URS6 Avant 5.2

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URS6 Avant 5.2

Postby jolio1994 » Sun Oct 27, 2019 9:38 pm

5.2 NOW SORRY

Figured I was going to make my way over here sooner or later so... :we:

-1995.5 S6 Avant
-C5 RS6 BCY Engine
-Stock Motronic 7.1.1 / Harness
-Steveken Adapter
-Ringer Racing Stage 4+ Clutch
-Top Mount Single Turbo (The more I look into it the more I want to run a T72/T76)
-Hellcat Fuelpump

*Stock injectors for now, will max out around 600hp. 1000cc later down the road once I get it running and driving

This beast of an engine had 282,000 miles on it, but since I sold my RS6... it would only make sense to have the BCY heart put into another Audi. Joy :boom:
Image20190914_164715 by Joel Francisco
Image20190915_194829 by Joel Francisco

Messy as f*ck
Image20190915_201407 by Joel Francisco

Got that BCY bug... 7hr's round trip to Pennsylvania.
Image20190919_174938 by Joel Francisco

And another 6hr's to New York to buy a 2.7T 01e parts car (Yup, drove her back.. just don't stall it. The starters no bueno).
Image20191021_102640 by Joel Francisco

God I dreaded cleaning this, but it's all I can do while I wait for the adapter kit...
Image20191027_151915 by Joel Francisco
Image20191027_192549 by Joel Francisco
Image20191027_193725 by Joel Francisco

And now we wait... the N/A 40v exhaust manifolds are on there way and should show up by the end of this coming week ALONG with the SteveKen Adapter Plate Kit. I'll then matte (?) up the 4.2 to the 01e in the car, set the driveshaft/trans angle, and fabricate some engine mounts!

Last edited by jolio1994 on Mon Nov 02, 2020 4:27 pm, edited 7 times in total.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby themagellan » Sun Oct 27, 2019 11:02 pm

This is going to be AWESOME! Will be following closely - hope everything goes smoothly (As can be expected)
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Re: URS6 + RS6 = URRSS66 Avant?

Postby PRY4SNO » Tue Oct 29, 2019 7:41 am

As mentioned elsewhere, this is going to be a beast. Can't wait to see this thing rip around.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Tue Oct 29, 2019 10:50 pm

I am foreseeing a multitude of issues, but I'll hold off on spilling the beans until I get the adapter plate and engine in the car.

Everything so far has a workaround, but damn, the cost is really adding up in my head.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby Marc » Thu Oct 31, 2019 5:18 pm

lol. I dont think any of this adds up to a 'cheap build'. I hope thats not a shock :)

rooting for you. done right this car will rip.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Mon Nov 04, 2019 4:33 pm

The adapter plate has been lost in shipping (thanks UPS), all you had to do was ship it from Pennsylvania to New Jersey and you f*cked it up. Still trying to push ahead to get a better understanding of what I need.
-Those 40v NA headers I bought aren't going to work so It'll have to be tubular coming up from the side of the heads into a 4-1 collector on either side.
-Going to need some really really small engine mounts and while I'll be using the stock engine mount bracket points on the chassis, they're pretty much going to be laying on the subframe above the swaybar.
-Coolant crossover needs to be cut so I can route it away from where the exhaust manifold will come up.

Placement isn't finalized and will change slightly, but this is where I stand (for the most part)

Image20191104_150947 by Joel Francisco
Image20191104_151027 by Joel Francisco
Image20191104_150812 by Joel Francisco
Image20191104_150804 by Joel Francisco
Image20191104_150840 by Joel Francisco
Image20191104_150852 by Joel Francisco
Image20191104_151600 by Joel Francisco
Image20191104_151122 by Joel Francisco
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Tue Nov 05, 2019 5:06 pm

A few fellow enthusiast tagged me in a FB group when this engine was offered for sale. After some talking with the owner I ended up buying the whole car minus fenders, front bumper, seats, brakes, and carbon trim. The rest is still there and aside from the engine/harness/ecu will be for sale in the near future. I'm going to see if a delicately placed cut in the stock RS6 exhaust manifold will allow me to route up the back of the head as a last last resort to clear everything, if not the Stainless will be the direction I go, thanks for the input!

