Shawn's 1.8t B6: This car deserves its own thread

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vt10vt
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Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

Okay well I have a sort-of thread for this car but I had such a good time taking it down to Carlisle I wanted to start a dedicated thread so here goes :)

About a year and a half ago I got a package deal on a pair of 3.0l B6 A4s. One of them had been hit but had a good engine and this one was an early '02 so it has the FYF 01E and a minty body and interior but a wrecked 3.0l. I bought them, parted the other car in a weekend, sold everything I didn't need and ended up with a $350 01E equipped, super clean roller. Then I traded an ABA/16v and 020 trans for a complete AWM with harness which is the later wideband version, small port head internal water pump etc.

The car sat at my parents for a few months in the winter and when spring came I moved it to downtown Burlington so I could work on it at my house. The plan was a big turbo 1.8t as they did come in that chassis so theoretically parts should be readily available when needed. I figured a bad ass Southbend clutch, some rods, a big 'ol Holset, VEMS and I could make good power on the cheap in comfort.

Exhaust valves were the only thing I didn't do that I felt like I should have, but we'll get to that...

So over the course of 5 months I put this thing together. It still rocks stock suspension and brakes but I got some HP2s for cheap I'm going to put on. Almost all the fab work was done in my garage, all the TIG welding was done at my work (Rennline Inc.) but I built the header, engine and everything else in the tiniest of garages. My intake manifold throttle body flange is really the only thing I didn't do myself, and there are some hacks (catch can and turbo outlet elbow :rofl: ) but overall I'm pretty happy with the result.

The list:
FYF 01E
VEMS standalone
Southbend custom 6 puck clutch and steel flywheel
AWM (now parts runner status)
Stock head/cams/valves
AEB Pistons
Scat rods
ARP headstuds
Walbro 460lph pump
Siemens 870cc injectors @4bar = 1000cc
Stock combo lines/rail (3.0l wasn't returnless)
Forge Splitter DV totally vented (junkyard find)
Home built divided equal(ish) length manifold
Holset HX35 7 blade- was stock 12cm, now .63 exhaust housing
Audi I5 wastegate
Stock intake manifold w/ VR6 TB flange
VR6 throttle body
CX Racing special gigantic intercooler
3" intercooler piping
3" downpipe -> 3" to diff -> 2x 2.25" home built $75 exhaust

Anyway, onto some pics!

Let's start with some good old 5cyl content: the $500 5k of win bringing the engine home
The Engine.jpg
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The shell losing it's 3.0l in the rents garage
The Shell.jpg
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Moved to my house! I live downtown and got really lucky and have a garage and relatively big driveway
Burlington Move.jpg
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Clean engine bay
Engine Bay.jpg
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Gromit with the 7 blade HX35
Holset Gromit.jpg
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Last edited by vt10vt on Thu May 26, 2016 12:46 pm, edited 1 time in total.
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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vt10vt
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Location: Winooski, VT

Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

Manifold mockup
Manifold Mock Up.jpg
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Manifold Mock Up 2.jpg
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Custom 6 puck Southbend clutch and 17lb steel flywheel
Southbend.jpg
Southbend.jpg (11.55 KiB) Viewed 25869 times


Intercooler install
Intercooler.jpg
Intercooler.jpg (18.96 KiB) Viewed 25869 times


Intercooler 2.jpg
Intercooler 2.jpg (16.8 KiB) Viewed 25869 times
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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vt10vt
Posts: 1021
Joined: Sun Mar 10, 2013 9:44 pm
Location: Winooski, VT

Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

AEB pistons and Scat rods
Pistons and Rods.jpg
Pistons and Rods.jpg (105.16 KiB) Viewed 25868 times


Coming together!
Artsy Manifold.jpg
Artsy Manifold.jpg (15.58 KiB) Viewed 25868 times


Across Manifold.jpg
Across Manifold.jpg (12.21 KiB) Viewed 25868 times


Money Shot.jpg
Money Shot.jpg (18.24 KiB) Viewed 25868 times


Real Bay.jpg
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-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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vt10vt
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Location: Winooski, VT

Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

These aren't really photoshopped except for a couple small grease spots despite their name :)
Photoshop Bay.jpg
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Photoshop Bay 2.jpg
Photoshop Bay 2.jpg (33.2 KiB) Viewed 25868 times


The 12cm was too laggy so I switched to a .63 Tim's Turbos hotside and it was much improved
New Hotside.jpg
New Hotside.jpg (17.4 KiB) Viewed 25868 times


And that's about where it sat until recently. I'm an idiot and didn't gap the rings on the first engine and they were Goetze. It had about 18k on it from September 2015-May 2016 and always ran well, but it had been losing power. My theory is the ring gap was too small and they ended up losing compression because it would smoke but much less when being beat (ie things expanding).
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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vt10vt
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Location: Winooski, VT

Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

Fast forward to 8 days before Carlisle 2016.

I'm on my way home, minding my own business, and a Focus ST hops on the highway with me. So there I am, radio cranked, foot through the floor, in it to win it, he pulled a bit but I pretty quickly reeled him in and walked around him. Halfway through 4th the car starts losing power, but remember I'm in it to win it, so I bang 5th and complete the stomping.

So I ended up here
Blown Motor.jpg
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Luckily I had my AAA card, my 'basic' tool kit, a compression tester, and some beers. By the time the truck got there I knew #2 had zero compression and was VERY melty and that all other cylinders were low.

With Carlisle in 8 days and going out of town on a mini-vacation Friday-Sunday the obvious thing to do was build a new motor from scratch in effectively 6 days.

