Dalers08's B5 S4 Project

[Dalers08]

My name is John and I have an addiction.
I figured it's about time I post my moneypit.

On the night of October 18th, 2013, almost a year ago today. I brought my baby home.





I didn't get to mod the car too much over the winter, really just cleaned her up and fixed a few things I wasn't happy with.

Early spring I put a different set of wheels (same wheels, different color, lol), a cupra lip and a set of OEM racks and she sat like this.





Over the summer I've done so much to the car, it's hard to keep track.
Biggest addition to the car was some corn! The car has enough power to confirm my sleeper status, she put down 465whp/418wtq on a stock never opened motor.



https://www.youtube.com/watch?v=HHeyrhVnn2Y

The past few weeks I started one of the largest project's I have ever undertaken, rebuilding my core/spare transmission to replace the one with the tight 1-2 collar in the car. Right now it is fully disassembled but I got distracted getting the wheels on the car for H20i.



Just this past week I finally got some 18's for the car and got it more to my liking. I still have to tweak the fitment in the front. I needed a spacer to clear my brakes so I picked up a 5mm to make sure I could make it to H20i, but I only need a 3mm, which will let me lower the front a bit and match the poke and height of the rear.

I'm very happy with where the car is at this point, and I am excited to start phase 2!








Near future plans include:
Me pulling the motor/trans to replace transmission, along with adding a 4:1 stock differential mod, install new clutch setup, and upgrade from 2.5" downpipes to 3".

Phase 2:
Tinted windshield
Euro rear bumper
Would love to go with a Porsche 18z front bkk and 17z rear bbk. But I have a Stoptech bbk right now in the front. And need to make my own brackets for the rear 17z. That's on the table.
034 Rear swaybar setup

Quick rundown on the mod list:

Outside
Cupra R lip
RS4 Grill
OEM Roof racks with thule bike attachments
Valeo E-codes

Inside
Sport white alcantara
Soort silver trim
JHM Weighted knob
RS4 Steering wheel and airbag
AWE Vent mounted boost gauge
VEI Dual Display Boost/AFR gauge steering wheel mounted

Lets me roll
18x9.5 ET27 NT03’s 5mm all around (going 3mm up front)

Lets me breathe
034 X Carbon CAI
RS4 Accordion Hose
034 85mm Billet MAF Housing
RS4 Inlets
PJ BW K04’s
Samco Boost Hose Kit
AWE Intercoolers and Shrouds
APR BI-Pipe
Bosch 710N’s

Makes me drink
Walbro 485
Bosch EV14 52lb Injectors
E85

Tells my motor what to do
Daz Dillenger E85 and 93 Tune
Coded out EGT & Rear 02’s
Innovative LC-2 Wideband

Lets shit out
AWE Tubular Exhaust Manifolds (ceramic coated)
ARD 3" Downpipes
Fast Intentions Stage 3

Hold the power, make it easier
Custom geared transmission. Updated 1-2 collar. RS4 3rd. Allroad 4th & 5th. TDI .56 6th.
4:1 Center Differential
JHM Cross rod
JHM Shifter
Southbend Stage 4 Clutch
AWE Lightweight Flywheel

Stiffies
RS4 Engine Mounts
APR Snub Mount
APIKOL Transmission Mounts
APIKOL Rear Carrier Mounts
APIKOL Differential Mount
AWE DTS

Kill that body roll
Vogltand front coilovers
ST rear coilovers (going full ST soon)

Breaks my neck
Stoptech ST40 Front BBK
Stoptech pads

[rani_aridi]

Wow. Congrats sir, you own my dream S4. Absolutely gorgeous car

[TTAvant]

Those NT03+M look great. That S4 on the Meisters though. Wasn't that for sale a while back?

[LJS]

Looks GOOD!
Like the new rims!
PS- You'll REALLY like the 4:1 center diff....

[Monty23]

Good work man and she looks great!
How long have the AWE manifolds been on the car? They haven't cracked yet?

