Brendan's 07K CQ rally car

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Brendan's 07K CQ rally car

Postby KTM990 » Wed Jan 09, 2019 9:45 pm

It's time to start documenting this build. I got an itch to go play in the dirt with an Audi rally car again and I have: 1 x '90 CQ, plenty of suspension and drivetrain parts, a built 07K bottom end - Why not?

The starting point:
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Starting operation weight reduction:
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I've tried direct dry ice, crushed dry ice with rubbing alcohol slurry in various ratios, inverted air cans with various hammers, but I can't seem to find anything that will work ANYTHING like the myriad of you tube videos showing this stuff come off in whole chunks/sheets. Back to the heat gun - seems to work better than slowly chipping away.
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After a few evenings of that grueling noise, I chose to do the only logical next step; to start cutting up an 01E to fit an 07K and truly commit to this project... I grabbed the closest GBE transmission in the garage and got this:

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And just for fun, a preview pic of a TTRS head vs 07K:
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I haven't decided which head I'll run, probably the 07K and save the TTRS head for a build that doesn't require a piddly 34mm restrictor
Last edited by KTM990 on Tue Jan 15, 2019 1:19 am, edited 2 times in total.
Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
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Re: Brendan's 07K CQ rally car

Postby KTM990 » Wed Jan 09, 2019 10:07 pm

It only took 2 tools to score that SOB trans, LOL
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Here are some more pics documenting the transmission bellhousing mods for the 07K:

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Test fitting the rear timing cover. You can see the sharpie outline of the bellhousing i traced onto the timing cover.

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Made a a couple 1/8" plates to fit the openings, prepped the bellhousing and TIG'd them in place. Welded really nicely with just some abrasive cleaning. Everlast 255EXT FTW!
Done Done.
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Including beer time, the total job probably took 1.5 hours and most of that was spent futzing, measuring and test fitting.
Last edited by KTM990 on Thu Jan 10, 2019 1:04 am, edited 1 time in total.
Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
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Re: Brendan's 07K CQ rally car

Postby KTM990 » Wed Jan 09, 2019 10:22 pm

While the trans was on the ground and "dry", it is always a good idea to pull the Torsen and swap it for a high bias unit from Scotty. The FYF/GBE Torsens can't be modified by Scotty at Advanced Automotion so I sent one out of an EDU (B5 S4) to be modified. Also test fitted the AK Motorsport trans mount. Decided to try this nice part out - the last time I did this, I made a similar mount out of plate steel and two pieces of angle, welded up, but this seemed so much more fitting :-)

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Note, the AK Mount needs 6 x M8x1.25 x 100mm bolts. The rear flange of the 01E is held on with 6 bolts, 2 of them are 100mm length for the heat shield, so 4 more long bolts must be procured to run the AK mount.
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Last edited by KTM990 on Mon Jan 14, 2019 10:39 pm, edited 2 times in total.
Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
KTM990
 
Posts: 12
Joined: Feb 18, 2016
Location: Seattle, WA

Re: Brendan's 07K CQ rally car

Postby Afterthought » Wed Jan 09, 2019 11:11 pm

Nice work!
A couple questions for you.
how much were those GBE’s ? I’m
Only a couple hours north of you and the cheapest one I could find was $700

On the AK mount . It appears as if you have to “make” a place on the bottom of the car in the tunnel for it to bolt to?
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Re: Brendan's 07K CQ rally car

Postby alxdgr8 » Wed Jan 09, 2019 11:22 pm

Awesome, can't wait to check it out in person sometime!
Good to know about the FYF/GBE diffs.

Did you get a pan from Hank already?
-Alex- @vexartmedia on Instagram
1992 Porsche 968 (07K transplant in progress)
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Re: Brendan's 07K CQ rally car

Postby KTM990 » Thu Jan 10, 2019 1:02 am

@Afterthought: Yes, the trans tunnel will need mounting provisions fabricated and welded into the tunnel. The mounting bolts will be installed from inside the car. As for FYF/GBE/EDU 6 speed prices, expect to pay $600-800 unless you can score one at a pick-n-pull ;-)

@Alex: The GBE/FYF Torsen is PN 01E409751F. The EDU diff is PN 01E 409 751E. I believe any of the other 01E diffs can be modded. The diffs on the left and middle are the same PN and came out of FYF/GBE. The diff on the right is from an EDU. I circled the primary different feature.

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Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
KTM990
 
Posts: 12
Joined: Feb 18, 2016
Location: Seattle, WA

Re: Brendan's 07K CQ rally car

Postby ChrisAudi80 » Thu Jan 10, 2019 10:02 am

Wow those are some opening posts!

