B6 S4 Turbo Build & Built Engine - Part 2

[AlexB6S4]

Going to start this one with the engine build and transitioning into the turbo build. Hopefully I can help or inspire some people along the way to do some cool stuff to this platform. If anyone has any questions please feel free to reach out to me.

Picture 1is the driver side bank before any reconditioning. The passenger side looked the same. Bores spec's out fantastic so my block was a great candidate to build with forged internals.



Picture 2 is after a green scotch-brite process. The green pad is supposedly a 600 grit. I used 1/4" green scotch-brite sheet and cut portions and applied them over the felt hone I made. I ran the hone with the scotch-brite in each bore for 15 seconds @ 600rpms. I oiled the pads and bores with 10w-30 dino oil. You can see that this process does cut in. BIG EDIT: I actually do not recommend this process because the green pad cuts in quite a bit and things can go downhill fast if you get carried away. I originally only did the green pad followed by the felt process but after closer inspection that the human eye could provide, it was evident that the green pad cross-hatch marks were not removed by the felt hone process even though it looked that way.



Picture 3 is after I ran a blue scotch-brite pad ran for 60+ seconds @600rpm to remove the cutting made from the green pad. The blue pad is supposedly a 1000 grit. I did a close up so you can see what it actually does to your bore. I guess iPhone camera's are really good :). If you are not very close, you will not see the cross hatching, whereas the green pad is visible from much farther away.



Picture 4 shows how I protected the oilers and crank from any debris or liquid seeping past the bores. I used half a paper towel roll for each bank and packed the lower portion of the bores. I swapped out the packing after the scotch-brite process and replaced with new for the felt hone process.



Picture 5 shows the amount of Sunnen AN-30 paste I applied to each bore.



Picture 6 shows the addition of 10w-30 dino oil over the paste to cut it down so the felt can travel through it and make contact with the bores. I am sure other oil's can be used, but this is what I used. I ran the felt hone in each bore for approximately 90~ seconds @ 600rpm. I recommend doing each step at a different vertical cross-hatch pattern so you are not running over the same lines. Think of polishing a rough piece of metal to a mirror finish, you need different angles to achieve the finish. End result should be a dull smooth matte finish.



Picture 7 show's the driver side bank after the process is complete. Picture 8 shows the passanger side. You can see that the scoring is drastically imporved. I did have a slightly larger score line in cylinder 2 that did not get removed. If you can get your finger nail caught in a score, it will not be removed by this process. There is a member on here that has used the appropriate hard stones which would remove more material if your scoring is extreme.




This last picture is the Felt hone I made to do this process with. For the Scotch-Brite (SB) steps, I simply cut portions to fit over the felt hone and secured them from the sides and rear with gorilla tape. After the SB, I ripped them off the perform the felt process.



We do also have a neat little group on FB called "Audi BHF / BBK 4.2L Engine & Boost Builds" if anyone is interested in things that sometimes is not posted on this site. I will be posting all my content both in that FB group and this build thread.

Parts list of the major components and website's where I sourced from.

JE Pistons and Pauter Rods: www.AMTuned.com
Garrett G35-1050 Turbo: www.AMTuned.com
DeatscheWerks 1500cc Injectors: www.AMTuned.com
Wastegates and BOV: www.AMTuned.com
Twin Disc Clutch Masters clutch kit: www.AMTuned.com
Rebuilt Transmission: www.jhmotorsports.com
Warlbro 525 pump: www.projectb5.com
Schedule 10 turbo manifold pipe: www.aceraceparts.com
Engine Gaskets www.fcpeuro.com
Insulation Material: www.summitracing.com
Intercooler piping, Exhaust piping, and AN fittings/line www.amazon.com

[NALS4]

Nice! Looking forward to another epic thread. You rock!

[shoemaker617]

what kind of turbo’s are you thinkin of using?


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[AlexB6S4]

what kind of turbo’s are you thinkin of using?


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I will be using a single Garrett G35-1050 with a 1.01AR turbine housing. I may need to go to a 1.21 housing for my power goals, but we shall see.


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[shoemaker617]

I will be using a single Garrett G35-1050 with a 1.01AR turbine housing. I may need to go to a 1.21 housing for my power goals, but we shall see.


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thats a tight engine bay to stuff that thing in, interesting to see how you get it done


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[Zolli]

Subbed because this is great stuff

[AlexB6S4]

I edited my original post with more info to include a higher grit scotch-brite pad and discourage people from using the green pad.

[Kambesama]

Can you list the tools needed to rehone the cylinder? I am looking to start collecting tools and materials to get this done on the next time I take my engine down.

[AlexB6S4]

I did the process with a handheld drill, and that felt honing tool I made. The tool originally had stones for a iron bore which I removed and replaced by adding the felt instead. Make sure you get a hone tool that you can adjust the pressure of the arms against the bore so that you can adjust in case there is not enough to have a stone/pad sit flat against the bore. I accomplished the Scotch-Brite process by temporarily securing the scotch pads over the felt which can then be removed.

Also to be clear, the process I did can be described as a "backyard" procedure. There is a more "precise" procedure that can be done utilizing the proper Sunnen stones and their procedures. Q posted a .pdf of that procedure on the Facebook group that was mentioned on the bottom of my initial post. I did it this way and shared with everyone so people have a cheap alternative with items that can be easily purchased.

[ngood1]

This is great. Any update?

[leogonzales]

Where's part 1 of this great thread?

[AlexB6S4]

Where's part 1 of this great thread?

https://www.audizine.com/forum/showt...-Turbski-Build

[AlexB6S4]

I am waiting on some parts to get in to finish the forged engine, so I am using a spare engine to mock up the new turbo manifold. The old 3 bolt flange will be cut away before everything is ceramic coated.





