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-   -   B5 A4 Quattro Sport B5 4,2L V8 6-Speed Manual. (https://forum.a8parts.co.uk/showthread.php?t=1224)

Siena 19th September 2009 10:33 AM

B5 A4 Quattro Sport 4,2L V8 6-Speed Manual.
 
Hi guys, as we don't have a specific "Projects" section, I thought I'd post mine here.

I've had over 32 Audi models since 1990, though never a V8-engined model. My current car, a B5 A4 Quattro Sport started life as a tired Agate Grey 2,6L V6 12V, with a 5-speed manual.

Today, she's the UK's only 4,2L 32V V8-engined model, mated to an 01E 6-speed manual, via one of my special 7,2kg single-mass steel flywheels.

But first, I wanted the body to look the part, and still look OEM, hence project B5 RS4 Sedan V8 was born.

Pictures of my base car, a '96 B5 A4 Quattro Sport 2,6L 12V V6, with 200,000 miles on the odometer:

http://i67.photobucket.com/albums/h2...5082007115.jpg

http://i67.photobucket.com/albums/h2...5082007114.jpg

http://i67.photobucket.com/albums/h2...5082007112.jpg

http://i67.photobucket.com/albums/h2...5082007110.jpg

http://i67.photobucket.com/albums/h2...5082007117.jpg

http://i67.photobucket.com/albums/h2...5082007116.jpg

Siena 19th September 2009 10:42 AM

After giving up on sourcing B5 RS4 parts used, I began ordering via Audi.

I first ordered the front fenders, rear quarters, and the rear doors.

Front fenders...

http://i67.photobucket.com/albums/h2...3102007235.jpg

http://i67.photobucket.com/albums/h2...3102007236.jpg

Rear doors...

http://i67.photobucket.com/albums/h2...3102007232.jpg

Rear quarters...

http://i67.photobucket.com/albums/h2...3102007228.jpg

RS4 front bumper...

http://i67.photobucket.com/albums/h2...6102007027.jpg

http://i67.photobucket.com/albums/h2...6102007025.jpg

Euro S4 rear bumper...

http://i67.photobucket.com/albums/h2...6102007018.jpg

http://i67.photobucket.com/albums/h2...6102007017.jpg

Siena 19th September 2009 10:47 AM

RS4 sideskirts...

http://i67.photobucket.com/albums/h2...6102007019.jpg

RS4 grille...

http://i67.photobucket.com/albums/h2...6102007013.jpg

RS4 bumper grilles...

http://i67.photobucket.com/albums/h2...6102007024.jpg

RS4 foglamps...

http://i67.photobucket.com/albums/h2...6102007020.jpg

RS4 bumper irons, they are longer than stock A4...

http://i67.photobucket.com/albums/h2...6102007023.jpg

Siena 19th September 2009 10:53 AM

Now, the RS4 front doors only differ from facelift ones, in that they lack mid and lower trims.

So, I decided to buy these used, all that they'd need then, would be to have the 6 little holes welded up, and the lower trim studs ground off.

I bought these, 2 of only 3 used parts in this project:

http://i67.photobucket.com/albums/h2...9102007039.jpg

http://i67.photobucket.com/albums/h2...9102007038.jpg

I also wanted the Euro facelift trunk lid, so bought from the same B5 that liberated its front doors. The 3rd of 3 used parts in this project:

http://i67.photobucket.com/albums/h2...9102007041.jpg

http://i67.photobucket.com/albums/h2...9102007040.jpg

I wasn't going to just slap the trunk on as it was, I wanted a subtle B6-style modification, but more of that later.

Siena 19th September 2009 11:02 AM

Then came RS4 cast aluminium mirrors - had I known about A8 Parts then, I'd have possibly bought used S8 ones, as they're the same, just the base plate would have needed changing over. But here we go...

http://i67.photobucket.com/albums/h2...2112007061.jpg

http://i67.photobucket.com/albums/h2...2112007060.jpg

http://i67.photobucket.com/albums/h2...2112007059.jpg

Then RS4 one-piece xenon headlamps...

http://i67.photobucket.com/albums/h2...2112007097.jpg

http://i67.photobucket.com/albums/h2...2112007096.jpg

I bought A4 facelift rear tails, to replace the ugly early version, with the chunky amber inserts...

http://i67.photobucket.com/albums/h2...1102007044.jpg

And matching A4 facelift rear bulb holders...

http://i67.photobucket.com/albums/h2...1102007048.jpg

RS4 front clip came next...

http://i67.photobucket.com/albums/h2...1112007050.jpg

Siena 19th September 2009 11:08 AM

My kitchen was gradually filling up with RS4 parts. :rolleyes:

Next were RS4 plastic wheel arch liners, left and right, rear, as the stock items would leave a mud trap, due to the wide-hipped RS4 rear end...

http://i67.photobucket.com/albums/h2...2112007056.jpg

http://i67.photobucket.com/albums/h2...2112007055.jpg

Then RS4 plastic wheel arch liners, left and right, front...

http://i67.photobucket.com/albums/h2...7102007037.jpg

B5 RS4 rear quarters extend as high as the fuel filler flap, so...

http://i67.photobucket.com/albums/h2...1102007047.jpg

I then realised that the RS4 MUST have wider rear wheel arch wells, to meet the wider arches.

