Dan's S8K...Strut towers gone :)

[40v4kq]

Thanks. There is much more to come.

[40v4kq]

Ok, so i forgot to take pics from underneath with the axles installed so i'll make this short and sweet. You can see in the previous pics that the rear driveshaft bolted up no problem. Had to swap the axle drive cups from the orginal 016 to the O1E. The driver side axle went in without a hitch, but the passenger side axle was too long by about an inch. Derek had a set of CQ axles laying around and we found that the passenger side(IIRC) was shorter than the 4k axle. So, we swapped the cv's form the original to the CQ axle and it went in prefectly. After that they got pulled out and taken apart,cleaned,and rebuilt with new boots and fresh grease.

The only pic I have right now. I think this is the passenger side frankenaxle before being disassembled for the rebuild.


With the drivetrain in place I wanted to turn my attention to the motor and get some service stuff done before bolting the front supprt back on. This was the easiest time to to the t-belt so I went to work. Replaced the timing belt,timing belt tensioner and roller,water pump, idler rollers, adn pulled the valve covers and cams to replace the all the cam seals and the cam tensioner gaskets. No pics of that stuff, but you get the idea.

While the valve covers were off Derek gave them a fresh coat of red wrinke and it all went back together and the support got bolted back on.




Yes, there is room for a radiator and a fan...but not too much. LOL.


We noticed that the variable runner stuff on the intake manifold was kinda frozen so we pulled the intake and split it for a clean and lube and found that all of the screws that hold the runner valves on their shafts were loose and a couple were only in by one thread. Everything got cleaned,lubed,and all the screws got loc-tight to hold them in. While the intake was off we decided to flip it around and have the throttle body face forward in an attemp to give some room at the back of the motor(possible future turbo location).


This was now time to start figuring out a throttle body solution because I'm not going to try and run teh factory drive by wire wet up. We scrounged the local pick and pull and found a close match in the for of an infinity q45 t-body. The bolts holes were close to the audi t-body and the opening was almost identicle. Still, it would need an adaptor so we made one out of 1/2" alluminum. The bolts that hold the adaptor to the intake were countersunk and then holes wer drilled and tapped for the t-body bolts. We cut off the coolant warm up portion of the q45 t-body and had to do a little grinding to get WOT.

[40v4kq]

With the manifold backwards it was hitting on the valley cover between the heads and on the PCV pipes that come out of teh valley cover near the back of the motor so we made some intake manifold spacers out of 3/8" alluminum. The holes eventually got ground out to match the intake runners. I think I lost the pics of the final product.



With the manifold backwards the fuel rails were backwards with the in and out at the driver side front of teh motor so I pulled the rails off and just spun em around back to where they were originally and grabbed a braided line form the CIS distrbutor and it bolted right on the and fuel rail and and the factory fuel line. No need to make a line to connect the two.

Only pic I can find right now of the fuel lines. I"ll get a better one soon.


Somewhere in there I had time to bolt in a battery box in the trunk. Standard fare stuff here.


We also ran a cable as thick as my thumb (double-ought?) from the battery to a distribution block from a V8Q that I mounted on the firewall. I"ll add a pic of that soon, just need to get one of it.

[Derracuda]

Man, I can't wait until this thing is done. I hope you post lots of videos!

[40v4kq]

Man, I can't wait until this thing is done. I hope you post lots of videos!

LMAO. The plan is to have the same amount of vidoes as there are pictures to have a good even raito of 1:1

[85oceanic]

:stupid:

[Justin517]

so cool, I have seen that 2-bennett car before I think.

I <3 V8's, hence my 540i/6 during these dark 1-car ownership times.

