And the process begins all over again! Got myself an AMK 1.8t cylinder head from an S3 to replace my current one as I didn't like the bearing surfaces on it. Going to give it a slight porting and then polish the exhaust ports and combustion chambers

blake kathryn
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@theaudiproject
And the process begins all over again! Got myself an AMK 1.8t cylinder head from an S3 to replace my current one as I didn't like the bearing surfaces on it. Going to give it a slight porting and then polish the exhaust ports and combustion chambers
Big update
The 1.8L turbo engine and gearbox are currently out and in pieces in preparation for the next step in my build:
2.0L TFSI forged crankshaft with modified oil pump gear
Mahle Motorsport 83mm forged pistons with reduced deck height and lower compression
Integrated Engineering Tuscan I-beam forged rods
Mahle Motorsport race main and rod bearings
ARP bolts all round
Garrett GTX3071R turbo
Forge Motorsport front mount intercooler
The engine block is being bored out from 81mm to 83mm and with the crank stroke being increased from 86.4mm to 92.8mm the displacement is going up from 1.781L to 2.008L. This will help me go to the larger turbo without sacrificing too much spool time.
Still have some little things to sort out like injector sizes and exhaust/intake plumbing but it’s slowly all coming together. The goal is a daily/streetable car with just under 400bhp and good reliability!
Gearbox is all bolted back in and with the modified clutch slave cylinder I have a working clutch pedal! Having fun remembering which bolts go where after spending a week in Austria between putting in the new flywheel + clutch and now
And the Audi S4 clutch is in the A6!
Effort of the day. Pulled the gearbox out this morning and spent the afternoon cleaning it up a little, took out the old dual mass flywheel and clutch, replaced the pinion bearing in the crank and bolted in the new solid lightweight ECS tuning flywheel. Got an Audi S4 clutch going in tomorrow, gearbox back in and I'll be back on the road!
Bought myself an early christmas present. Going from a DMF and stock clutch on my A6 to an ECS Tuning lightweight solid flywheel and Audi S4 clutch
I’ve finally got my cylinder head all ready to install again after the saga of the sheared exhaust valve (lets not go into that). Had a slow day today, reinstalled the camshafts with a new cam tensioner and timing chain, bolted the head down to the block and set the timing with a new belt. A couple of things to do tomorrow and it should be all ready to get back on the road!
1: Head bolted to the block
2: Timing belt installed
3: New cam tensioner (£££!) and timing chain
A quick before and after of the engine block
Todays piston repair
I feel like I've had the worst luck with this car. I replaced the old, burnt out stock exhaust valves with Ferrea Competition Plus valves and after the engine running for only 10 minutes or so one of these valves sheers right between the retainer and stem seal. Did not expect that to happen with top performance products.
I found the cause of the power steering fluid leak. A big split down the fluid return line going from the rack to the coolant pipe. Going to play the "guess how much Audi will charge for a part" game tomorrow and then probably make something myself to replace it as usual haha
Engine completed. I have also ripped out the entire PCV system and replaced it with an Integrated Engineering oil catch can to prevent the intercooler and intake system filling up with oil and stopping any more oil vapour going through the engine and producing knock.
It came off the road with around 130bhp and will be going back on with just under 230bhp!
Just started reassembling the head! First installing new valve stem seals then assembling the valve springs/retainers/collets. I can then install the camshafts, timing chain and timing adjuster.
A little update on my cylinder head. It's currently in the hands of Chris Taylor who is pressing in new exhaust valve guides, recutting all the valve seats and skimming the head surface for me but is slightly delayed as he is racing in the Isle of Man TT this week and next week
Restored my headlights yesterday
I've never felt more manly
I’ve been set back a little by my air compressor deciding to set itself on fire