B5 S4, operation money pit. Forever evolving, never ending.

[stonea]

How many people have left this thread for a craigslist s4? lol - keep up the posts, it's great

God knows I have. I really want one now, but at the same time I also want a e39 M5.

[HennaE30]

How many people have left this thread for a craigslist s4? lol - keep up the posts, it's great

More times than I can count. Exodus, you'll regret painting it black at least. It makes it a pain to see oil leaks.

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[Northern]

Yeah once or twice. I would go for an avant.

[Julien]

How many people have left this thread for a craigslist s4? lol - keep up the posts, it's great

[Exodus_2pt0]

Woo boost!

Gt28rs hybrids are ordered. Should be good for up to 36psi and near 700awhp. I'm still shooting for 600whp now, and down the road maybe a little more.

Almost there, still need to order random bits and pieces to complete the engine, downpipes, and injectors.

Decided to do some painting, which I didn't intend to do and will surely regret. Since I didn't involve a machine shop or even remove the crank I didn't bother to clean anything other than gasket mating surfaces (don't want to wash oil out of bearings by spraying chemicals everywhere). Once everything is back together I'll tape off the open ports and give it a thorough bath.

[Exodus_2pt0]

I had a noggy. I miss that car.

I can imagine. I don't see myself parting with this car any time soon.

Got the heads bolted down, front and rear mains changed. Had to put together a small order list with ECS for misalaneous items before I can finish assembling the engine. (Crank bolt, random o-rings, crank breather gasket, and some other random bits and pieces that nobody thinks about until needed.)

[Clintoxx]

I had a noggy. I miss that car.

[Exodus_2pt0]

Off topic, long after my Daughter gets bored playing in the garage and heads to the house, this guy is glad to keep me company.



Probably just because of the fire, but I'll take it.

[Exodus_2pt0]

Had some bad info on rod orientation. I was told that the bearing tangs should be towards the exhaust side of each bank. Removed and flipped the rods to the intake side, and magically everything is just how it should be.

Moving on....



Now to order a few more odds and ends and I can assemble the engine. Then it's on to the trans.

In turbo news, these new ball bearing turbos I've been told have authentic Garret gt28rs CHRA's and have put down 675whp so far.

It kind of makes a single not worth the extra effort.

[Exodus_2pt0]

Aggravated right now. Installed the 4th piston and noticed that it was much harder to turn over. These engines have a offset rod journal on the crank where journals are shared by opposing banks.

There's no thrust play for the rods once both are installed, and they rub pretty good. IMO it's shit, feels like shit, and would be an enemy to horsepower.

Waiting to hear back from some guys with 2.7T experience to either confirm or deny my concerns. I'm hoping that by some chance they are designed to wear in to each other.

[Exodus_2pt0]

Well after a lot of back and forth, I decided to gap the rings and throw it together. Taking out the ridge ended up with a bit of taper, but all above where the top ring will ride. From that point down I only have about .001" of taper, which I'm OK with. Worst case scenario I tear it down in 20,000 miles and punch it out to a 2.8.

Gapped the rings at .021, and finally got to do some more work. Got one bank done and installed tonight.





I need to order some more tools, crank lock pin so I can change the front main. Cam lock tool for timing belt install, cam gear puller for the seals. Then a new timing belt/pulleys.

Still a long way to go, need to clean the engine bay, rebuild the trans, and order turbos. Found my 4:1 center diff kit though, so that should be a fun bit when it gets running again.

Also, found a great alternative to burning pallets. These things run $2.50 a pack and I am able to get a night's worth of heat out of one. Load the stove and it burns around 600* for hours on end. With the pallets I was loading every 30 minutes.

[Exodus_2pt0]

Got the bore mic in and did some work on it tonight. Tons of meat left in the cylinders. Did a proper hone and remeasured afterwards. Gotta do the other side and then start fitting the rings.

[Exodus_2pt0]

Little update:. The k24 turbos I mentioned above have finally been released in a ball bearing variant. From what I understand they use a Garrett bearing setup and are comparable in size to gt28's.

Still early, but they are saying these are capable of 50hp more than the JB variant. If that's the case, then these are capable of about 650 at the wheels on e85..... :devil:

[Exodus_2pt0]

Honed the cylinders today, waiting on my bore mic to be delivered and I'll know exactly where I stand. I honed it and got the ridge almost completely gone, depending on the measurements I might go a little further. Time will tell.

At this point though, I need to borrow a friend's ring grinder. Checked one cylinder and need to grind it 2 thousandths.

Oh well, taking my time and doing this right!

Also, I might be going back on the single aspect. I'm shooting for 600whp, there's a twin option out there that offers that number without breaking the bank. I just don't have much time to work on this car, let alone build a entirely new turbo setup. I would like to drive it come spring.

So, looking at SRM K24 turbos at the moment, still going to have a nitrous setup for "kill mode". The only goal that really matters is I would like to trap 135mph in the 1/4.

[Exodus_2pt0]

Progress!



I need to get a good bore mic. Have a noticeable ridge at the top of the cylinders on the new block. I really want to use this block though as it's a little stronger than the one that came out.

Fingers crossed that everything checks out after being honed. I'm actually considering punching it out to a 2.8 now.....