Audi CQ (S2 clone) rally car project

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Audi CQ (S2 clone) rally car project

Postby rallyfreak202 » Wed Apr 06, 2016 8:30 am

Hey everyone,

Here is my 1990 Audi Coupe Quattro (pretty much an S2!). It has a lot of history. Was built in 1998/1999 by George Plsek and campaigned by him until 2001 when Leon Styles took it over. Felix Tang and another owned it since I purchased it. All owners have been responsive and nice to deal with, especially George. In the early days Alex Gelsomino co-drove it for George. Pretty awesome. No expense was spared with the construction of this car. I’ve been told it was acid dipped several times. I am very fortunate to have picked up this car and am excited about the future with it. My good friend drove the car at Sandblast this year and it did well. I hope to do BRS in NY this October.


To-do list:
-many small, boring, tidy tasks not worth mentioning
-detune to pump gas
-throw out bearing
-cage update
-paint the car (white with Audi Sport livery)
-rebuild turbo or swap to BorgWarner EFR 6758. I believe it’s sucking oil through the shaft piston rings due to pressure differential inside bearing housing. The restrictor isn’t helping…
-acquire lots of spares!

Diagnose and fix high RPM misfire: changed the loud fuel pump out and put a new MSD Blaster coil in it. Next up, change the cap, rotor, plugs, and maybe ignition box.

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Last edited by rallyfreak202 on Thu Apr 07, 2016 2:36 pm, edited 3 times in total.
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Re: Audi CQ (S2 clone) rally car project

Postby PRY4SNO » Wed Apr 06, 2016 9:47 am

What an awesome machine!

What size of turbo do you run now that needs a restrictor (class requirements, I assume)?
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|| 2010 Golf Sportwagen TDI /// Farmenwagen
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar

|| Spare parts for sale
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Re: Audi CQ (S2 clone) rally car project

Postby LeafBox » Wed Apr 06, 2016 2:12 pm

Really cool!
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Re: Audi CQ (S2 clone) rally car project

Postby the german » Wed Apr 06, 2016 10:49 pm

Awesome! Would love to see more pictures of it.
Kirk

1990 ABZ CQ
1990 lifted CQ
2005 S4 6MT
2011 A4 2.0T Avant (ok, it's my wife's car but it's sexy and I love it)
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Re: Audi CQ (S2 clone) rally car project

Postby dalspaugh » Thu Apr 07, 2016 7:25 am

Nice! Another Rally CQ build!

Was this the car that popped up for sale in CT and had everyone talking?? I messaged the seller just to walk around it and take notes (since I'm building an NA CQ for rally), but sadly got response! More pics please!

Anyway, excited to see what happens here!
'95 Audi 90Q
'91 Audi CQ Project: Davescq.wordpress.com
'00 Buell X1 Racing Stripe
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Re: Audi CQ (S2 clone) rally car project

Postby rallyfreak202 » Thu Apr 07, 2016 2:08 pm

PRY4SNO wrote:What an awesome machine!

What size of turbo do you run now that needs a restrictor (class requirements, I assume)?


Thanks. In rally you must run a restrictor on the turbo. 34mm inlet restrictor.


dalspaugh wrote:Nice! Another Rally CQ build!

Was this the car that popped up for sale in CT and had everyone talking?? I messaged the seller just to walk around it and take notes (since I'm building an NA CQ for rally), but sadly got response! More pics please!

Anyway, excited to see what happens here!


Yep, this is the car. I was able to get it titled and registered legally. I'll post more photos.
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Re: Audi CQ (S2 clone) rally car project

Postby PRY4SNO » Thu Apr 07, 2016 2:16 pm

If you're restricted, why not run a smaller turbo to get more torque down low? Like an EFR 6258?

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|| 2010 Golf Sportwagen TDI /// Farmenwagen
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar

|| Spare parts for sale
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Re: Audi CQ (S2 clone) rally car project

Postby rallyfreak202 » Thu Apr 07, 2016 2:40 pm

PRY4SNO wrote:If you're restricted, why not run a smaller turbo to get more torque down low? Like an EFR 6258?

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That is most likely what I'll do but this engine might have a higher displacement than stock. I mean, who knows? :D
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Re: Audi CQ (S2 clone) rally car project

Postby Dan McBoost » Thu Apr 07, 2016 8:38 pm

If you go to BRS, please let us know. I would go cover that event for you guys. I have a bunch of friends that go too.

awesome stuff!
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Supras: ● 88T ● 87T ● 87T ● 85P
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Audis: ● 04 A8L ● 97 A8Q ● 91 200 TQA ● 90 CQ ● 85 4000Q
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Re: Audi CQ (S2 clone) rally car project

Postby WOMBAT » Fri Apr 08, 2016 8:38 am

Dan McBoost wrote:If you go to BRS, please let us know. I would go cover that event for you guys. I have a bunch of friends that go too.

awesome stuff!