So, I ordered these...

http://i67.photobucket.com/albums/h2...1102007046.jpg

http://i67.photobucket.com/albums/h2...1102007045.jpg

Siena 19th September 2009 11:13 AM

Then came the little bits and pieces, that are easy to over look.

B7 aero wiper arms and blades...

http://i67.photobucket.com/albums/h2...6102007030.jpg

http://i67.photobucket.com/albums/h2...6102007029.jpg

RS4 side repeaters...

http://i67.photobucket.com/albums/h2...6102007032.jpg

RS4 headlamp washer covers...

http://i67.photobucket.com/albums/h2...6102007028.jpg

RS4 headlamp washer pump...

http://i67.photobucket.com/albums/h2...7102007036.jpg

RS4 headlamp washer bottle...

http://i67.photobucket.com/albums/h2...2112007057.jpg

Siena 19th September 2009 11:29 AM

As I previously mentioned, I wanted to subtly modify my Euro facelift B5 trunk, so this happened...

http://i67.photobucket.com/albums/h2...2112007068.jpg

http://i67.photobucket.com/albums/h2...2112007066.jpg

http://i67.photobucket.com/albums/h2...2112007065.jpg

http://i67.photobucket.com/albums/h2...2112007064.jpg

...a subtle B6-style swage line and licence plate recess.

My base car had over 200,000 miles under her belt, so it was obvious the suspension would be shot to hell.

I purchased -30mm Eibach Sport Springs, designed for the heavier RS4. It would lower my car less, but as I planned a larger, heavier engine and 6-speed tranny from the onset, I allowed for that.

Eibach springs...

http://i67.photobucket.com/albums/h2...2112007077.jpg

http://i67.photobucket.com/albums/h2...2112007076.jpg

Then RS4 Bilstein Sport Dampers, ordered from my local Audi dealership...

http://i67.photobucket.com/albums/h2...7112007070.jpg

I also ordered the front lower arms...

http://i67.photobucket.com/albums/h2...8112007072.jpg

...And a complete set of rear bushes...

http://i67.photobucket.com/albums/h2...3112007078.jpg

Siena 19th September 2009 12:45 PM

I then settled on my wheels - BBS RX II's splits, in 8,5"x18" ET 20, with Dunlop Sport 9000's, in 255/35x18, the correct dimensions for an RS4.

I ordered them, and they turned up from Germany 2 weeks later...

http://i67.photobucket.com/albums/h2...5112007088.jpg

http://i67.photobucket.com/albums/h2...5112007087.jpg

http://i67.photobucket.com/albums/h2...5112007086.jpg

http://i67.photobucket.com/albums/h2...5112007085.jpg

S8 Brembos with pads...

http://i67.photobucket.com/albums/h2...8112007242.jpg

http://i67.photobucket.com/albums/h2...8112007240.jpg

Engine originally destined for Project B5:

http://i67.photobucket.com/albums/h2...6012007491.jpg

http://i67.photobucket.com/albums/h2...6012007490.jpg

http://i67.photobucket.com/albums/h2...6012007488.jpg

Sold February 2008 to make way for D2 power...:cool:

http://i67.photobucket.com/albums/h2...5042008471.jpg

http://i67.photobucket.com/albums/h2...5042008474.jpg

http://i67.photobucket.com/albums/h2...5042008470.jpg

I never liked auto trannies, besides the maintenance issues, they rob valuable power, are damn heavy, and not fuel consumption friendly. They are also slower, and limit the amount of torque you can shove through them.

Rebuilt 2000 S4 6-speed tranny. I also bought a 6-speed from a wrecked Allroad 2,5TDI, and robbed it of the 5th and 6th gears to replace the 5th and 6th cogs in my S4 box.

Now geared to do 37.5mph per 1,000rpm...

http://i67.photobucket.com/albums/h2...5032008391.jpg

http://i67.photobucket.com/albums/h2...5032008390.jpg

Manual V8-engined Audi's were never imported to the UK.

So, I had to have a flywheel custom made. This is the Gen. 1 version, and used a seperate pressed-in boss to take an OEM spigot bearing. My later Gen. 2 versions have an integral boss.

D11 / D2 32V Gen. 1 single mass flywheel, weighing 7,2kgs:

http://i67.photobucket.com/albums/h2...2062008637.jpg

http://i67.photobucket.com/albums/h2...2062008641.jpg

http://i67.photobucket.com/albums/h2...2062008640.jpg

http://i67.photobucket.com/albums/h2...2062008643.jpg

Siena 19th September 2009 12:55 PM

A quick detour to the other side, where the exterior work commenced.

My car went into the bodyshop on the 17th November 2007, and was ready for collection on the 29th January 2008.

My B5 sliced open, all her tired old bones showing...

http://i67.photobucket.com/albums/h2...2008_00001.jpg

More pictures:

http://i67.photobucket.com/albums/h2...2012008100.jpg

http://i67.photobucket.com/albums/h2...2012008101.jpg

http://i67.photobucket.com/albums/h2...2012008102.jpg

http://i67.photobucket.com/albums/h2...2012008103.jpg

http://i67.photobucket.com/albums/h2...2012008104.jpg

http://i67.photobucket.com/albums/h2...2012008105.jpg

http://i67.photobucket.com/albums/h2...2012008106.jpg

http://i67.photobucket.com/albums/h2...2012008107.jpg

http://i67.photobucket.com/albums/h2...2012008108.jpg


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