So the same night I blew the motor it was out
That Night.jpg
That Night.jpg (15.36 KiB) Viewed 25868 times

After discussion with Marc at Carlisle the diagnosis is that I broke a piece of exhaust valve off on #2 and let that cylinder run crazy lean which caused the crazy piston melting. The hole in the valve is almost perfectly above the melting

The Cause.jpg
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Ouch
Melted piston.jpg
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It didn't actually melt the rod but there was melted piston all over it. I scraped as much as I could off and used my little belt sander to clean it up. The wrist pin bearing looked fine as did the mains on all the rods.
Melted Rod.jpg
Melted Rod.jpg (9.04 KiB) Viewed 25868 times
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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vt10vt
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Location: Winooski, VT

Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

I work a 4/10 schedule so Thursday was my day off so I borrowed the (wonderful ;) ) girlfriend's Prius C and found a new block and head from my friend Rusty who works at the local VW dealership. It's now an AWP block with AUG head, AWM cams and AEB pistons #partsrunner :rofl:
prius 2.jpg
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prius.jpg
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More carnage from the old motor
Carnage.jpg
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Then the lady and I stopped at Jim's on the way back from vacation and grabbed a AEB block from him
Canibalizing AEB.jpg
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Then I had a LOT of engines to build one out of
Motor Explosion.jpg
Motor Explosion.jpg (18.83 KiB) Viewed 25865 times
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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vt10vt
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Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

New head
New Head.jpg
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New Head 2.jpg
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New Head 3.jpg
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New Head 4.jpg
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The Tuesday before Carlisle the neighboring house burned down :o This is the view from my kitchen window- that's my MK2 and those flames are maybe 30ft from my garage/house
New Head 4.jpg
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Attachments
House fire.jpg
House fire.jpg (9.99 KiB) Viewed 25865 times
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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vt10vt
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Joined: Sun Mar 10, 2013 9:44 pm
Location: Winooski, VT

Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

3 old and 1 new AEB pistons and reused Scat rods
New pistons 2.jpg
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My girlfriend did a LOT of the build including the majority of the deglazing/honing, installing/torquing rod bearings, putting the manifolds on etc. Jokes were had at Carlisle regarding a built motor with a feminine touch :rofl:
New Motor.jpg
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New motor 2.jpg
New motor 2.jpg (13.86 KiB) Viewed 25862 times



So I finished building putting the motor together the Thursday before Carlisle and Dana came over at 5 that night. We dropped the engine first thanks to a missing pin in the hoist, and then successfully got it in the bay and hooked up. We got it running at about 12:30am, threw the front end together, drove it 100 yards up the block and back and said 'well, seems like it should make it 1,000 miles tomorrow morning.'
Ready For Carlisle.jpg
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And it did! I changed the oil Friday morning, finished a couple minor things, and drove it 450 miles to Carlisle at 13psi. Everything looked good once we got there so the MAC valve got plugged back in, the oil got changed again and I ran it at 25psi the rest of the weekend and trip home and it ran PERFECT.
Rolling.jpg
Rolling.jpg (11.13 KiB) Viewed 25862 times


And all I can say is "oh damn" :rofl:
[youtube]https://www.youtube.com/watch?v=lgLyD5k9OtM[/youtube]

Sorry for all the posts, but we're caught up now- thank you for reading along! :wave:
Last edited by vt10vt on Fri May 27, 2016 5:51 pm, edited 2 times in total.
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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loxxrider
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Re: Shawn's 1.8t B6: This car deserves its own thread

Post by loxxrider »

Hahaha damn is right!

Man, I didn't even realize what you went through to get to Carlisle. Another classic Carlisle story! Thanks for sharing that. I wish I would have had more time to discuss even though it's missing a cylinder.
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
E34 530i (maybe rear-mount soon)
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vt10vt
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Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

loxxrider wrote:Hahaha damn is right!

Man, I didn't even realize what you went through to get to Carlisle. Another classic Carlisle story! Thanks for sharing that. I wish I would have had more time to discuss even though it's missing a cylinder.

Yeah it was one of those things where I just did't have time to post haha definitely a helluva thrash to get there though. And yeah the missing cylinder sucks but unfortunately it maked the most sense for this project. I did test fit a 5cyl block though ;)
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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scubagli
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Re: Shawn's 1.8t B6: This car deserves its own thread

Post by scubagli »

Lol epic.

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dana
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Re: Shawn's 1.8t B6: This car deserves its own thread

Post by dana »

what a good time that Carlisle adventure was. Perfectly chaotic.
current:
-mk4 tdi wagon with some mods
-TDI b3 90q, holset turbo, be strong little connecting rods!
-the turbo tractor
past:
-11 second 90q junker
-20vt swapped 90q winter beater
-efi 20vt 4kq
-way too many other long gone urs's, 200's 4000's, b5's
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PRY4SNO
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Re: Shawn's 1.8t B6: This car deserves its own thread

Post by PRY4SNO »

Great read, that was quite the adventure.

This thread needs more kill vidz
Find me on Instagram @pry4sno

|| 2010 Golf Sportwagen TDI /// #farmenwagen
|| 2002 Dodge Ram 2500 24vt 4x4 #bertancummins
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar
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vt10vt
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Re: Shawn's 1.8t B6: This car deserves its own thread

Post by vt10vt »

As Dana put it, this will definitely go down as one of the most "insane but not totally insane" Carlisle trips ever.

I'll try to get some more videos for now, but here's some brake boosting-fuel cut-flyby-coolness from the Carlisle return trip

[youtube]https://www.youtube.com/watch?v=nANgTUsIQNM[/youtube]
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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