Kennys UrS4 (Volvo turbo to BW S257 SX-E Turbo Built engine)

[morris400]

New to me lol. It's an early Gen 4 stromung with added flex. Should do nicely

[PRY4SNO]

Nice find. Will be nice to clean up the stock dual downpipe.

[morris400]

Yes sir, I'm hoping to get it installed this winter. Need a lower 02 bung welded in for WBO2 first.

[morris400]

More updates to come on this Urs soon.

[morris400]

Been a while since ive updated this thread, i was trying to focus on the coupe i bought. I reached a point where i realized the Coupe would never be what i wanted. It was much more of a full restoration then a simple build. The Coupe is sold, and im gonna focus on the UrS this summer. The engine is build to hold just north of 550Whp, but im only planning to hit mid 400s this summer. For next summer ill be looking to get closer to that 550whp mark. 

I will be installing the AAN engine i build this spring. The specs are:

Block was tanked and decked
Por15 on the block
Issam crank breather 
Issam billet thermostat housing
034 billet coolant outlet 
DM Forged AAN rods
Calico coated main bearings 
Calico coated rod bearing
Stock pistons with ceramic coatings 
Rings Gapped to .19
Ballanced Crankshaft 
Fluidamper crank damper. 
All bearing clearances confirmed re checked and documented. 
(All hand build by me alone) 

Cylinder head rebuild specs:
Vapor hone cleaning 
Stock valve springs 
Stock retainers
Stock keepers
Ferrea 6000 series valves 
7A cam shafts 
New timing chain
ARP Head studs
MLS head gasket
7A Valve cover powdercoated purple
Audi R8 coil packs
(All hand build by me) 

Turbo setup
BW SXE 257
Kavon tubular manifold 
3" SS downpipe with Vband into a 3in with 1 MF muffler
Stock rebuilt wastegate with 1.9bar spring

Engine Management:
Audi AAN ECU 
3BAR Map sensor
EFI Express chip set ( 94 Oct with W/M)
Innovate AFR gauge
Podi Boost gauge ( new one ) 

Intake setup
Snow performance W/M setup
Stock AAN intake manifold 
034 intake spacer
31 x 12 x 3 FMIC

Fueling 
630cc injectors
Walbro 450 intank pump
EFI Express dual pump bracket

Clutch
Southbend 7A clutch stage 2 PP stage 4 Disc.
034 lightweight Aluminum flywheel 
034 all metal throw out bearing
ARP FW bolts (7A fitment)


Sent the Fluidamper to Issam today for some light machine work. Planning this swap in the next few weeks. Id like to try and get a few 1/4mi passes on the current k24 7400 setup before i put in the built engine. 

Parts and services for this build came from the following distributor's:
Autobahn performance 
Fourstar motors 
BEL engine services ( fixing previous machine shop mess up)
INA engineering 
EFI express 
034 motorsport 
Ferrea valves 
Podi.ca 

Powdecoating, media blasting and Ceramic coating services 
Fourstar motors ( Edmonton) 
Strongarm cylinder heads (Panoka)

People who have gone out of their way to help
Lars Bjornstad ( previous owner of Coupe)
Nate Jesperson 
Dustin Donovan 
Neacail Campbell (Fourstar Motors)
Sterling Ball
Jeff Gerner (Worlds fastest C4 S4) spent hours on the phone with me. 
Remi Szafransk (Autobahn Performance) 

These people gave me their time, help, advice, donations, parts, connections, name it, they were there. Huge thanks for their continued support as this project get closer to completion. 

[PRY4SNO]

What did you decide about the downpipe since you're installing the built motor into the rocket couch and not the Cq?

[morris400]

What did you decide about the downpipe since you're installing the built motor into the rocket couch and not the Cq?

EFI Down pipe will fit ive been told.

[jbrentd]

What did you decide about the downpipe since you're installing the built motor into the rocket couch and not the Cq?

Does that make a built CQ a rocket love seat?

I'll be following along, Kenny!

[Spooky Quattro]

Looking forward to following this build

[PRY4SNO]

What did you decide about the downpipe since you're installing the built motor into the rocket couch and not the Cq?

EFI Down pipe will fit ive been told.

What are you planning for your Stromung?