I'll be picking it up this weekend and I swear school seems like it's slowing down, maybe I'll even get the adapter plate in (still lost) and can finally make head-way on this URS6!

Image20191105_091519 by Joel Francisco
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Sun Nov 10, 2019 5:07 pm

Picked up that RS6 last night and pulled the engine out today. URS6 progress is at a standstill until I can get that adapter plate in. Now I have an extra BCY 4.2 for when I blow up the O.G. one!
Image20191110_114735 by Joel Francisco
Image20191110_131736 by Joel Francisco
Image20191110_154010 by Joel Francisco
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Tue Nov 19, 2019 6:35 pm

Adapter plate came in today... I guess I know what I'm doing this weekend!

Image20191119_181022 by Joel Francisco
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Sun Nov 24, 2019 9:29 pm

It kinda fits! Had to cut out the subframe, but it's in there! Practiced making an engine mount bracket and it came out pretty damn good I think. Full penetration on the first practice piece, it's solid as a rock. Yes I know I need more practice, but hey this entire project is a first for me. I'll be moving the plate down 2" on the final piece to add a bushing but:
A. I'm still looking for something suitable (Any mounts that would work given the clearance would be greatly appreciated)
B. I just need something to begin tubular header and turbo mock-up.

Image20191124_115220 by Joel Francisco
Image20191124_134355 by Joel Francisco
Image2019-11-24_09-18-54 by Joel Francisco
Image20191124_200702 by Joel Francisco
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Image20191124_201253 by Joel Francisco
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Re: URS6 + RS6 = URRSS66 Avant?

Postby varia » Mon Nov 25, 2019 11:15 am

If you can fit that thing in.... it will be a miracle itself. but it will rock!


What cart/dolly is this?
https://www.flickr.com/photos/150736981 ... 044817893/


Thank you
¯\_(ツ)_/¯

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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Mon Nov 25, 2019 11:20 pm

It's actually the base for a laundry cart we use at my job. It supports 2000lbs and we throw them away like it's nothing, so I decided to re-use it.

I finished up the passenger side mount, and the engine is all bolted down and what not. Now to wait for Black Friday turbo sales and hopefully even an exhaust manifold kit sale.

Image2019-11-25_10-40-31 by Joel Francisco
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Sun Dec 01, 2019 5:12 pm

Little small kinda big update, but will add when I get everything in; Black Friday was very kind to me.

Two Mishimoto 12" Slim fans
Mishimoto 19 Row Oil-Cooler
Mishimoto R-Line Intercooler (Big Boy)
Tial 44mm MVR Wastegate
Tial Sport Q BOV
Stainless 304 Audi 4.2 Exhaust Turbo Header Kit
Dual Ball Bearing Billet T76 T4 .81 A/R Turbo

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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Tue Dec 03, 2019 9:38 pm

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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Fri Dec 13, 2019 6:46 pm

Mini update.

Driverside manifold is tact'd up. If the passenger side comes out any better I may end up redoing it. It's a step in the right direction.

Image20191213_160710 by Joel Francisco
Image20191213_161026 by Joel Francisco
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Re: URS6 + RS6 = URRSS66 Avant?

Postby alxdgr8 » Sat Dec 14, 2019 3:06 pm

That's gonna lag quite a bit with such huge pipe size... And I was really hoping you were joking about turbo above the hood. Props for doing this swap but it would be a shame to madmax a clean car like that.

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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Sun Dec 15, 2019 11:04 am

Thanks for the feedback. I'm really going into this whole thing blind, but I guess this is a case of bigger isnt always better. What if put a reducer down to 2.5" right after the merge collector on either side?