Samesies, would go out and support! Always willing to crew as well..
Casey O

Current Attire:
- 2007 Audi A3 3.2 quattro

Past Projects:
- 07 Cooper S - 91 200 20vt - 91 90 20v - 85 4000CS - 96 Audi Cabriolet 5 Spd - 02 A4 1.8T - 91 V8 5 Spd - 01 A6 2.7T 6 Spd Sport - 86 5000CS - 91 100
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Re: Audi CQ (S2 clone) rally car project

Postby dalspaugh » Mon Apr 11, 2016 10:12 am

Good pictures. what's the brake set up like? looks like no booster?
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'91 Audi CQ Project: Davescq.wordpress.com
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Re: Audi CQ (S2 clone) rally car project

Postby rallyfreak202 » Thu Jul 28, 2016 12:47 pm

New livery!

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Re: Audi CQ (S2 clone) rally car project

Postby rallyfreak202 » Thu Jul 28, 2016 12:50 pm

dalspaugh wrote:Good pictures. what's the brake set up like? looks like no booster?


Correct. AP Racing 2 piece all around. Hydro ebrake. Need to rebuild the rear calipers before ESPR.

Casey, I'll let you know! Would love to see you up there.
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Re: Audi CQ (S2 clone) rally car project

Postby ringbearer » Thu Jul 28, 2016 7:17 pm

Awesome! Have fun with that :)
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Re: Audi CQ (S2 clone) rally car project

Postby vt10vt » Fri Jul 29, 2016 12:07 pm

You're co driving your own car?!?!?! WHY???
-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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Re: Audi CQ (S2 clone) rally car project

Postby rallyfreak202 » Thu Sep 14, 2017 9:45 am

I'm long overdue for an update.

The car has completed 2 rallies since last update; Sandblast rally in SC and ESPR in NY. ESPR we had a fuel pump failure due to anti-slosh material clogging the pump. I guess they installed this anti-slosh stuff when the car was originally built. We limped back to service and replaced the fuel pump with a spare. Finished the rally although technically DNF'ing due to missing a stage. At Sandblast we finished without any problems. I fucking love this car. Sometimes I just go in the garage and look at it and dream. I can't believe I own this beast.
Completed:
-new livery!
-EFR turbo install with 3D printed restrictor
-cage update
-DW200 fuel pump instal-Thanks Marc!
-DMS suspension overhaul $$$$
-new seats (thanks Dad!)
-new safety harnesses
-AFR gauge
-momo steering wheel
-detuned for 93oct

To Do:
-might need a new roll cage due to this being outdated (mat'l used is chromoly)
-rear control arm bushings. Custom control arms and bushings so sourcing it might mean making my own
-fabricate wheel scrapers
-change trans oil
-alignment
-add flex pipe in exhaust
-oil pan gasket. PITA due to dropping subframe (custom)
-replace broken front axle (doing now)
-procrastinate on replacing the worn AP Racing 2 piece rotors
-pin-style jack stands
-repair cracking paint


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Last edited by rallyfreak202 on Fri Jul 27, 2018 1:57 pm, edited 2 times in total.
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Re: Audi CQ (S2 clone) rally car project

Postby WOMBAT » Thu Sep 14, 2017 10:24 am

Car looks equally happy out there!
Casey O

Current Attire:
- 2007 Audi A3 3.2 quattro

Past Projects:
- 07 Cooper S - 91 200 20vt - 91 90 20v - 85 4000CS - 96 Audi Cabriolet 5 Spd - 02 A4 1.8T - 91 V8 5 Spd - 01 A6 2.7T 6 Spd Sport - 86 5000CS - 91 100
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Re: Audi CQ (S2 clone) rally car project

Postby lorge1989 » Thu Sep 14, 2017 10:47 am

Amazing, I need to put a purpose to my garage queen car. Maybe something like this.
1988 Audi 90Q 1.8T 20v megasquirt'd and Holset'd
1994 Audi 90Q V6 oil burner, soon to be ABZ
1978 GMC High Sierra

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Re: Audi CQ (S2 clone) rally car project

Postby Foscora » Thu Sep 14, 2017 3:13 pm

Awesome pics / driving
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Re: Audi CQ (S2 clone) rally car project

Postby vt10vt » Fri Sep 15, 2017 7:12 am

Looking good Nick! Crazy to think about all those years ago at Sportscar to now.