[Sole_]

Gorgeous! Built properly!

[ggg20t]

This car looks immaculate. Post some pictures of that interior too!

Cant wait to see your future plans come together.

[Dalers08]

Wow. Congrats sir, you own my dream S4. Absolutely gorgeous car

Thank you man that means a lot!

That S4 on the Meisters though. Wasn't that for sale a while back?

Yeah he went nuts and I wouldn't let him sell it! It's S4BigHead's car.

Looks GOOD!
Like the new rims!
PS- You'll REALLY like the 4:1 center diff....

I'm very excited to be able to bang 2nd gear in this car, and for the 4:1 diff!

Good work man and she looks great!
How long have the AWE manifolds been on the car? They haven't cracked yet?

Thanks man!
The manifolds have been on the car for about 6 years/20k, no cracks... but why you gotta jinx me like dat?!

PS: Your tool went in the mail this morning.

Gorgeous! Built properly!

Thank you!

This car looks immaculate. Post some pictures of that interior too!

Cant wait to see your future plans come together.

If I had some good ones I would haha.



If anyone is interested, I am organizing a group buy for Autopower race roll bar/cages... shoot me a PM if you're interested.

[boconnor811]

Are your nt-03's redrilled? Fitment looks spot on, what are the tire sizes you're running? Any fender mods required to fit?

[Dalers08]

Are your nt-03's redrilled? Fitment looks spot on, what are the tire sizes you're running? Any fender mods required to fit?

They are not redrilled, I'm running a stud conversion. Tires are 225/40. Front fenders are rolled flat, rears are untouched. I'd like to fit a little wider tire in there, my 225/40 runs a little small... but I don't have much room to play with currently.

[topquarkpc]

do you have 034 diff carrier or is it something Apikol produce?
i'd recommend going Vogtland GT3 if i were you...just my 2cents.
otherwise...nice PJ silver stage 3 s4.

[Dalers08]

do you have 034 diff carrier or is it something Apikol produce?
i'd recommend going Vogtland GT3 if i were you...just my 2cents.
otherwise...nice PJ silver stage 3 s4.

034 Diff carrier with Apikol bushings and Apikol diff mount.

I originally bought the car with Vogtlands, but when I went to lower the driver rear the collar was frozen. So I picked up a set of used ST's in an emergency situation to lower the car and have the wheels on for H20i. I'm happy with the ST's in the rear so I'm going to put them in the front too. I'll be picking up a new perch for the frozen Vogtland and selling them as a set. If I was going to go crazy I would go KW V3.

[topquarkpc]

or pss9 or stasis ohlins...

[E36 Hater]

Looking good

sent from merica using f yeah!

[crazyazz]

Awesome looking car man!

[cinimod25461]

You'll love the 4:1. Just got mine done at JHM last week and it's sweet! Especially since it won't affect daily driving but will make a difference when you want it to.

[Dalers08]

Looking good

sent from merica using f yeah!

My dudeeeeeeeeeeee. Fogs! Fogs! Fogs!

Awesome looking car man!

Thanks bro!

You'll love the 4:1. Just got mine done at JHM last week and it's sweet! Especially since it won't affect daily driving but will make a difference when you want it to.

I'm very excited for this. I don't think about it too much because I'm just excited to get a working transmission in the car and enjoy nice hard 1-2 shifts. But I am very excited to see how the 4:1 makes the car drive.

I think the 4:1 + cage + 034 rear sway = very tail happy car. Excited to see.

[erykv1]

beautiful ride man!! i hope daz doesnt go anywhere, i'll be needing him in the near future!

[eagano]

That is one beautiful Silver And of course it's the fastest color...
Nicely done! Love the stance, clear corners, every bit of it!

[S4 00 2.7]

Nice wheels.

[Dalers08]

So this happened last night. Adrain again with the photo!