Cool to see you are using AK MS parts. I have a bunch of their bushings. Overall good quality.

Any ideas about what turbo, injectors and ECU you are going to use? What about wiring? Are you going to do that yourself?
96 S6 auto
95 80Q AEB VEMS
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Re: Brendan's 07K CQ rally car

Postby audifreakjim » Thu Jan 10, 2019 11:23 am

Yes, Yes and Yes. Glad to see this picking up steam :)
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Re: Brendan's 07K CQ rally car

Postby Afterthought » Thu Jan 10, 2019 12:56 pm

Yeah stoked to see this stuff popping up. I guess Ill have to start a thread
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Re: Brendan's 07K CQ rally car

Postby vt10vt » Thu Jan 10, 2019 6:19 pm

Afterthought wrote:Yeah stoked to see this stuff popping up. I guess Ill have to start a thread

I was planning on starting one Sunday but now this and yours popped up...

Love this and will be watching closely, like was already said, helluva introduction!
-Shawn C.
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2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
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Re: Brendan's 07K CQ rally car

Postby Lucky » Thu Jan 10, 2019 8:18 pm

KTM990 wrote: The FYF/GBE Torsens can't be modified so I sent one out of an EDU (B5 S4) to be modified.


The Fyf torsion can be modified, mine is done. Jhm offers the service for them.
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Re: Brendan's 07K CQ rally car

Postby PRY4SNO » Thu Jan 10, 2019 8:41 pm

Great project and work so far. I like where this is heading.
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Re: Brendan's 07K CQ rally car

Postby FFF » Sat Jan 12, 2019 4:58 pm

This is looking very good. Keep the updates coming.


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Re: Brendan's 07K CQ rally car

Postby KTM990 » Mon Jan 14, 2019 10:54 pm

audifreakjim wrote:Yes, Yes and Yes. Glad to see this picking up steam :)


"07K the world" is a Jim Green quote that has firmly stuck in my head :-)
Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
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Location: Seattle, WA

Re: Brendan's 07K CQ rally car

Postby KTM990 » Mon Jan 14, 2019 10:56 pm

Lucky wrote:
KTM990 wrote: The FYF/GBE Torsens can't be modified so I sent one out of an EDU (B5 S4) to be modified.


The Fyf torsion can be modified, mine is done. Jhm offers the service for them.


Thanks for pointing that out. I've updated the above to say that Advanced Automotion can not modify the late 01E diffs.
Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
KTM990
 
Posts: 12
Joined: Feb 18, 2016
Location: Seattle, WA

Re: Brendan's 07K CQ rally car

Postby KTM990 » Mon Jan 14, 2019 11:05 pm

ChrisAudi80 wrote:Wow those are some opening posts!

Cool to see you are using AK MS parts. I have a bunch of their bushings. Overall good quality.

Any ideas about what turbo, injectors and ECU you are going to use? What about wiring? Are you going to do that yourself?


Turbo: Probably a GTX 2860R or the EFR 6258. Ideally I would build a smaller displacement motor, but the 07K is too tempting. With the larger displacement the choke flow power band gets narrower due to the godforsaken restrictor. I'm honestly tempted to just try using a junkyard 07K motor with a TTRS headgasket to drop the compression a little and save the built motor for fun street project. Step 1 is to get an 07K in the car and get everything fabbed up around it.

Wiring: Yep, I'll be wiring the whole mess myself. Automotive wiring is sort of a soothing pleasure of mine - when it's new/fresh harness building :geek:

ECU: Maybe a VEMS for the rally car and save this bad boy for something more, or I may say F it and just go for it :rofl: :rofl: :rofl:
Image
Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
KTM990
 
Posts: 12
Joined: Feb 18, 2016
Location: Seattle, WA

Re: Brendan's 07K CQ rally car

Postby Afterthought » Tue Jan 15, 2019 8:35 am

34mm restrictor ... damn that’s small.
One of Those Indy turbos would be cool since they have the bolt Holes for a restrictor
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Re: Brendan's 07K CQ rally car

Postby ChrisAudi80 » Tue Jan 15, 2019 10:54 pm

KTM990 wrote:
ChrisAudi80 wrote:Wow those are some opening posts!

Cool to see you are using AK MS parts. I have a bunch of their bushings. Overall good quality.

Any ideas about what turbo, injectors and ECU you are going to use? What about wiring? Are you going to do that yourself?


Turbo: Probably a GTX 2860R or the EFR 6258. Ideally I would build a smaller displacement motor, but the 07K is too tempting. With the larger displacement the choke flow power band gets narrower due to the godforsaken restrictor. I'm honestly tempted to just try using a junkyard 07K motor with a TTRS headgasket to drop the compression a little and save the built motor for fun street project. Step 1 is to get an 07K in the car and get everything fabbed up around it.

