The Project Pad

I'm finally getting around to starting a project page for my addiction of this car. It's an 89 200 quattro. This endless money pit project started from the frustration of a 20 valve with CIS, which gave me so many problems I couldn't take it any more so I jerked the motor and trans to come up with something different. Getting rid of the car was not an option as it is sentimental. (Uncle's last Audi of 5). More power is of course the main goal so I thought of some other big displacement transplants and decided to keep it all Audi. I then knew that A well built 20 valve was going to be the answer and that one exhaust and intake valve per cylinder was not going to flow enough. I even wanted the 25 valve until I found just how rare it is. Still wanting more displacement, I decided to look into a stroked motor which led me to the question of tall deck or short...95.5....or 92.8mm. I decided on the 92.8 because of many unanswered questions I had about doing a tall deck 6 years ago. Anyway, finally made the decision to do a 92.8 stroker but I waited too long. 034 sold what factory MYSTERY cranks they had left in stock. That slowed this project down by several years. I called Eurospec, just about every junk yard in South Africa, and did endless hours of google search to find out how or where I can get this crank. While living in Iraq and in Europe, I found that I was on the trails of dead end leads. I translated German sites which led me to be 6 months behind the last one fore sale. I began trying to work with Eurospec to see if the could reproduce them. They told me they already tried it and all of them came from the manufacturer unusable. I asked if they had a blueprint of it and I would go to U.K. And have a manufacturer make some. The company said if I had the drawing, they could do a minimum of four. Eurospec said they did not want to release the drawing because the were working on another manufacturer to get a better quality product. So of course wanting to get started on my project, I bugged them every several months if they were ready. Nope. No. Not yet. Almost. I gave up and posted wanted ads for the crank. Turned up nothing but scammers from Nigeria. The car just sat in the garage while I was overseas. One day, I happened to be looking through a "for sale" posting and called a guy on some parts... He mentioned he had a stroker crank! My ears perked up. I was trying to find out if it was legit or some custom made one. At this time Eurospec had started supplying the reproduction cranks to 034, but I didn't want to pay $1,500.00 for the crank. He said he bought this a long time ago but couldn't start/finish the project. Needless to say I jumped on it. I bought the crank along with some other parts for the build. One of the main puzzle pieces had been found. To this day, I still don't know what the crank came out of. I have heard a a diesel, a generator, some rare Audi marine motor, a mini buss, and the list goes on. I know Hap McGuire has one in Da Green Monstah, Chaloux, Quattro87, Hank, and myself. The main goal for this car is for it to be a high horsepower, 8-8500rpm limit, E-85, convenient to drive, daily car, hopefully a sleeper.
So here is the build for my 200
AAN block O-ringed
92.8mm stroker crank modified for extra flow (oil)
JE pistons
Eurospec Rods
Polished 7a oil pan and baffle with AAN windage tray
Ported AAN oil pump for extra flow
EFI express billet crank gear
034 60-2 harmonic balancer
Polished engine mount brackets
Polished water manifold
Polished accessory brackets
Big valve head. Custom valve seats. 34mm exhaust 29.5mm intake. PORTED!
Lightweight lifters, yes hydraulic
Titanium retainers
High rate valve springs
Cat custom cams
Tommis billet adjustable cam gear
Four Ring Performance exhaust manifold
Bored throttle body to 70 mm and throttle wedge removed
Polished Wagner high output manifold port matched to head & port matched to throttle body
ARP fasteners
Spec lightweight aluminum flywheel. (For sale, never installed)
Spec stage 5+ clutch (For sale, never installed)
[planned] fuel injector clinic 2150 cc injectors for E-85
[planned] 01E speed not sure if going to stay 3:89 or go 4:11
[planned] EFR series Borg Warner turbo

Wow, welcome! Projects are coming out of the woodwork over here! Glad you are going to share this project with us, hopefully with a bunch of pictures of the art that comes out of Jeff's shop. We usually only get Jeff's work in small video clips of him ripping across the salt at 200+. Keep the updates coming!

Yeah, I have some great pics, but don't know if I can attach them from my iPhone. I might have to wait until I am at my lap top unless anyone knows how to upload from a phone. Jeff is awesome to work with and has saved me from many costly mistakes. He does great work, doesn't try to sell you stuff that you don't need and takes the time to answer questions thoroughly. I told him I don't need to run 250- 260 mph but It would nice!

I'm going to get fired and not have any more money for this million dollar build if I can't get away from this MG/PP tennis match. The entertainment is too good!

Welcome Josh. I'll be watching this build. Go ahead and add me to the list of those with a 92.8 stroker crank. I need to put mine together before Hank gets the 07ks rolling. The difference with my build now is that I have decided to go tall deck long rod with mine. How far along are you with the build?

Really! Is it a factory 92.8?

Everything is ready except one item holding the whole thing up. I'm waiting on a solid copper head gasket to mate up to the O-ring job on the block. I will add you to the list though.

Hey, my new motor is a 92.8 too

OK, adding yours to the list too.

Welcome Josh! I'm excited to see another T44 project, especially of this level! Can't wait to see some photos.