Other updates...
3mm spacers don't clear the brakes :(. Haven't decided what I want to do yet. I'll probably be selling the stoptech kit anyway so I don't want to touch my fenders yet.
Also started working on my transmission again a few days after getting back from H2Oi, an hour in I broke a roller bearing on the 1-2 pinion shaft, $230! I'll be ordering that soon, just crying until I do haha.
Also picked something up that is currently at my fabricator, update on that in a week or two.

[Congratulati0ns]

Weakk

[E36 Hater]

Tru dat

sent from merica using f yeah!

[pipe7284]

so clean and fast.

[JJ.]

Ughh so perfect! Seen this on IG!


Sent from my iPhone 5s using Tapatalk

[Dalers08]

Been awhile. Seems like I haven't been up to much but now that I'm updating the thread I realize I've been busy!


Got the 3mm spacer to clear. So now I'm running those up front, takes care of most of the rubbing.

Picked up an autopower roll cage. It's the race version so it has the harness bar and the race bar. I gave them to my fab guy to make them removable so I could still have people in the back seat if they're willing to climb back there. Also got it powdercoated wrinkle black. I've noticed the car is a bit stiffer, but I also have full mounts everywhere. I don't have the cross bars in yet as they aren't done, but I imagine that will stiffen it up a bit more.




Traded my AWE Twin 1 for a Fast Intentions Stage 3. Don't have any pictures of it but I do have this video.
AWE Manifolds - AWE Downpipes - Gutted AWE Midpipes - Stage 3 Fast Intentions catback. (Will have 3" downpipes soon, keep scrolling...)
https://www.youtube.com/watch?v=RO8QJp3EV70

Big update is I picked up a built transmission. Was going to finish putting mine back together but just couldn't pass this one up. So... I finally pulled my motor. First motor pull ever. Me and a fellow member on here had it out in about 8 hours. Not too happy with that but it was both our first time and we went slow and careful, had a problem with the A/C that cost a few hours. But it's out!





Turbos look mint (minus being covered in oil from a previous valve cover leak)! I'm very happy about this.



Didn't take many more pictures of everything but I'm doing a lot while the motor is out...
3" ARD Downpipes
3"-2.5" 034 Midpipes

Redid the leaking valve cover gasket (with a new one)

Stage 4 Southbend extreme clutch with a custom disk
New friction surface for my AWE flywheel

Built transmission (4.5k miles on it)
RS4 3rd, Allroad 4th and 5th and TDI .56 6th. 4:1 High Bias diff. New Fuch's fluid.

Full timing belt kit.

Current status is...
I had the motor out Friday night.
So far I've swapped the linkage onto the new transmission, drained the fluid, put new fluid in it. Swapped in the 4:1 diff (had a welded diff in there).
Took off the AWE downpipes.
Took the friction disk off the AWE flywheel (this sucked). Need to clean it up and mount the new disk on there. Then I'll mount up the clutch and throw the transmission on. Then the new downpipes go on.
I'm halfway through the timing belt job. Not too bad just going slow as I was alone and it's my first belt job ever. New thermostat, water pump and crank seal are on so far.

Goal is to have the motor in the car and running by the end of next weekend. Won't get too much time to work on it during the week. By the time I get home from work the sun is down and it's freezing outside.

Who decides to pull a motor in the driveway in the middle of NY December? This guy. B5 S4 life.

[JJ.]

Nice progress so far, respect for doing all of that on your driveway, in December...

[LJS]

"Who decides to pull a motor in the driveway in the middle of NY December? This guy"
DAMN-
I get upset when I've got to do an oil change in an unheated garage.
You da man!

[erykv1]

are you running adapters for the nt03's? or wobble bolts? looks great man!

[Monty23]

Be sure to preload the timing belt before tightening the cam pulleys back down.

[Dalers08]

are you running adapters for the nt03's? or wobble bolts? looks great man!

I'm running a stud conversion.


:(


Front of the motor apart for the timing belt kit.


