My B6 "S4" - Project Lemonade?

[witchcraftz]

Re: My B6 "S4" - Project Lemonade?

Huge job but you make it look easy. Nice work!

[Ur0Drivr]

Re: My B6 "S4" - Project Lemonade?

Great job Jason!!

[GingerBeef]

Re: My B6 "S4" - Project Lemonade?

More stuffs a happenin'!

So I got the FWD rear subframe and gas tank out. This was super easy! Without a rear diff there was barely weight to that subframe, and luckily the fuel tank was pretty empty. No pics of this process as Kyle and I just dove under the car and ripped all this crap out in like 30mins.

Next job was to shove this Quattro fuel tank in!



This went pretty well, I was surprised at how different the FWD and Quattro tanks really were. The straps that hold them in are completely different! This caused a bit of a minor freak out...
At first glance it appeared that most of the bolt holes for the Quattro fuel tank were missing... but upon closer inspection I noticed a faint square in the undercoating where the bolt hole should have been. I started picking at the corner and it started peeling away...



Here you can see the piece of tape with undercoating in my fingers, if you look closely my suspicions were confirmed... theres a nicely tapped hole hiding underneath! My best guess is that Audi taped these off to mask the threads from getting gummed up by the undercoating. Since this model was FWD, i suppose they just never bothered to unmask it?



With the gas tank fitted, and plumbed it was time to dig out that rear diff and subframe. (Worth noting, fuel tank fittings are completely different from B6 to B7, despite them being the same physical shape and size. Took some minor modifications but i managed to get all the evap and other random crap hooked up to the fuel tank.



Lined up and ready to go...



Jack it up, a few ugga duggas later and we have Quattro!



The springs were being a royal cunt, and spring compressors wouldnt fit in the tight space.... so sketchy ziptie spring compressing was performed... remember, if it sounds stupid, but works, then its not stupid? [emoji14]



And with that, all major mechanical components are in! I have a ton of wiring, plumbing, and freaking out to do... but this is good... very good.

[GingerBeef]

Re: My B6 "S4" - Project Lemonade?

BAM! V8 and 6sp manual is officially bolted in! (For reals this time).



Today was subframe bolt hole disaster recovery day. I was under the impression that to fix that stripped hole I would need to completely remove the engine/subframe again. Thankfully I was wrong. By just dropping the rear bolts and using the hoist to tilt the assembly I managed to get enough room to remove the old helicoil, tap the threads, and install the new helicoil!



Above shows the old helicoil... below compares it to the proper helicoil. Previous owner decided to put in a helicoil that was completely the wrong thread pitch... the one in there was alot more coarse, so thats what kept fucking my life up.









Theres the new helicoil, sitting in its new home. HUGE thanks to Jonathan Gheron for lending me his helicoil kit. Owe you one!

[kujiwara]

Re: My B6 "S4" - Project Lemonade?

I think you should take the time to swap the harness since a lot of thing are different between a fwd b6 and awd b7, it might take just as long if not longer to figure out the wirings and make adapters(or repining to different plugs). Also a lot of the accessories you want to swap in from the B7 could very well use different plugs or different connections. Swapping the full harness in correctly should make sure that you won't have anymore issues in the wiring department(biggest pain in the ass department).

[GingerBeef]

Re: My B6 "S4" - Project Lemonade?

I've got depinning tools if you need them.

As for the threads - check to make sure the bolt isnt actually broken off inside the body of the car?

I was planning on making a plug and play harness adapter but ill let you know if i go that route! Thanks!

As for the chassis, im sire theres no broken bolt in there, I ve looked down that hole so much to try to figure out wtf is going on lol

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[onceover]

Re: My B6 "S4" - Project Lemonade?

I've got depinning tools if you need them.

As for the threads - check to make sure the bolt isnt actually broken off inside the body of the car?

[GingerBeef]

Re: My B6 "S4" - Project Lemonade?

Yay! More updates! So I spent like 2 days looking for my manual shifter. For some reason, 2 years ago i completely dissasembled it... and proceeded to store said pieces all over my garage. But i managed to slowly find all the pieces!



Put it all together and then threw it into the car.


While looking for the shifter parts i decided to tear apart the 1.8t a bit. Stripped it of all its wiring, sold a few accesories and took off the valve cover... pure carnage. All the grey you see are metal shavings... cant wait to tear apart the bottom end.







Continued to assemble the "S-Faux" but ran into a problem... the subframe must have been removed at some time in the past and an improper bolt was put in and ruined the threads in the chassis. Ive tried tapping it but the tap gets jammed and wont tap anymore than about 1/2" of thread...