[dubsmith]

Looking awesome dude! The 4k is a perfect platform for a v8. Keep up the good work! (know you will with derek's supervision lol)

[ringbearer]

Chris - It does take up a lot of room, but i noticed that in the pictures with the front support off the car the motor really looks bigger than it is. It still takes up a lot of space but its not horrible, especially with all the factory emissions/evap crap gone and all the wiring I dont need it really freed up some working space.
Justin - Here is the car that set my mind on having a small chassis with a V8 in it. It belongs to a friend and was built by 2bennett...full cage,BBK,suspension,seats,harnesses,gutted, and an ABZ for motorvation, This thing goes like stink and once i got my first ride out at thunderhill I was determined to go V8.


Ben - Thanks. It may be a beast, but I think it will be plenty daily driveable.

Is that Marshall's car?

[40v4kq]

@ justin - Since I sold my roadrunner I've been without a running V8 and miss the wonderfull noise. My mustang is close to running but I want the audi done more.
@ dubsmith - Thanks. Derek has done mare than supervise. He's like a mad scientist with this audi stuff, and never runs out of ideas, and he has all the fab skills that I've been relying on to make this car happen.
@ ringbearer - Yes, that is Marshall's car. Hes a great guy, and a great driver. He sold me the wheels that are on the car in the picture. I think I've had them about two years. So, if anyone thinks I jumped on the white wheel bandwagon...Just know that I had them(and loved them) before the craze set in. You can ask Derek. I always loved the red with white look since I saw my first red sport quattro.

[40v4kq]

I just wanted to mention one thing. Once this car has been made running and debugged it will be disassembled(drivetrain) and everything will get cleaned/repainted as it is necessary and the underside/wheelwells will get a fresh undercoat. So if you notice things that arent super clean dont worry, it will be made to look like new eventually. A lot of this build has happened during the cold months of the year in oregon and that isn't very condusive for painting, so what needed to be painted has been and the rest like the subrames, drive line,cv shafts, etc will eventually get their turn as I do want this car to have the cleanliness that it deserves after so much time and effort has been put into this conversion. Plus Derek simply refuses to be seen in a 4KQ unless its pristine

PS, I added my plan for the car to the bottom of my first post on page 1.

[ringbearer]

Really cool project.

[ringbearer]

Marshall bought my 1st UrS4 from me a few years ago. Pearl on ecru, still miss that one.

[40v4kq]

Cool. I didn't know he has an S4. He brings his audi's to my friends shop for service so I wonder if he still has it, I should have heard about it or seen it by now.

[Sciroccohp]

Ok, so i forgot to take pics from underneath with the axles installed so i'll make this short and sweet. You can see in the previous pics that the rear driveshaft bolted up no problem. Had to swap the axle drive cups from the orginal 016 to the O1E. The driver side axle went in without a hitch, but the passenger side axle was too long by about an inch. Derek had a set of CQ axles laying around and we found that the passenger side(IIRC) was shorter than the 4k axle. So, we swapped the cv's form the original to the CQ axle and it went in prefectly. After that they got pulled out and taken apart,cleaned,and rebuilt with new boots and fresh grease.

The only pic I have right now. I think this is the passenger side frankenaxle before being disassembled for the rebuild.

Can you verify that it was the passenger side axle that you used from the CQ as I need to find one.
Thanks David
P.S. awesome build so far

[(4x5)v=20v]

I hope you left some room for the exhaust. Those mounts turned out nice. Lookin' good!

[40v4kq]

David - I spoke with Derek about this since I cant remember 100%. After a couple conversations it seems that the axle used in my car is from a B3 20v 80 or 90, not from a CQ like I had said. It has to be from the right front as that is the short side. I was informed that the 20v 90 and the the CQ have larger diameter bearings that use a different hub and cv's and therefore the axle shaft itself has larger splines that wont except the cv's front the 4k axle. That would explain why I had to find struts,knuckles,and the outer cv's from a 20v b3 80 when i upgraded to two-peice struts on the front of my car. I grabbed all those parts from a front wheel drive 80 out in the local pick and pull. Hope this helps.

Paul - No worries mon :wink: and thanks.