If you do revamp/build a new cage keep us in the loop, do you have to go full FIA certified for RA now? I was browsing the rule book a couple weeks ago and that seemed to be the case (upon initial, not very thorough read).
-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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Re: Audi CQ (S2 clone) rally car project

Postby PRY4SNO » Fri Sep 15, 2017 12:57 pm

Damn. That's awesome.
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|| 2010 Golf Sportwagen TDI /// Farmenwagen
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar

|| Spare parts for sale
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Re: Audi CQ (S2 clone) rally car project

Postby mrdeye » Fri Sep 15, 2017 7:34 pm

Hell yeah!!! Somebody's get'n it! :thumbsup: :drive:
Matt
Daily driver: '01 Toyota 4Runner
Project car: '84 Audi Coupe GT
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'95 S6 Avant, '87 5K TQ, '95 VW Golf, '84 VW Jetta turbo diesel, '84 VW GTI
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Re: Audi CQ (S2 clone) rally car project

Postby Afterthought » Sat Sep 16, 2017 3:49 pm

Awesome pics.
You have any engine bay shots with the EFR in there?
****
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Re: Audi CQ (S2 clone) rally car project

Postby rallyfreak202 » Tue Oct 17, 2017 1:16 pm

vt10vt wrote:Looking good Nick! Crazy to think about all those years ago at Sportscar to now.

If you do revamp/build a new cage keep us in the loop, do you have to go full FIA certified for RA now? I was browsing the rule book a couple weeks ago and that seemed to be the case (upon initial, not very thorough read).


I'm hoping to modify the cage again and be able to run. Must get approval from all governing bodies (ARA, NASA, RA). The issue is I have chromoly cage and my door-sill bars are 1.5 x .095 instead of 1.5 x .120

Afterthought wrote:Awesome pics.
You have any engine bay shots with the EFR in there?


Yep! See below. Random photo dump. Old school laptop tuning the Motec M48 for pump gas, new seats, blow shocks, rebuilt shocks, inlet restrictor 3D printed, sugary TIG welds,

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I never said I was a welder!
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Re: Audi CQ (S2 clone) rally car project

Postby rallyfreak202 » Fri Jul 27, 2018 3:02 pm

Long time since update. Well, engine failure caused me to DNF at Sandblast 2018. During stage 3 I noticed it was consuming a lot of water and coolant temp was fluctuating during transit. Temp stayed OK during stage 3 and stage 4. Engine knocking at high load/boost. Car was tuned for 104 so I put 110 in it to help curb the knocking. No luck. Anyway, towards end of stage 4 detonation event caused cylinders 1 and 2 to share air. Sharing is caring? Cylinder wall on the head blew a hole in it. Forged JE Pistons showed no signs of detonation, which is a testament to their strength. Bottom end bearings look great, piston skirts look good besides sharp rings. When we limped it off the stage we thought it was a bad coil wire due to it being crusty and only partially intact. Perhaps that was the reason for detonation? You can see burn marks on block where leakage was happening (between coolant ports and cylinders too). Leakage between 3 and 4 was starting to happen. See pics for details.

Sold the Motec M48 and harness. Bought VEMS and built harness from EFI Express. Very happy with the harness.

Because I’m stupid, I’m building 2 engines for the rally car. Maybe I’ll put one in my S6. First engine is AAN with 92.8mm crank, 144mm rods, 2L 16v pistons (block bored to 82.5mm). I’ll use the repaired ported head that came on the car (from Eurospec) since it has extensive port work done.

Rebuilding the car’s original engine from Eurospec; 2.5L. 95.5mm stroker. Most likely decking the block to eliminate the o-ringed block. I’lll use thicker headgasket to displace loss of block height. Pistons are recessed in the block so that’s not an issue.



Done:
-cage update. Now have ARA logbook!
-control arm bushings custom machined
-fab’d wheel scrapers to thread into rear hubs
-trans oil changed, still doesn’t like 4th gear fast shift
-inlet restrictor made out of aluminum due to 3D printed warping from heat.

To do:
-build and install new engine
-diagnose brake bias issue. Way too much rear bias. AP racing brakes with bias controller which doesn’t seem to work. Need to bleed the brakes first!
-alignment (slapped a bank and threw out the toe pretty bad, crew fixed it at service before engine blew)
-VEMS wire harness install with launch control
-VEMS tune 93 and 104 octane tunes
-flex pipe in exhaust
-repair cracked paint
-repair bumper
-new ClutchNet Stage 4 kit, t/o bearing
-check/redesign rear susp mounts

it starts...
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before it blew
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making control arm bushes for custom control arms
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bumper repair
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fun sponge (inlet restrictor)
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belts
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cage updates
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shredded suspension mount
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wheel scrapers
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95.5mm 2.5L engine
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92.8 2.5L engine build
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Harness from Marc. VEMS!
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Last edited by rallyfreak202 on Mon Aug 06, 2018 12:19 pm, edited 1 time in total.
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