URS6 + 4.2T Getting Them Breakin Miles

[jolio1994]

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

-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
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Messy as f*ck
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Got that BCY bug... 7hr's round trip to Pennsylvania.
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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).
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God I dreaded cleaning this, but it's all I can do while I wait for the adapter kit...
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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!

[themagellan]

This is going to be AWESOME! Will be following closely - hope everything goes smoothly (As can be expected)

[PRY4SNO]

As mentioned elsewhere, this is going to be a beast. Can't wait to see this thing rip around.

[jolio1994]

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.

[Marc]

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.

[jolio1994]

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)

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[jolio1994]

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!

20191105_091519 by Joel Francisco

[jolio1994]

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!
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[jolio1994]

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

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[jolio1994]

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.

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[varia]

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

[jolio1994]

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.

2019-11-25_10-40-31 by Joel Francisco

[jolio1994]

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

[jolio1994]

2019-12-03_09-33-02 by Joel Francisco

[jolio1994]

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.

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[alxdgr8]

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.

Sent from my Pixel 4 XL using Tapatalk

[jolio1994]

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.

[quattrobros]

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.

[jolio1994]

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?

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[PRY4SNO]

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.

[themagellan]

Sick fab work +1 on the stealth mode, but it's your car so do whatever

[alxdgr8]

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.

[jolio1994]

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!

[quattrobros]

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.

[jolio1994]

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?