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A4/S4/RS4 B5 1994-2001

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  #1  
Old 19th September 2009, 10:33 AM
Siena
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Default 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:












Last edited by Siena; 20th September 2009 at 09:35 AM.
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  #2  
Old 19th September 2009, 10:42 AM
Siena
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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...





Rear doors...



Rear quarters...



RS4 front bumper...





Euro S4 rear bumper...



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  #3  
Old 19th September 2009, 10:47 AM
Siena
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RS4 sideskirts...



RS4 grille...



RS4 bumper grilles...



RS4 foglamps...



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

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  #4  
Old 19th September 2009, 10:53 AM
Siena
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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:





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:





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.
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  #5  
Old 19th September 2009, 11:02 AM
Siena
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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...







Then RS4 one-piece xenon headlamps...





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



And matching A4 facelift rear bulb holders...



RS4 front clip came next...

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  #6  
Old 19th September 2009, 11:08 AM
Siena
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My kitchen was gradually filling up with RS4 parts.

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...





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



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



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

So, I ordered these...



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  #7  
Old 19th September 2009, 11:13 AM
Siena
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Then came the little bits and pieces, that are easy to over look.

B7 aero wiper arms and blades...





RS4 side repeaters...



RS4 headlamp washer covers...



RS4 headlamp washer pump...



RS4 headlamp washer bottle...

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  #8  
Old 19th September 2009, 11:29 AM
Siena
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As I previously mentioned, I wanted to subtly modify my Euro facelift B5 trunk, so this happened...









...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...





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



I also ordered the front lower arms...



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

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  #9  
Old 19th September 2009, 12:45 PM
Siena
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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...









S8 Brembos with pads...





Engine originally destined for Project B5:







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







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...





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:







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  #10  
Old 19th September 2009, 12:55 PM
Siena
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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...



More pictures:

















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