J.Moss@TorqueFactory

Hi Everyone,


Thought I would share some more updates on our project car. You can look <a href="https://forums.audiworld.com/s4/msgs/2658578.phtml">here</a> here for our last post on our new fender flares, wheels and tires, brake ducts and bigger than our last big brakes.

As most of you know we ran this car under the <a href="http://awe-tuning.com">AWE-Tuning</a>/<a href="http://torque-factory.com">Torque-Factory</a>/<a href="http://giacusa.com">GIAC</a> banner in last years <a href="http://www.eurotuner.com/eventcoverage/160_0701_et_tuner_grand_prix_event_coverage/index.html">Eurotuner Grand Prix (aka ETGP) </a> and were awarded the overall win. We also ran this car at this year <a href="http://germaninvasion.com/Home_Page.html">German Invasion</a> put on by <a href="http://wicked-motorsports.net">Wicked Motorsports</a> and our car was the quickest street car there with an 11.62 with a density altitude of over 6000 ft. We had added a small dry shot of nitrous that is mappable by rpm vs solenoid duty cycle. In testing the car was ferociously more powerful than our 11.47@122 tune so only hitting 11.62 was a disappointment. More on this later...

We have some goals and with Eurotuner GP coming up again and hopes of getting in the Sport Compact Car USCC event we wanted to be able to hit this car harder with bigger/stronger hardware. We decided it was time to crack open the motor to freshen it up, check it out and put in some connecting rods to strengthen it. We will be going with a full factory style rebuild with the exception of the connecting rod and head gaskets. The rods were purchased from <a href="http://pauter.com">Pauter Machine</a>. This company is very well respected in the engine building industry and I have used dozens of their con-rods in the past with excellent results and service. We decided to drop the compression ratio and <a href="http://www.034motorsport.com">034 Motorsport</a> had just released their new headgaskets which use oem style construction with a thicker shim. A quick call and they were on the way.

Everyone is probably waiting for me to talk about the ported, coated, forged thermal barrier coated, 290,000 psi studs.... But when we tore down the 62,000 mile it looked really good with one exception I will get back to later.
Headgaskets - Perfect.
Pistons and rings - Perfect.
Skirts - Perfect.
Bearings - Perfect.
Bores still have factory cross hatches all the way around - Perfect.
Valves and the rest up there- Decent, Needed valve guides which is a common wear part and had 3 slightly bent exhaust valves. Puzzling as the car ran so well.
Turbos - Perfect.

Connecting Rods - Not so perfect. Although bearing surface and wrist pins were 100% intact and all look like a really well maintained motor it was found that when we had <a href="http://pauter.com">Pauter Machine</a> look at our factory rod and the one sample we sent was .030 shorter than spec... Don@Pauter called it a "Horse-shoe." Funny guy!!! Upon closer examination if you look at the forging seam you can see that one side is perfectly straight and the other has a slight bend. Since there was absolutely no evidence of detonation I think we have definitely found a power limit here and feel extremely fortunate that we tore it down when we did. We had suspected that we were slightly down on power, and our lowered compression connecting rods seems to support this. Odd thing is that the car drove perfectly up until we tore it down. We figure it made close to 700 ft/lbs during testing. Definitely too much for a stock motor.


Off with the heads and lets take a look at what the punishment has done to this motor.

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<a href="http://photobucket.com" target="_blank"><img src="http://i33.photobucket.com/albums/d78/J_Moss/Brent/Engine%20Teardown/batch%202/valves_bent.jpg" border="0" alt="Photo Sharing and Video Hosting at Photobucket"></a>
We had 3 bent exhaust valves. This really surprised us as the motor had no misfires...

On to some of the new shiny stuff!
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From what we can assess our prior setups was one of the most powerful K04 based setups tested and defineately one of the quickest. It had run 11.40's uncorrected for elevation. The track official said that was a 10.90 to 11.0 at sea level. Not bad for about 3500 lbs without porky driver.
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Since we have not extended the rev range much over stock and we have seen some of these motors with some "interesting" cam and lifter wear we left the valve springs and retainers stock Audi.
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Headbolts penetrate over 2 inches into the meat of the block.
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Audi High-Output turbo head bolts. We ran close to 700 ft/lbs with this prior. They get two big thumbs up!

Here is where things get interesting:
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Wait... Does that <a href="http://pauter.com">Pauter Machine</a>. rod look a bit longer than the stock one shown?

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<a href="http://photobucket.com" target="_blank"><img src="http://i33.photobucket.com/albums/d78/J_Moss/Brent/Engine%20Teardown/batch%202/pauter_vs_horseshoe.jpg" border="0" alt="Photo Sharing and Video Hosting at Photobucket"></a>
Defineately a horseshoe. Don from <a href="http://pauter.com">Pauter Machine</a>. had told us that the sample we had sent him was .0030 shorter than spec... &lt;note to self and Brent&gt; Maybe the small shot of Nitrous was over the top for a stock motor...&lt;/note to self and Brent&gt;

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Check out how you cannot even see the split where the big end comes apart.

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"Quickaudi" wanted to see our 600 hp fuel rail. It looks just like a stock one ? And our new 700 hp rail.



Motor did not have any misfires and passed a smog test prior to teardown.




This post is a couple of months late in coming, but here you go.

mike (@home)

that looks sick!

Slave IV

Nice, thanks for the info. I'm going to call you when I'm ready to go stage 3.

Mike/A.W.E.

Nice post. Love it!

But how about some smaller watermarks?

Slave IV

Do the Labree split DP's fit the RS6 turbos? I haven't looked into this much but remember reading that the RS6 turbos have some kind of internally split wastegate and the DP's in question have a split design (I'm assuming for turbos that don't have the internal design). Will these still work together and is there any added benefit or detriment?

AJN334

to the nitrous usage or just a bit too much power overall? Also how much longer do you think the car could have ran as it was before the problems would have come apparent?

You guys have done some really impressive work and the informative posts are great, congrats and keep it coming ;-)

J.Moss@TorqueFactory

related.

J.Moss@TorqueFactory

J.Moss@TorqueFactory

be sure.

J.Moss@TorqueFactory

Look forward to hearing from you.