It had some rust on it and the body has seen better days. I figured if there was an avant to do this to, this was definitely it.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby quattrobros » Sun Dec 15, 2019 12:31 pm

I think as long as you dont angle grinder the hood with your eyes closed you can pull it off and still have the car look great. Definitely not for everyone but you have to make some sacrifices.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Mon Dec 16, 2019 6:14 pm

It's not going to be a hackery job. Don't assume that just because I cannot weld doesn't mean I can't cut! Haha.
Before I weld them I'll order the remaining exhaust piping and mock everything up including turbo/wastegate placement. I may end up re cutting some of the runners as the fitment isn't 100% there.

For the folk's who have made their own headers, how big of a bottle of argon should I get ahead of time that I can use strictly for back-purging?

Image20191216_171609 by Joel Francisco
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Re: URS6 + RS6 = URRSS66 Avant?

Postby PRY4SNO » Mon Dec 16, 2019 6:19 pm

You won't need a 5ft tall cylinder, but don't skimp. Purge is crucial to proper penetration and avoiding porosity. If you get any sugar at all you're not using enough. Too much will cause arc blow out so it is a delicate balance.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby themagellan » Mon Dec 16, 2019 6:55 pm

Sick fab work +1 on the stealth mode, but it's your car so do whatever :)
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Re: URS6 + RS6 = URRSS66 Avant?

Postby alxdgr8 » Mon Dec 16, 2019 11:19 pm

jolio1994 wrote:Thanks for the feedback. I'm really going into this whole thing blind, but I guess this is a case of bigger isnt always better. What if put a reducer down to 2.5" right after the merge collector on either side?

It had some rust on it and the body has seen better days. I figured if there was an avant to do this to, this was definitely it.


How are the size of the primaries?
Hank on 07ks said he didn't see a difference in power at 200hp/cylinder with 1.25" vs 1.5" primaries, only a decrease in spool by about 250-300rpm for the 1.5"
With two full headers and piping to join you've got a lot of volume to fill to spool, so it's best to keep everything as small as possible.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Mon Dec 16, 2019 11:58 pm

alxdgr8 wrote:
jolio1994 wrote:Thanks for the feedback. I'm really going into this whole thing blind, but I guess this is a case of bigger isnt always better. What if put a reducer down to 2.5" right after the merge collector on either side?

It had some rust on it and the body has seen better days. I figured if there was an avant to do this to, this was definitely it.


How are the size of the primaries?
Hank on 07ks said he didn't see a difference in power at 200hp/cylinder with 1.25" vs 1.5" primaries, only a decrease in spool by about 250-300rpm for the 1.5"
With two full headers and piping to join you've got a lot of volume to fill to spool, so it's best to keep everything as small as possible.


Oh dang man, the primaries are 1 5/8. That's a tad worrying if I'm honest. I've never built and engine aside from redoing rings on one, and I've certainly never done anything to this extent... I really should've asked because I straight up dont really know what I'm doing.

Im not fully expecting these headers to last more than a year as they're my first set, so if anything I will redo them later down the road with 321 SS (Again, I didn't even know the difference between 304 vs 321).

I guess what threw me off in terms of pipe size was N/A vs Turbo. From what I've been reading N/A can be larger and turbo applications need to be as small as possible to provide as much pressure as possible.

Either way it's good info for me to know going into the future, thank you!
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Re: URS6 + RS6 = URRSS66 Avant?

Postby quattrobros » Tue Dec 17, 2019 12:32 am

I recently back purged a full length 3" exhaust for an audi 90 and it worked out to exactly one 40 cu ft bottle worth of purge.
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Re: URS6 + RS6 = URRSS66 Avant?

Postby jolio1994 » Tue Dec 17, 2019 1:21 am

I already have a 57" tank, but I'm thinking I may just rent out another 57" or even 60" with regulator specifically to backpurge. What's the general consensus, 10-15 cfh?
Last edited by jolio1994 on Tue Dec 17, 2019 7:44 am, edited 1 time in total.
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