbend stage 1 clutch (GONE)
• 19" OEM RS4 wheels - Winter setup
• Miltek 2.5 downpipes with Magnaflow high-flow cats
• Magnaflow 2.5 catback exhaust with custom quad oval tips
• OEM All-Weather mats
• RS6 upper grill
• LED tail lights
• S8 Intake manifold
• Gruvenparts billet variable intake rods
• S8 complete heads with port and polish by Gord Bush Performance
• 20" wheel summer setup
• JHM shift knob
• JHM lightweight crank pulley
• JHM short shifter
• 034 Motor mounts
• aluminum coolant pipe
• JHM tune
• Clutchmasters FX400 6-puck clutch
• Fidanza lightweight flywheel
• Innovate LM2 wideband O2 sensor

Upcoming mods

• Bosch 36# fuel injectors
• RS6 front bumper
• Full exterior paint job

Background

I purchased the 2000 A6 4.2 in the summer of 2010. It was bone stock, and needed immediate attention. I fixed the cluster, brakes, ABS sensor, turn signal indicator, and installed H&R sport springs. Timing belt and transmission fluid change, around with thousands of dollars of other work, had been done by the previous owner. So, after putting about $3000 into the car, I thought that I would be good for awhile. Wrong.


In early 2011, my transmission died suddenly one day. This was my second C5 A6 4.2, and both had the trans die within the first six months of ownership. I was not pleased.


Pic of my first A6 (2001 4.2), which is long gone...





This time around, I decided to do a 6-speed manual conversion. I sourced the parts from different wreckers, and ordered a Southbend clutch to complete the job. Eurotech in Etobicoke performed the job, minus the ECU coding, which I still have yet to complete. The swap transformed the car!

Note: To this day, if anyone asks me about purchasing a C5 A6 4.2, the first thing that I mention is the weak transmissions. I know that some people have never had a problem with them over many miles, but after you have two die on you costing you over $10000, you learn to really dislike the Audi TIPs.


In the spring of 2011, I finally scraped enough money together for some new wheels. On my old A6, I had run 19s and 20s. This time around, I thought I would try out an 18 in a wider size. I settled on some MB Battles in 18x9.5 with a et15 offset.


















The wheels looked great, and I had many compliments. The offset was aggressive, so I had to cut trim the liners from the front and rear fenders, and *slowly* roll the aluminum front fenders.

Next Step, S8 cylinder heads!

[v8a6]

In mid-2011 I found a pair of S8 complete cylinder heads at a wreckers that I had previously bought an S8 intake manifold from. Although I couldnt really afford them at the time, Jeremy at B & R Auto Wrecking gave me a deal that I couldn't refuse. So, I purchased them and dropped them off at Gord Bush performance in Toronto to get them checked out.


Gord found that they looked pretty good, aside from one problem. One of the cam chain tensioners had a broken casting, and was irreparable. I contacted Jeremy about the problem, and he refunded me enough money to purchase a used replacement from Bryan at audis4parts. Just want to mention that Jeremy went out of his way to make things right regarding the transaction. At the original price that I paid for the heads, there was really no guarantee. So, I owed him a big thanks. Bryan at audis4parts also gave me a great deal on the replacement tensioner.


Gord Bush is a local legend when it comes to his work on engines, and specifically, head work. So, I figured while the heads were out and disassembled, why not get them port and polished. Here is what they looked like when I got them...








Even covered in grease and carbon bulidup, they still look beautiful :) Can't wait to see what they look like after Gord has worked his magic on them.

Next step - RS6 Body Parts!

[v8a6]

Browsing eBay for RS6 parts one night, and came across RS6 side skirts, door blades, and rear spoiler. Couldn't wait for the new paint job to try them out, so I put them on in my driveway.








After fitting them, I found that the 18 inch wheels didn't look right anymore. The whole car looks bigger with the RS6 package on it, and, IMHO, it needs at least 19s.


Found a set of OEM RS4 wheels with 255/35/19s. Swapped the tires for some winters in the same size, and installed the wheels with the 15mm spacers that I already had, to bring the final offset to et14.











Thanks to another Audizine member, I came across a full euro-spec Recaro interior on eBay UK. Another purchase that I couldn't really afford at the time, but just couldn't pass up...







Just the fronts installed for now, and planning on installing the rears and door cards in the spring.

[v8a6]

For exhaust, I went with Miltek catless 2.5" downpipes and a Magnaflow 2.5" catback. Magnaflow high flow cats were welded in, along with custom quad tip oval exhaust tips.






Still can't believe how loud the setup is. Sounds amazing from the outside, but between 1200 and 2000 rpm inside is way too loud. Will likely install sound deadening in the trunk and under the back seat to try to decrease the low rpm drone.

[in2thenightaudi]

nice work, its looking good. does your catback system have a center resonator, or just the rear mufflers?

[v8a6]

Thanks.

The catback actually has dual resonators plus the mufflers.




After a long discussion in the thread below, the general consensus was that adding sound deading to the car interior would be the best first step in trying to resolve the noise problem. Just haven't gotten around to it yet.

http://www.audizine.com/forum/showth...ighlight=drone

[Hambone101]

Loving the progress of the car. Do you have a video of the exhaust yet? Did you get the cat-back as a kit or piece it together yourself? I've heard ilikeaudis car, no resonator with magnaflow mufflers and it sounds awesome in person.

A lot of cool mods you have planned, looking forward to the progress.