Wiring: Yep, I'll be wiring the whole mess myself. Automotive wiring is sort of a soothing pleasure of mine - when it's new/fresh harness building :geek:

ECU: Maybe a VEMS for the rally car and save this bad boy for something more, or I may say F it and just go for it :rofl: :rofl: :rofl:
Image


Yes! Another wiring geek! I recently remade my Motronic to VEMS EC adapter and other stuff. A full harness build is something I aspire to.

That Bosch MS ECU is secks yo! Where did you get that?

What's this about a restrictor? Where?
96 S6 auto
95 80Q AEB VEMS
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Re: Brendan's 07K CQ rally car

Postby KTM990 » Tue Jan 15, 2019 11:57 pm

If you can build an adapter you can build a full harness! Attention to detail, confirming your crimps are solid and getting the order of operations right is all it takes.
The MS6 ECU came from Sakata Motorsports. I've been wanted to learn a different ECU platform for a long time, I figure this will be a good one :-D
Restrictor: Per all US rally sanctioning bodies, all air coming into the engine for this class car must flow through a 34mm diam. inlet restrictor - which I believe still aligns with WRC rules.
Trust me, I plan to have a non-restricted inlet and larger turbo option!
Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
KTM990
 
Posts: 12
Joined: Feb 18, 2016
Location: Seattle, WA

Suspension time

Postby KTM990 » Wed Jan 16, 2019 12:18 am

Started on the suspension mods tonight.
Specs:
Cabriolet front uprights modified w/ BBSE
Koni 86.2149 Sport dampers all 4 corners
Threaded perch adjusters: Coleman Racing PN 421-700 bored out to 2.16". 3.5" length in front and 7" length in back
These are steel collars and will be welded to the strut tubes.
Springs: GKR 100mm ID coils compatible with 2.5" lower spring perches

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Created a masking tape cut line and carefully cut with an angle grinder and cutoff wheel:
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Left, Coleman threaded collar, bored to 2.16" ID. Center: BBSE bored to 47.85mm for Koni's. Right: Cutoff scrap from factory upright
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The Koni's get held in with a supplied steel ring that centers them and the shock nut contacts the top of this part. The supplied ring is designed for the factory strut tube. I had to remove material on the OD to fit inside the BBSE. This was carefully done with my homemade lathe/grinder... Chucked the steel ring in my angle grinder and centered it. Then ran the angle grinder against my running belt sander :thumbsup:
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Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
KTM990
 
Posts: 12
Joined: Feb 18, 2016
Location: Seattle, WA

Re: Brendan's 07K CQ rally car

Postby ChrisAudi80 » Wed Jan 16, 2019 12:53 am

KTM990 wrote:If you can build an adapter you can build a full harness! Attention to detail, confirming your crimps are solid and getting the order of operations right is all it takes.
The MS6 ECU came from Sakata Motorsports. I've been wanted to learn a different ECU platform for a long time, I figure this will be a good one :-D
Restrictor: Per all US rally sanctioning bodies, all air coming into the engine for this class car must flow through a 34mm diam. inlet restrictor - which I believe still aligns with WRC rules.
Trust me, I plan to have a non-restricted inlet and larger turbo option!


That 6.1 is very advanced. 196 pins! Just skimmed through the datasheet. It is very versatile. You can go hog wild on sensor inputs. Temps, pressures everywhere! Might be good to put the 6.1 on your rally class spec car. That way you could run linear travel sensors on all 4 corners to dial in suspension.

What are the regulations for the restrictor? Can you make it yourself or does it have to come from the sanctioning body? If you can make it yourself, you could make the venturi transitions as smooth as possible.
96 S6 auto
95 80Q AEB VEMS
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TTRS vs 07K Cylinder Head

Postby KTM990 » Thu Jan 17, 2019 1:08 am

Here are some more side by side pics of the heads:
Most notable here is how they bored the head for the cams:
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Exhaust side:
TTRS: No EGR , exhaust manifold mounting studs and provisions for sensor for cam VVT.
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Intake Side:
TTRS: Direct Injection, Intake port plates.
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Valve Cover Removed:
TTRS: HPFP, Exhaust cam adjuster solenoid/sensor provisions,
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Brendan
------------------------------
'82 UrQ '98 A4 2.0tq
'93 S4 '08 A4 2.0tq
'90 CQ '17 Alltrack
KTM990
 
Posts: 12
Joined: Feb 18, 2016
Location: Seattle, WA


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