Ended up snapping a cam sprocket while pulling it off. Thank god Monty23 saved the day and overnighted me one!


Went to re-install my flywheel with the new friction disk. I got some new OEM bolts (left) and realized they were longer. So I just reused the old ones because they weren't even stretch bolts.


In!


Clutch on!


What my garage looks like when I pack up for the night.



Overall I'm putting in a lot more work then I was expecting during the week. Been braving out the cold and rain and getting shit done. Front of the motor is back together and done. Clutch is mounted. Now just need to mount the new transmission, install my USP metal slave and line and bleed it, put my shiny downpipes on and she will be just about ready to go in. Going to try to get her all buttoned up tonight. Goal is to drive it to work on Monday!

[Monty23]

Be sure to pressure test your wastegate lines and check for any leaks near the turbos before the motor goes back in. Also try and pressure test the coolant system (10psi max) to verify you don't have leaks at the turbo banjo fittings.

Don't rush it or you will be pulling your motor out again.

[Dalers08]

I didn't touch my wastegates or lines and they didn't leak before.

How would you pressurize the coolant system?

[Monty23]

Hook up your radiator/core support to your hoses on your motor. Hook up your coolant overflow tank. Take off the smallest line at the top of the coolant overflow tank (the one that goes to the T fitting) and cap off the overflow tank nipple and attach the 1/4" coolant hose to a fitting that can hook up to your air compressor. Make sure to turn your air compressor regulator down to 10psi MAX or you could blow your coolant tank apart (not sure what pressure it's rated for??).

This is only one way, I'm sure you could get creative and pressurize the coolant system differently, but I know this way works.

I would still inspect your wastegate lines and pressure test them anyways since they are a hard to reach item when the car is together.

[Dalers08]

Hook up your radiator/core support to your hoses on your motor. Hook up your coolant overflow tank. Take off the smallest line at the top of the coolant overflow tank (the one that goes to the T fitting) and cap off the overflow tank nipple and attach the 1/4" coolant hose to a fitting that can hook up to your air compressor. Make sure to turn your air compressor regulator down to 10psi MAX or you could blow your coolant tank apart (not sure what pressure it's rated for??).

This is only one way, I'm sure you could get creative and pressurize the coolant system differently, but I know this way works.

I would still inspect your wastegate lines and pressure test them anyways since they are a hard to reach item when the car is together.

Good idea. I'll do this to make sure it doesn't have to come back out when I'm done haha.

[erykv1]

build looks like its coming along great.

i wish i could find that flywheel washer you have there so i can use it on my fidanza flywheel :(

could you elaborate on how the stud conversion works? i see a bunch of m14 to m12 studs, but if i replace the studs, isnt it essentially still on the same 5x112 bolt pattern?

[Monty23]

build looks like its coming along great.

i wish i could find that flywheel washer you have there so i can use it on my fidanza flywheel :(

could you elaborate on how the stud conversion works? i see a bunch of m14 to m12 studs, but if i replace the studs, isnt it essentially still on the same 5x112 bolt pattern?

Wobble bolts:
http://www.ecstuning.com/Search/Wobble/ES2130074/

The bolt features a floating seat collar that allows movement of up to 3mm of a wheel's PDC, allowing you to run a 5x114 wheel on your 5x112 vehicle.

[Dalers08]

build looks like its coming along great.

i wish i could find that flywheel washer you have there so i can use it on my fidanza flywheel :(

could you elaborate on how the stud conversion works? i see a bunch of m14 to m12 studs, but if i replace the studs, isnt it essentially still on the same 5x112 bolt pattern?

I'm just running these
http://www.ringer-racing.com/product.sc?productId=65

From what I've heard they will work on most wheels. Some wheels the lug holes aren't large enough and you have to drill out anyway.

[gtsingh91]

You psychopath. Mad respect to you I didn't know you were doing this until yesterday lmao

[Rdp616]

Fucking love the NT03's. Much respect for working in the cold also.