Here are some pics of elbow grease application. some shot comparisons of My 7A next to an AAN pan. I like being able to use the 7A baffle with the AAN windage tray. And yes, I shaved off the cooling fins, made it a lot easier to polish. I don't think it will cause problems. That is what the external oil cooler is for.

showing some more pics of intake manifold mixed with some more elbow grease. It is a Polished Wagner High Output manifold with a 034 fuel rail that has the runners port matched to the head and the intake bored to match the bored throttle body. In one of the pics, you can see how much ''meat'' had to be removed to match the 70mm throttle body.

removing 5mm to match throttle body

Thanks AMD. You have a clean 200 yourself. I been in your postings many times. Great progress. I'm sure I will be asking info on ''the do's and don'ts'' about an 01E swap.

here are some more goodies for the breathing monster. Tommis Billet adjustable cam gear and Cat Cams.

nice high flow stainless exhuast manifold guaranteed for life and proven to flow enough for Jeff's Bonneville race car

I will upload more pics tomorrow.

WOW is all I can say! What are you planning for a turbo.

That polishing work is out of this world. I'd never have to patience to accomplish something like that. More so, keeping it clean.

Which model Cat cams are those? Still planning for hydro lifters?

I'm still going to use the lightweight hydraulic lifters which is why we are limiting it to around 8000.... maybe 8500 rpm. Jeff had to specify the duration of the cams to Cat as they did not have a pre selected pair of "of the shelf" selection. I want to try to push it as far as I can while still making it a daily driver. I don't want to have to wrench on it and adjust it all of the time. I could be forced to go to solid lifters later if I get greedy for more rpm and horsepower, but I will fight it as much as I can. I'm trying to use self control and not going all out like putting some massive turbo and winding it out. I want to try to build it tough and treat it nice except for an occasional hard pull leaving some loud American V8's in shock as they see a big four door luxury boat blow past them.
As far as the turbo, I might get criticism, but I am thinking of running a Borg Warner EFR series. I really like the internal waste gate and BOV. I know that had supply issues with the hot side but it seems they are shipping now. And I do know about the ugliness from the casting which is why they are doing a "free" ceramic coating. I just like the idea of cleaning up the engine bay with less piping. The claim is that they spool up faster than most with the gamma Ti material. If I'm not satisfied, I will pull it off and use a twin scroll from another company in conjunction with a quick spool valve. I bought one from Sound Performance but have backed away from the idea using it just yet.

Forgot to add... If you like the oil pan, you should see my valve cover, engine brackets, water manifold, and mounts. I'm thinking of taking a spare emblem that I have from the trunk and putting it on the polished wave cover. I will send some pictures of different ideas. I just don't want it to start to look "tacky" or "gaudy".

Looks good. I am excited to see an EFR on a 2.5L. What one are you looking at? Get it in Twin Scroll so you can use the valve on it! 8374 from the looks of other hardware? Have you put in the order yet and grabbed a seat in line?

They are BIG turbos in the sense of packaging. In a Type44, you probably have the room. in the type85, they take up every ounce of real estate.

Yeah, they are quite a bit larger... No doubt about it. I just like the simplistic look of everything being internal. The T4 twin scroll 8374 83mm .92 ar is the largest turbo i can get and still have everything internal so that is the plan for now. They are saying that the hp rating is super conservative and guys are seeing well over that to the wheels. Full Race is telling me that there is a four week waiting list because they are still getting mixed batches of the good castings with the bad. they did say they polish them all and coat them though to make up for it. If whomever tuner i decide to use is comfortable with setting up the acuator to open the quickspool valve, we will do it. Still open to suggestions though. I was original thinking of a divided comp and quick spool. Turbo sizing and experience is something I don't have much knowledge of, just testimonials and write-ups. I was reading in AMD's project that you are working on some transmission mounts for us 200 guys... How is that going?

I started changing the front for two reasons.... One is.... you know that rubber filler that runs along the bottom of the head lights?... The one that is no longer available... I had to come up with something to hide the gap. The other reason is... I am going to need to increase airflow to the intercooler up front. So I am working on a stainless grille for the factory grill as well as the bumper. I gathered up some factory 200 trim pieces to keep it as factory looking as possible. You can see where I am adding a long stainless trim all the way across the front just under the headlights and where the black trim used to be which I no longer have. Don't make fun of it yet. I still have tie wraps holding the pieces to the factory grille until I bolt them on. The pieces on the bumper are bolted on. I sloted some stainless bolts to slide into the channel where the factory plastic clips used to be. (hated them, always breaking) I still need to cut out the air slots for the aluminum portion of the bumper. I am cutting just below and above the bends to leave them in there to keep the rigidity and not compromise too much strengnth. I pray that I never have to worry about a collision and if I have one, the air slots I am cutting out will be the absolute least of my problems.

Here are some ''in progress pics''

And what does anyone thing about a small, subtle, low, cowl hood. maybe 1 1/2''

I also added V8 brushed aluminum entry guards with the Audi logo as well as the V8 C pillar trims (I think that is what they are called)

awesome project!