AuditechS4's Single turbo build - The DIY way

[AudiTechS4]

Well this will probably be a slow moving project but going to build my own single turbo kit or at least try :) Shooting for mid 500hp .
This isn't going to be some all out build with a crazy budget. Just going to try and make it a clean and effective setup for under 4k total (minus some parts i had already)

Starting with a 2000 audi s4 with 96k miles on it - put the full 3" dp ssac stuff on it. full timing belt kit ,a wide band and greddy boost gauge,lowered and refinished some wheels , no they are not black
)


Plans
Engine
starting with a BEL -BF block pretty basic rebuild and will be using the rpm rods
-bel engine $400 - received
-Rods $408 - received
-engine parts for rebuild and full timing belt kit - $940 - received
-034 block off and oil return kit -$74 - received
-total $1822

Drive-train
-Stasis built trans - installed
-Fx300 - installed
-Fidanza Flywheel - installed
Total - $Free

Turbo
-BW s360 .91 - $629 - received
-Precision 39mm Waste-gate - $240
-Bov? - $250
-Total - $1119

Manifold/Turbo pipes
- 2.8 manifolds from ebay- $55 - received
- Flanges (034) - $150
-material for up-pipe ,dp and related stuff like gaskets,lines and fittings - $400 - received
-- up-pipe and dp materials ($323 so far used ace stainless supplies and Columbia River Mandrel Bending)
-Total - $605

Fueling
-i have a set of 80lb Siemens already - $free
-walbro 450 - $138 - received
-total - $138

- some machine shop work - chemical clean,hone,check and polish crank,balance rods and hone wrist pin ends.check rod clearances (did on his own - i was going to like crank) and balance full crank assembly - ill be pulling apart heads and gasket matching intake and polishing exhaust runners and re lapping valves) $580 - updated page 2

- inter cooler and pipes - no clue yet .
Treadstone TR10C Intercooler 666HP $274 - received

-total so far is $4180

Parts to sell
-bel engine came with a apr bi-pipe and 2 evolution diverter valves - Hoping for around $400
-rs4 accordian hose -$ 40
-Auto trans $100 ?

-total $590 -$690 -$150 = $440-550

Pics - when i picked it up



Got it into the shop yesterday and started tear down







Hopefully by the end of the year this will be running in the car and not blow up :)

[Monty23]

Looks good man, let the fun begin

[pipe7284]

very inspiring for under $4000

[mightemouce]

Anxious to see how that turbo works out for you! I've been thinking of using the same one for a build over the winter possibly

[ggg20t]

willing to sell the apr bi-pipes without the dv's?

Great build! good luck to you

[Jmills]

Awesome build! nothing like a budget single turbo!

[AudiTechS4]

Ahh we will see how budget it really is. If im under $5k ill be happy. being able to do most of the work myself will save me alot.Ill save all receipts and have a very detailed build.

[Monty23]

Yeah my budget went out the window pretty much right away lol

[rockcandy]

Yeah my budget went out the window pretty much right away lol

That's why it's better to have your budget = hp number and just make it happen. haha

[rockcandy]

sucks to see you guys went to the wurth brake cleaner cans. Those things are complete junk!!!!

[AudiTechS4]

yeah they are , we still have the drum to fill the sureshot's though

[cb s4]

B5 s4 and a s14 I like your style

[AudiTechS4]

B5 s4 and a s14 I like your style

Not done yet

this will be under the knife when im done with the s4 - 67k miles all stock and perfect - keeping it that way :0

[AudiTechS4]

these just got here

[cb s4]

Nice I figured it was a drift better nice to see some one takes care of one. This may be the next purchase or bigger turbos for the s haven't decided yet......

[cb s4]

Is it a original 5 spd with 67k? If so nice find

[AudiTechS4]

auto ,se no sunroof - converted to 5 speed already

[AudiTechS4]

well pretty much everything has been ordered - hopefully have everything by the end of next week.
block goes to machine shop monday for a good old cleaning and hone

[JKnight41]

Love it, looking like a good build! Keep it up.

[2.8L]

What are you planning for software?

[AudiTechS4]

well ill be doing the self tuning route with a little help from a friend.

[2.8L]

Standalone?

[AudiTechS4]

no me7

[AudiTechS4]

So what size fmic are you single turbo guys going with ?

i was thinking of going with the treadstone TR10C

Core
-Core Size, 10.5" X 22" X 3.5"
-Overall length 28"
-1050 CFM flow rate
-666 HP efficient
-Less than 1.5psi pressure drop at max flow

[hibiscusS4]

looks like itll be a good build

[AudiTechS4]

sure hope so lol , never doing this kind of thing before will make it interesting :)

[hibiscusS4]

ya i know what you mean im still saving and making a parts list to try my luck making my own kit aswell.

[Monty23]

So what size fmic are you single turbo guys going with ?

i was thinking of going with the treadstone TR10C

Core
-Core Size, 10.5" X 22" X 3.5"
-Overall length 28"
-1050 CFM flow rate
-666 HP efficient
-Less than 1.5psi pressure drop at max flow

I run the TR1035, I like the placement of the inlet/outlet better on my previous precision fmic. I am planning at some point to redo my up pipe and add a quick spool valve, so you may want to consider one. The lag from my 6262 is annoying compared to the instant spool of my old 5858. I am hoping a QSV will solve that issue.

[RedRocketS4]

We won't get into the vertical flow vs. horizontal, but I'm running the TRV185 intercooler on of my single turbo s4's and the TRV25 on my other single turbo s4. For a small turbo, you could probably get away with the TRV185. It's much easier to mount and fab the piping than the massive TRV25.

I'm almost done fabricating the intercooler piping on one of the cars. i am using my MIG machine to tack all of the aluminum together. I highly recommend to have the final weld TIG'd at a shop. Welding aluminum sucks in general, but MIG welding it is just a very ugly nightmare.

[AudiTechS4]

i was looking at the tr1035 but the tr10c specs show .5 less pressure drop and 50 cfm more flow. i also found it for $279 with free shipping

[AudiTechS4]

for ic piping did you just buy a universal ebay kit and then just cut and weld?

[AudiTechS4]

fedex guy came by :)
i think i got too many elbows lol

[AudiTechS4]

ups just showed up with more

[Monty23]

Yeah I just used a universal ebay kit. One 2.5" kit will be enough unless you want to run 2.5" off the turbo and switch to 3" like I did you will need one of each kit.

[AudiTechS4]

Turbo came in :)


Got the wrong piston rings so it will be another couple days till i can get to the machine shop for some work

[AudiTechS4]

Engine is still at the maching shop . the guy i went to is like 5 min away but he's by him self and had like 4 engine in front of mine so no biggie i'm in no hurry . cleaned and honed . balancing this week . so in the meantime in cleaning up the heads

Cleaned and valves lapped

[AudiTechS4]

get my engine back next week all cleaned,balanced and pretty yay . then time for assembly . hopefully i remember where everything goes hah

[Quattro_2.7tt]

looking good!

[Quattro_2.7tt]

get my engine back next week all cleaned,balanced and pretty yay . then time for assembly . hopefully i remember where everything goes hah

I'll be in Scottsdale/fountain hills next month from 25th-31st, if you need any help id be happy to lend a hand for a day or two.
Joe

[suntzu]

Im going to be rebuilding my new lump over the winter so im in for info, good luck brah!