[40v4kq]

Time for suspension and brakes. I wanted the suspension to be adjustable but I dont have the money for some KV V3's so I did the next best thing thats a cheaper do-it-yourself setup. Also wanted to beef it up with nice bushings and what not. For brake it will be a simple bolt on upgrade for now but someday it will get a nice BBK.

Ground Control with 400lb springs front and rear.


Koni adjustables. These are the original konis from Dereks alpine 4kq so to me it is an honor to have them since they are from a car that I have some good memories of. RIP alpine car. All four of them are front shocks so they are all external adjust(no compressing and spinning to adjust) with spacers on the ones that go in the rear to take up the gap that is created inside the strut housing because front shocks have a smaller diameter than rears.
In suprisingly great condition for being about 7 years old. No rust or leakage.


I changed to front struts to two peice from a b3 20v 80 or 90 that was at the local pick and pull. To do this required changing the outer cv's to the ones off of the car I snagged all the suspension goodies from. Luckily the new boots I had already put on fit the new outer cv's and I was able the reuse the outer boot clamp.


Once I had the spring perched cut off the strut housings everything got sand blasted before the new perches for the coilovers were welded on then everything recieved a coat of primer then a couple good coats of satin black paint. Nothin you guys havn't seen so heres the final product. Strut mounts are 034 track density.


For brakes I went with calipers and rotors from a b5 a4. Cleaned the calipers and painted them red with a duplicolor calipaint kit. Turned the rotors on the brake lathe at work to clean them up...although they have gotten some surface rust from sitting. Redrilled the hat to 4x108. Installed braided brake lines with the a4 calipers. And since I hate wheel bolts I installed wheel studs from prestige wheel. The wheel studs have a hex in the end for an allen wrench so you know you got em all the way in. I added blue loctight in the threads to keep them from backing out.



Took the time while the suspension was out of the rear to install this subframe that has the solid spacers and a swaybar.



Heres the rear susension put back together with the old calipers. I have another set that will get the same treatment that the front a4 calipers got unless I find a good set of b5 s4 calipers before I get around to it.


I wanted to install delrin bushings in the control arms and it just so happened that Derek had a full set of control arns laying around that already had them installed so I snagged em up. These just happen to be THE prototype delrin bushings from Billzcat1. The control arms were already stich welded so they were sandblasted and repainted then bolted in place when everything went back together.



The booster got sanded and repainted with black wrinkle by the master of the wrinkle paint himself. The original master cylinder was replaced with one from a 200 20VT and the original leak prone proportioning valve was replaced with a Willwood adjustable unit that bolted in where the cruise control pump used to be.

[loxxrider]

you're going to love that suspension setup

[40v4kq]

you're going to love that suspension setup

Oh yes I will. It's the exact same setup Derek had on his alpine car and it was rock solid.

[edigi]

That will be one mean 4000! sweet project, Can't wait to hear it run.
the A4 front brakes bolt right up to the 80/90 hubs (minus the re-drill for 4x108)?
Love the wheels too, they will be perfect for this car.

[40v4kq]

edigi - Thanks, and yes the a4 brakes just bolt up to the 80/90 hubs and I forogt to mention the redrill on the rotors. I'll edit my post. You reminded me that I forgot to post up a picture of the wheels. Wheels are old school Ronal 16x7.5 ET35(dont know what model) and are powder coated white. Tires are brand new Khumo XS 215/45/16 and fit just about perfect. Heres what I got...



And this is how the car sits now. 600 miles away from me. Looks pinkish in the pics but thats just cuz it was overcast and the car was all wet.

[edigi]

Love it! Makes me wish I had slowed down and built my car "Cleaner".
All the wrinkle coated and fresh painted parts look nice.
are you using 034 or the stock computer to run this beast?

[40v4kq]

VEMS built by Marc at EFI express will be running this beast. I guess I forgot to mention that too. I beleive its a V3. It has a 3 bar map sensor for future plans :wink:

[dubsmith]

WOW! Car is looking super sick man. Do you know the ET on those wheels? Hellaflush lol