B5 S4 Build

[Vieussuex*]

So back in early 2011 I was only suppose to just get my Polo serviced by Seb from Euro Automotive and saw a rare gem sitting in the corner of his workshop being neglected it was a B5 S4 Avant.

Now originally he told me this was going to become his family car but that never eventuated as his partner doesn't drive manual...and she refuses to learn how to>D

So I struct a deal with Seb to buy the car and just to do a KO4 upgrade.
One thing lead to another and I decided to rebuild the gearbox......... I then said to myself the S4 is going to be sitting around for a while so I might rebuild then engine, then I thought with all that power I'm going to need bigger brakes, then I found myself trawling for s4 builds on vortex, audizine, rs246 and audiworld forums and came across all these guys in the US with RS4 outlaws or RS4 conversions and now I find myself trying to do the same!

Why do this you may ask?
I've always wanted a B5 RS4, to get one new back in it's day they were priced around the $160K (quoting forum here say:rolleyes:), and still second hand they start from $50K......a decent one unmodified and low km's is up around $70K when they decide to surface.
I've done the maths and for around about the same price I can have a stage 3 completed, thats 300kw+ atw>D

So join me, I will take you on a journey of heartache and probably financial hardship (as my budget will most likely blow out)!


This is how I got her:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00032201108141251-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00034201108141252-1.jpg
she didnt turnover but I was still excited!

Got cracking and started to strip her down:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00058201112041246-1.jpg

Engine out:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00061201112111402-1.jpg

RS6+ brakes arrive from Austria!:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00003201102081009-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00005201102081009-1.jpg

..test fitted with 19" VMR v701's:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00051201108211752-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00037201108141704-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG00038201108141704-1.jpg

Should have some more photos and updates after this weekend of the rear 034 motorsport 300mm rear brake kit, ported exhaust manifolds and full exhaust!

[ope126]

WOW I'm excited!!!

Keep us up to date, that's a rare find there mate!

[robbie]

Wow what a special find!!!

I'm keen to see how this build will pan out :)

[Vieussuex*]

Ok so here is some stuff that has been lying around the workshop for a while but just been to lazy to take some photos

Painted the factory rocker covers ...not a fan of the plain dis-coloured raw aluminium!
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/Sydney2012021900035-1.jpg

After market Bi-Pipes from ARD which are about 30% larger then stock:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/Sydney2012021900032-1.jpg

Ported out the factory exhaust manifolds....probably increased the diameter buy about 7-8mm on each port. Now ready to be ceramic coated!:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG2012021900018-1.jpg

SMIC. These are the CX Racing one's from eBay, now these haven't had a the best reviews as people in the States have complained about heat soak as the cores are cheap but because they are less then a third of the price of ER's, Apikol's or AWE's shipped here I'll risk giving them a go. I'm going to be running water/meth so I should be able to keep intake temps down anyway:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/Sydney2012021900037-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/Sydney2012021900038-1.jpg

[Vieussuex*]

Now the fun stuff that arrived on Friday!:grin:

JE pistons:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG2012021900025-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/Sydney2012021900027-1.jpg

Rods, valves, lifters all from Intergrated:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG2012021900021-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG2012021900020-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/Sydney2012021900029-1.jpg

Borg Warner K04's:-
http://www.vwwatercooled.com.au/forums/images/imported/2012/02/IMG2012021900014-1.jpg

...with all the internals here we should be able to get the engine builder to turn the engine around in 2-3weeks:grin:

[Njay]

you should put this on ozaudi, hardly any build threads on that forum

[Vieussuex*]

Been a while since I've posted but I'm almost done this build but will give you a run down on how it went.

Got the heads and block back from the engine builder and started assembly:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121009_160359-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121009_160348-1.jpg

Replaced the stock suspension with KW v3's:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121007_142056-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121007_142111-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121007_201436-1.jpghttp://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121007_201527-1.jpg

Gearbox was also rebuilt with a custom input shaft with a wider 1st gear, new carbon syncro's from 034 Motorsports and a 4:1 centre diff from JHM:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121117_101500-1.jpg

Engine, gearbox, K04's, inlet pipes, down pipes etc all bolted up:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121117_155206-1.jpg

Engine back in also running ARC Bi-pipes with meth bungs, and Forge DV's:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121201_183947-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121201_183924-1.jpg

[Vieussuex*]

Rest of the piping, SMIC, shrouds and radiator fitted:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121202_163040-1.jpg

(At the time of this pic I was originally going to run a 034 95mm MAF housing with a Hitachi MAF but due to scaling issues in the tune I've gone for a factory B5 RS4 MAF running a Bosch MAF instead.)

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121202_163210-1.jpg

When I got the car there was a bit of panel damage so my initial plan was to go widebody with RS4 guards bumpers etc. After finding out how much this would set me back I canned the widebody conversion.
I found a decent aftermarket RS4 replica bumper made by Dietrich concepts that would also fit the factory RS4 grill inserts:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121117_172020-1.jpg

I had her resprayed in the factory silver and also removed the lower doorsils:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121223_155139-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121223_155159-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20121223_155309-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20130104_173511-1.jpg

Also added a Cupra R front lip:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20130104_190525-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20130104_184407-1.jpg

[Vieussuex*]

Installed a JHM Drive train stabiliser bar in:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20130128_200226-1.jpg

BMC CDA airbox and 034 Carbon Y pipe:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20130128_231403-1.jpg

Also installed a Zeitronix Wideband AFR and LCD display:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20130725_100627-1.jpg

Whiteline 18mm heavy duty rear sway bar to help it turn in a little better:-

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20130824_132621-1.jpg

[Deadpool]

Incredible build, can't wait for more.

[Vieussuex*]

The first time I tried to run the engine in I've been plagued with issues.
Initially I thought I had a headgasket blow within the first 200km after the engine build, I was taking off very sedately at an intersection only to hear a pop and loose drive and whole heap of smoke come pouring out the hood with the distinct smell of coolant and oil.
When we got it back to the workshop we worked out that the oil cooler for the gearbox ruptured letting coolant fill my gearbox and the coolant system full of geabox oil:facepalm:
To top that off one of the metal coolant pipes that runs along the top of the block ruptured at the same time pouring a mixture of coolant and oil all over the engine hence the steam/smoking.
I'm sure your asking "but why did the car loose drive it's only coolant and gearbox oil?" well it so happened to also blow a driveshaft, drivers side to be exact....again all at the same time!:facepalm::facepalm:

Fun times, at this point I almost canned the rebuild altogether.
I ended up coming to my senses and kept on going replacing everything that failed and had the gearbox pulled apart again.

Recently my only issue has been cam timing which I've finally sorted out..ended up being a tooth out on the intake cam in Bank 2.

While I was doing redoing the timing I also installed a ICM delete kit from 034 and also upgraded my coilpacks to Beru white tops.

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20131229_115630-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20131229_175931-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20131229_180416-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20131229_182512-1.jpg

So fingers crossed I can get back to logging now!

I'll finish with a pic of how she currently sits with some BBS LM's

http://www.vwwatercooled.com.au/forums/images/imported/2014/01/20140104_103224_Ingrid_Smoke-1.jpg

[quattro5v]

I like this thread!

[Vieussuex*]

The logging/tuning begin!

http://www.vwwatercooled.com.au/forums/images/imported/2014/02/20140129_201254-2.jpg

[golfmeup]

Great looking car, don't see many B5's on the road.
Can't wait to see the power results after tuning!!