Exciting day though, the V8 has been mocked up! Currently being help up by that stupid subframe bolt.... any help/advice would be greatly appreciated as im currently at a loss as to what to do :(
All the other subframe bolts are all in.





Discovered some more disheartening news... the plugs from the engine harness to the chassis are completely different, so i have alot of wiring in my future :(

[witchcraftz]

Re: My B6 "S4" - Project Lemonade?

Nice progress, it's going to be awesome.

[Geobmx4life]

Re: My B6 "S4" - Project Lemonade?

Great to see you back at it Jason....I was wondering what was going on with this...

[Ur0Drivr]

Re: My B6 "S4" - Project Lemonade?

I like the name! Good seeing some progress buddy!!

[GingerBeef]

Re: My B6 "S4" - Project Lemonade?

Welp, another summer that im not done this project. I keep running out of time each summer to accomplish what ive set out to do. But thats really just my fault for planning my schedule out horrifically. (Doesnt help that my bags blew on my GTI in Aug last summer lol)

But progress has been made! This last two weeks ive been getting some sh*t done! I really hope i can make more progress this summer than the last two.
First and foremost, excuse the picture quality... ive been really bad at taking progress photos lately, I find im alot more focused/less forgetful when i just put my head down and get sh*t done... which makes sense i suppose... So what few picture i have are cell phone quality.

But anyways, onto the car! Took care of the V8 first. I replaced those leaky valve cover gaskets, and also it turns out my engine mounts were completely shattered in the accident. I picked up some 034 Motorsports High Density mounts and threw them in!



Next, I had a minor disaster when I tried to remove the drivers side axle bolt... this is a situation where ill let the pictures do the talking...









Success! Saved once again by my shitty $80 Kijiji MIG welder. (Seriously, best $80 ive ever spent!)
Continuing on the A4, this time instead of dropping the whole subframe and engine as one piece I decided to just pull the 1.8T engine and trans.





I did this because I originally planned to drop the V8 and 6sp right onto the A4 subframe. I then realized that if i did that i would need to individually swap over each piece of suspension.... so after jacking the car up approximately 15km into the air, out came the subframe...



Im super pumped with the latest progress, we did a few more things such as:

-removed all the automatic things (shifter, pedals, linkages, TCU etc)
-started taking apart the interior and removed the 1.8T cluster

And lastly... a big milestone for this project. After spending the last 2 years ripping apart audis, I installed something back into the car for the first time!
The manual pedal cluster was put into the A4, now I just need to find where i put the 6sp shifter and clutch line 2 years ago and I can continue. WOO!

P.S this car has finally got a name.. its always been weird calling it my S4 project cause its not an S4 anymore... so meet the "S Faux"!

[PRY4SNO]

Re: My B6 "S4" - Project Lemonade?

Yesssssss!

Keep at it.

[GingerBeef]

Re: My B6 "S4" - Project Lemonade?

Ugh, so many more distractions... not enough time to work on this thing. But, since my Mk3 has actually been relatively trouble free lately and now that Das Volks is over I had time today to finally start tearing apart the B6 body donor!
This is what I started the day with.



The day started out pretty gross... took that dinkly little ram air filter to find of course what I estimate is a pile consisting of approximately 35 dead dragonflies and wasps.


After vacuuming that nightmare up I continued to tear the car apart slowly.


Drained the oil.. it looked like fancy black metallic paint. Neat, wonder what the hell caused all of this.


Tore more stuff off. Oh, by the way, every single intake pipe I took off was filled with oil... hmm..



I quickly found the problem when I took the pipe off the turbo inlet. Warning: Ko3 carnage ahead.


Took some videos to show the extent of the damage...
First, the intake side.

Notice how the nut thats supposed to hold on the front turbine was missing? And somehow, despite how aweful that was, of course the exhaust side managed to be in worse shape. Yep.

This could have been a factor to why the engine seized, but it also may have just been another casualty of neglect. I cant wait to tear apart the motor...

[GingerBeef]

Re: My B6 "S4" - Project Lemonade?

Can you explain what's going on here? I haven't been following the thread.

Hope you have the mk3 still

Edit: Nevermind, went back through the thread. thought you were trying to get a 4.2 V8 in to a Corrado. A AWD S4 Corrado would have been some project!

Wait what.. v8 corrado was never the plan. Also, probably will never get rid of the mk3

I got a B7, i got in an accident with it, and now im swapping everything good into a Fwd auto B6 a4 haha

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