[v8a6]

Thanks Hambone.

I got the catback as a kit, so it is possible that ilikeaudis has different mufflers. I should be able to get a video of the exhaust up pretty soon. Just been really busy lately and have had to put the car stuff on hold.

Hopefully, Ill have all the engine mods done within the next two months. Then, the last stage is the front bumper and paint.

[Hambone101]

When you do get the S8 intake and heads on, get that thing dyno'd, would love to see what it's putting down, comparing it to my stock numbers.

[in2thenightaudi]

quad tips looks great, kind of strange since it's so loud with the magnaflow full kit with resonators. some people remove the resonators (from systems like APR or custom) since it was too quiet. would love to hear a sound clip of the system on a 4.2

[Vinchenzo51]

I love how every mod starts with "really couldn't afford this, but..." LOL. Story of my life as well my friend. Keep up the excellent work!

[v8a6]

Yeah, this car modding thing is definitely an addiction.

Here is a short exhaust clip until I put something better together...

[speedtrapped]

I love the seats, how was shipping with customs and airbags....as I want to do the same to my RS6

[v8a6]

Shipping worked out to 700 pounds, which is about average from Europe/UK, from what I hear.

Duties and taxes is based on your location. In Ontario Canada, we pay 13% of the item, and then sometimes another ~6% duties. Also, depending on how the item is shipped, there may also be a brokerage charge.

There was no problem with the airbags, and shipping only took about a week, IIRC. The items were shipped wrapped in black plastic. Two front seats, the top of the rear, the rear bottom, and the door cards (5 packages in total). The seat belt on one of the seats was bad, so I just swapped in the connector from my old seats (which I had to do anyway for them to work properly with the ECU).

IMHO, If you can find a really good price on a set from Europe (i.e. less than $1000) then it may be worth it to ship. Otherwise, you are better off going with Scotty's set for $4K, as you are guaranteed that they are in top condition, and have the very rare inserts. I realized after I bought mine, if there were any major problems, I would be out of luck. eBay requires that you ship the item back to the seller for a refund, and at $1100 in shipping, plus brokerage and taxes, it wouldn't be worth it.

[jaycurn]

Subscribed! Always loved this car and can't wait to see the progress!!! Do you have more info on the interior Scotty has for sale??

[speedtrapped]

I know scotty has a set.......and I keep telling myself maybe, maybe....I bought a set of recaro sports for the front, $1000 for pair, black leather....installing them next week.....if I really end up hating the fact the just the fronts.....I guess I can sale the recaros, sell my rs6 interior, and use proceeds for scottys stuff....hmmm

[v8a6]

Sorry, I don't have any more info on Scotty's Recaros. I'll msg him for you to see if he still has them for sale.

[speedtrapped]

your car looks awesome btw

[Scotty@Advanced]

I'm currently in negotiations with 2 different parties on the set I have.

[v8a6]

When you do get the S8 intake and heads on, get that thing dyno'd, would love to see what it's putting down, comparing it to my stock numbers.

Yes, I definitely will be dyno'ing the car after the engine work. I'm going to wait until JHM does their followup tunes before I get the dyno done, so it may be a few months off still.

[speedtrapped]

Nice Scotty...I'm way off anyway, going to use the recaros I have for now, store my rs6 fronts, and when I decide to swap back and front pull trigger....as I would rather not deal w/ customs and shipping, the sets are around.

[beemercer]

nice writeup, best of luck with the car... wish mine looked as good

[A6Avant]

The car is looking great!

[v8a6]

Thanks guys!

[v8a6]

Sneak peak of the new wheels...






Will have some better pics once I get the height on the coilovers set. Moar lowering is needed :)

20x9.5 et25 in front
20x10.5 et33 in rear

[Audi4.2]

Nice Michael! ;)

[Hambone101]

Ooohhh I'm jelly, looking forward to moar pics

[8520]

I've said it before, and I'll say it again.... With the right wheels, and the right drop, c5's can pull off 20's.

[v8a6]

Thanks for the comments.

Here's a few more pics...





Try and ignore the mismatched coloured panels :) Bodywork will be the last step in the project.

I think the height is about right on the rear. May go a bit lower on the front.

[beemercer]

looks good

[ilikeaudis]

i like! what size tires?

[v8a6]

Thanks!

20x9.5 et25 in front
20x10.5 et33 in rear

245/35/20 F&R

[SleeperAvant]

Your car is fucking sick.

[v8a6]

Your car is fucking sick.

Best compliment yet!

Thanks!

Your's is quite the machine too, with 350 @ the wheels. Crazy!

[SleeperAvant]

Haha thanks. I've rarely seen a 4.2 C5 A6, especially one that's been converted to a 6MT. Awesome.

[beemercer]

Your's is quite the machine too, with 350 @ the wheels. Crazy!

you can get yours there too

[ChrisEsco1]

This makes me want a widebody real bad. Nice work!

[v8a6]

Thanks!

you can get yours there too

That's what I am hoping for, if I ever get my S8 heads back from the shop...

[Richard]

Oh, why, hello there car of my dreams. I cannot wait for you to finish this beast. I have often talked with the wife about doing something like this, but will an allroad (because, well, why not?). It's nice to see the older platforms are still getting fresh and new ideas.

[v8a6]

Yeah, the Allroad is the perfect project car, with the 2.7t and the wide fenders. We briefly considered buying a second car, and it was one that I looked at (and an S6).