[morris400]

Got to doing some prep for the EFR motor. Got the gauges and pod installed. Might have to swap the boost gauge and AFR gauge around as the boost is a little hard to see when driving.

Meth and WB not hooked up yet but thats coming soon.

The Pod is a old deck board, sanded and stained. Drilled 3 holes and its really tight but they fit.

[morris400]

Anddddddd...im chaging again lol

Moving away from the EFR 6258 setup in search for mor power. Sold the Wagner manifold and got in touch with Jay at Race3motorsport in Ontario Canada to build me a Tubular manifold.

With the manifold decided now, i need to work on the turbo choice. Looking at PTE 5858 but option to suggestions.

I did however get the damper on and sorted out with alot of help from Issam. Also got his thermostat housing on now as well.

[morris400]

Managed to get on a trip out to Jasper, AB Canada yesterday. Had a blast. Managed to snag a few pictures of the car in her glory. The trip was 672km total, and the car managed 9.3l per 100km the whole way ( 25 MPG ) which is outstanding.

[themagellan]

Congrats on the reliable adventure, beautiful pictures.

[morris400]

Cars doing well. Had some new stuff lined up and then the shop became a bit flaky.

I got in touch with race3motorsport in Ont Canada to build me a manifold. All seemed well. After i paid the communication became few and far between. After 8 weeks of no progress or even 1 picture i said enough was enough. The owner assured me it was shipped but refused to call his "3rd party packer" to see if they in fact shipped it. Not sure why a 1 man operation in small town Canada is using a 3rd party packer for custom manifolds. 8 weeks of time lost.

Ive since been in touch with Kavon Kashe, and hes now buildingvme a manifold and Down pipe for my new setup.

Ive decided to sell off the whole Wagner/EFR set up and am switching to a Borg Warner S257 SX-E turbo. .64 Turbine housing. Still aiming for next year lol. Im honestly having fun with the car on the 7400 right now and want to enjoy it before winter hits.

Need to make an oil drain line and a feed line. But i have figured out what direction im going now... i think.

SXE 257 from Ebay, with FMIC.

[morris400]

And we have a FMIC

[Neacail]

You're gonna love that turbo dude.
Want my oil feed and drain lines? I don't need 'em anymore.

[jbrentd]

Looking good!


Sent from my iPhone using Tapatalk

[morris400]

Finally have a manifold downpipe and turbo setup. Going to be looking at getting the exhaust side all coated and "hopfully" engine installed in Dec.

[PRY4SNO]

Where are you getting the coating done?

The "ceramic coating" I had done on my 7A bag-o-snakes header at Impact Coatings in the west end flaked off after a couple oil changes or so.

[morris400]

I was going to use 4 Star on Gateway. He did his and it lasted all summer. I also have some heat wrap i may consider if i dont feel like coating. Its not a winter car so it wont be exposed to the elements.

[PRY4SNO]

If that coating held up I'd definitely go back, nice to support local businesses who provide a quality product. Heat wrap is something I'd avoid, winter or not. The wrap will retain condensation, promoting corrosion and also premature wear from abrasion. Plus it doesn't look half as cool

[Neacail]

The coating all depends on the prep.
If it flaked off they may not have used an aggresive enough blast media (should be somewhere around 80 grit aluminum oxide) and may not have outgassed it properly.
My downpipe, wastegate and turbine housing held up incredibly well, because I blasted them myself. I had outsourced blasting my header to another local business and the coating flaked off of it in a couple spots because he used glass bead.
Kenny, I'm finishing up my oven right now (just taking a break) so I should be up and running for the coatings again soon. I would avoid heat wrap, make metal heat shields for any sensitive components that you're concerned about. Can just use sheet aluminum, hose clamps and pop rivets, although I bought some of the embossed/corrugated aluminum sheet like the OEM shields are made of because it's super easy to form.

[morris400]

Going back to Vems for this project, picked it up this week. Thanks Neacail.

Also have my compressor housing out to get powdercoated, again tha ks Neacail.

Gone is the k24 7400 setup, its been removed and sold. Time to move forward. Need to get the garage situated and the car up on something to allow me to get under it to remove some crap and disconnect the exhaust. Were getting somewhat close. Kinda.

[Afterthought]

this is gonna be awesome, taking this thing to the next level.