B5 S4 Build

[Vieussuex*]

So back in early 2011 I was only suppose to just get my Polo serviced by Seb from Euro Automotive and saw a rare gem sitting in the corner of his workshop being neglected it was a B5 S4 Avant.

Now originally he told me this was going to become his family car but that never eventuated as his partner doesn't drive manual...and she refuses to learn how to>D

So I struct a deal with Seb to buy the car and just to do a KO4 upgrade.
One thing lead to another and I decided to rebuild the gearbox......... I then said to myself the S4 is going to be sitting around for a while so I might rebuild then engine, then I thought with all that power I'm going to need bigger brakes, then I found myself trawling for s4 builds on vortex, audizine, rs246 and audiworld forums and came across all these guys in the US with RS4 outlaws or RS4 conversions and now I find myself trying to do the same!

Why do this you may ask?
I've always wanted a B5 RS4, to get one new back in it's day they were priced around the $160K (quoting forum here say), and still second hand they start from $50K......a decent one unmodified and low km's is up around $70K when they decide to surface.
I've done the maths and for around about the same price I can have a stage 3 completed, thats 300kw+ atw>D

So join me, I will take you on a journey of heartache and probably financial hardship (as my budget will most likely blow out)!


This is how I got her:-


she didnt turnover but I was still excited!

Got cracking and started to strip her down:-


Engine out:-


RS6+ brakes arrive from Austria!:-



..test fitted with 19" VMR v701's:-




Should have some more photos and updates after this weekend of the rear 034 motorsport 300mm rear brake kit, ported exhaust manifolds and full exhaust!

[ope126]

WOW I'm excited!!!

Keep us up to date, that's a rare find there mate!

[robbie]

Wow what a special find!!!

I'm keen to see how this build will pan out

[Vieussuex*]

Ok so here is some stuff that has been lying around the workshop for a while but just been to lazy to take some photos

Painted the factory rocker covers ...not a fan of the plain dis-coloured raw aluminium!


After market Bi-Pipes from ARD which are about 30% larger then stock:-


Ported out the factory exhaust manifolds....probably increased the diameter buy about 7-8mm on each port. Now ready to be ceramic coated!:-


SMIC. These are the CX Racing one's from eBay, now these haven't had a the best reviews as people in the States have complained about heat soak as the cores are cheap but because they are less then a third of the price of ER's, Apikol's or AWE's shipped here I'll risk giving them a go. I'm going to be running water/meth so I should be able to keep intake temps down anyway:-

[Vieussuex*]

Now the fun stuff that arrived on Friday!

JE pistons:-



Rods, valves, lifters all from Intergrated:-




Borg Warner K04's:-


...with all the internals here we should be able to get the engine builder to turn the engine around in 2-3weeks

[Njay]

you should put this on ozaudi, hardly any build threads on that forum

[Vieussuex*]

Been a while since I've posted but I'm almost done this build but will give you a run down on how it went.

Got the heads and block back from the engine builder and started assembly:-





Replaced the stock suspension with KW v3's:-







Gearbox was also rebuilt with a custom input shaft with a wider 1st gear, new carbon syncro's from 034 Motorsports and a 4:1 centre diff from JHM:-



Engine, gearbox, K04's, inlet pipes, down pipes etc all bolted up:-



Engine back in also running ARC Bi-pipes with meth bungs, and Forge DV's:-

[Vieussuex*]

Rest of the piping, SMIC, shrouds and radiator fitted:-



(At the time of this pic I was originally going to run a 034 95mm MAF housing with a Hitachi MAF but due to scaling issues in the tune I've gone for a factory B5 RS4 MAF running a Bosch MAF instead.)



When I got the car there was a bit of panel damage so my initial plan was to go widebody with RS4 guards bumpers etc. After finding out how much this would set me back I canned the widebody conversion.
I found a decent aftermarket RS4 replica bumper made by Dietrich concepts that would also fit the factory RS4 grill inserts:-



I had her resprayed in the factory silver and also removed the lower doorsils:-









Also added a Cupra R front lip:-

[Vieussuex*]

Installed a JHM Drive train stabiliser bar in:-



BMC CDA airbox and 034 Carbon Y pipe:-



Also installed a Zeitronix Wideband AFR and LCD display:-



Whiteline 18mm heavy duty rear sway bar to help it turn in a little better:-

[Deadpool]

Incredible build, can't wait for more.