Locating the V band flanges in what I feel is the most accessible area for servicing.


Fusion root


Fill pass after root.


Turbo inlet Y I made with the schedule 10 pipe.

[NALS4]

Nice! That transmission doesn't look real.

[AlexB6S4]

[AlexB6S4]

The turbo manifold is complete. I will work on the Downpipe next week and then send off the parts to get ceramic coated in preparation for the final install.

[mnvwaudiguy]

Nice work on the bores. Watching with interest.

[shoemaker617]

looks like your biggest enemy is going to be heat, it looks pretty cool though

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[Kambesama]

Considering the position of the turbo, is it safe to assume you'll be removing sections of the OG battery location?

[AlexB6S4]

I am not too worried about heat with this setup. My last turbo setup kept MUCH more heat in the bay.

Yes, a good portion of sheet metal was removed from the front of the battery tray for this to work. I will fabricate a new strut bar once everything is complete for rigidity.


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[neilpaku]

I performed the cylinder hone on the wife's car about 3-4 years ago, and at that time after run-in it was about 1 qt per 1000mi. It's about half that now, around 1qt per 2000mi so it's held up very well. So, I think you should be in good shape with your engine. It worked so well and the transmission is in good shape so I decided to replace the front doors and fenders and get it and the wheels painted so it'll last another 10 years at our rate of usage. After it comes back from the painter this week, it's going to get a Woolwax treatment to avoid any further rust issues.

[AlexB6S4]

[esell]

Lookin good!!

Any plans to brace the manifold/turbo to the block or do you think everything will hold (long-term) as-is?

[AlexB6S4]

Lookin good!!

Any plans to brace the manifold/turbo to the block or do you think everything will hold (long-term) as-is?

The schedule 10 pipe I used is plenty strong to support the turbo. The stock manifolds are now actually the weakest part of the system, but I believe they are still plenty strong to support it.


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[Jake@JHM]

Sweet build!

[boogernz]

Hi Alex,

Sorry to hijack your thread amte , but could you possibly post a couple of close up photos on my thread of this area on the a/c compressor side with the arrow is where the coolant appears to be leaking or weeping out of my block ?
I cant figure out where its coming from, perhaps the seam between the upper sump/block but I woudnt think water jackets would go down that far ?

Cheers

[AlexB6S4]

Thanks Jake. @ Boogernz, I replied to your separate thread.

More pictures of tonight's work.

[AlexB6S4]

When riding solo and setting timing.



Mounting the strapped twin disc



Installing the gravity drain bung for the turbo.




Everything got Cerakote to keep down the temps.

[AlexB6S4]

Got some good work in today. Mock up engine is back in the corner where it belongs. I sectioned the center part of the rear coolant pipe and clocked it so the temp sensor is clear of the exhaust. Built engine is mated to the trans and pretty much ready to be dropped in. Have to make some Coolant and Oil lines for the turbo and then she will be ready. Did some heat shielding of the rear coolant lines and power steering rack. I used shielding from "Heatshield Products". Cool stuff, .125" Thick fiberglass backed stick on product that is rated for 1,100 degrees continuous.

[Kambesama]

Love it. Still amazed at how clean that transmission is. Not sure if you said but is it a brand new one and if so what happend to the previous?

PS: Flip flops in a work area!?!?!

[AlexB6S4]

Love it. Still amazed at how clean that transmission is. Not sure if you said but is it a brand new one and if so what happend to the previous?

PS: Flip flops in a work area!?!?!

Thanks! It is a rebuilt transmission done by JHM since they are 30 minutes from me. They repaint them when rebuilt. This is the same shell and some of the same inerds. 2nd gear went bye bye thus the rebuild.

Flip flops everywhere!


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[AlexB6S4]

Some video updates:

https://youtu.be/R8NnGdGGLwI

https://youtu.be/AOSmkdDHO78

[AlexB6S4]

Got all the piping fabricated. I am waiting on a tight radius 90 degree cast aluminum elbow so I can weld it off the compressor housing instead of having that silicone reinforced 90. I am going to wrap the downpipe and possible the manifold with DEI exhaust wrap to further help with heat. I had to order a new radiator after finding a small hairline crack that is not yet leaking.

[shoemaker617]

looks good , lets see some dyno charts!

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[Kambesama]

How's the pipe clearance at the back there in relation to the hood. It might be the angle but it looks like it'll contact before you get a chance to fully close.

[AlexB6S4]

How's the pipe clearance at the back there in relation to the hood. It might be the angle but it looks like it'll contact before you get a chance to fully close.

There is actually like .75” of clearance per the tinfoil test. The hood closes above the plastic grill plate. I am hoping that with the cast 90 I am welding on, I will be able to bring that high point down a bit. But it is strictly for aesthetics.

I played around with sending the piping forward over the 3.5” TB connected pipe, but I would have to oval a small position of pipe for clearance and I just did not think it looked as clean.


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[AlexB6S4]

Update.

Here is a fun video of some spool noise: https://youtu.be/zeMUFq1rzpA

Going to do about 500 miles on here with my old tune and current fuel setup. It may be a few weeks before I can put some good mileage on here as I am moving out of state, and driving across to Florida on Monday. I will share my new fueling setup once I get it all installed on the East coast.

[Atomic Avant]

mhmm, those spool noises!

[ottocycle]

Sounds good Alex! Where in Florida are you headed?

[AlexB6S4]

Sounds good Alex! Where in Florida are you headed?

Ft. Lauderdale-ish. We are going to rent a temporary place for a few months to see where we want to settle down. I grew up there, so I am pretty excited about going back.


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