The Project Pad

Hi all, welcome to the 'Judas' thread here on Iroz Motorsport forum.

Many of you already may know of this project, those of you who are new to it, I hope you like it. Please feel free to opine, question, comment, flame etc.

Summary:

I picked up a 2003 Audi RS6 a few years ago that was being parted out. I picked it up to save it from that fate, with the intention of doing something fun with it much later. It got shoved in my storage unit for about six months and then one drunken evening I bought a GM LS1 from a 2004 Pontiac GTO as I had always wanted to mess with one. One thing led to another and 'judas' was born!

The project is called 'Judas' as in some purists opinion, what I did to a very rare car is sacrilegious, and that is just fine with me, I hate purists anyway so winding them up makes me happy

The goal was to create the same or more power (and power potential), with a fraction of the cost and complexity of the original RS6 V8TT powerplant, while retaining AWD and all the creature comforts of Audi's top of the line supercar of that era.

My main build thread is over on Motorgeek here http://www.motorgeek.com/viewtopic.php?f=6&t=39901 is you want to check out all the history so far.

Summary detail: (Current incarnation)

2003 Audi RS6, 100K miles, bought without motor, front fenders, front bumper and a few other odds and ends that had already been parted out.
GM LS1, fully built 383 stroker motor with SCAT crank and rods, JE pistons, Clevite bearings etc.
AFR Mongoose 230 heads
Custom grind Comp Cams cam, high rpm lifters, molly rods and 1.75 Gold roller rockers
Custom flywheel
Clutchmasters FX850 twin disc clutch
etc....

Pair of ebay Chinese special turbos rear mounted.
4" SS exhasut
3" Charge tube
4" DBW throttle body
Reworked RS6 intercoolers in the trunk tat had the spare wheel well removed to make some space

Built (By Scott) Euro TDI spec 01E 6 speed trans with 0.56 final gear.
Custom engine to trans adaptor

Lots and lots and lots of custom fabrication.

275/40/19 Toyo Proxes R888's on fancy light wheels
Stock (massive) RS6 brakes with track pads

ECU is GM corvette unit, tuned with HP tuners.

Hand built Carbon front bumper
some minor exterior and interior tweaks.

Link to build picture gallery: https://plus.google.com/photos/11767181 ... banner=pwa

a few choice pics for titillation!

























Should be up and running in a few weeks, but still a lot of finishing up to do after that.

This thing is just straight up nutzoid.

What size fasteners on the flywheel bolts Haydn? Wierd to see a 6 bolt on a something that is gonna see crazy torque like this, but I am sure they are big fasteners.

Hank wrote:What size fasteners on the flywheel bolts Haydn? Wierd to see a 6 bolt on a something that is gonna see crazy torque like this, but I am sure they are big fasteners.

They are very odd! M11 fine I believe - whatever the stock LS cranks are....and I cant remember right now for sure, sorry.

'merican bolts

Can't wait to hear this thing WOT

Wow, 11mm isn't very big really. Any friction material between the crank and FW?

Hank wrote:Wow, 11mm isn't very big really. Any friction material between the crank and FW?

Yup, M11F They are put in reasonably tight at 75ftlb, hence the fine thread I guess.

Friction material in my case is the flex plate which is sandwhiched between the crank and the custom FW.

I have not heard of any issues with big HP LS motors doing anything other than ARP bolts.

WOW.

i have problems keeping 6xM10F ARP Pro bolts tight on mine. fully balanced, with Fluidaper (might be the problem?). than again i see 10k rpm sometimes....

there were some guys that even did an experiment with the FW bolts we use, measuring stretch and whatnot. and IIRC, these bolts went to just > 100ft/lb before they stretched .0015. i take them to 95 ft/lb WITH Red Loctite. and have STILL HAD ISSUE!

so, we drilled and tapped the cranks (3 cranks, 3 motors to use one FW) so now i run an 11bolt setup. the newest motor is being built now and balanced with the FW on, too. it didnt come loose from the last runs this time...

Yeah, I knew people were having problems with 6x10mm thus my curiosity.

Aaron, what are the detection signs that they are coming loose?

Hank

when you pull the motor for some reason and the flywheel moves or you go to remove the flywheel and they are loose?

i noticed ZERO indicators.

I was more asking if there were noises you heard to make you suspect it and then sure enough they are loose.

nope, nothing i could tell/hear/feel to indicate otherwise. i actually felt lucky that when we pulled the motor to check after the 12,011 rev i found out then. cuz if we did not over-rev that time i wouldnt have pulled it.

Fantastic project, really very cool. Being that I have 4 audi's of various state in my garage right now this is awesome.

Did you have someone clone recreate a front bumper? How different to the factory one is it?

Brilliant project, that would be awesome for my S6

Tory

Sneaking a few hours in here and there and making a little progress. I should have all the fabrication wrapped up this weekend and be getting ready to fire things up.

Made the other turbo oil drain.

Mounted the oil scavenge pump and rough plumbed.

Made most of the exhaust heat shields and mounted them

Added bungs and brackets where needed

Added hot side turbo heat shields (still need to wire them on) and make a dent so I can see the flow glass)

Wrapped all the front end exhaust plumbing so that is ready for final install.

cactuss4 wrote:Fantastic project, really very cool. Being that I have 4 audi's of various state in my garage right now this is awesome.

Did you have someone clone recreate a front bumper? How different to the factory one is it?

Brilliant project, that would be awesome for my S6

Tory

Thx

I cloned the front bumper myself in Carbon. I borrowed a factory RS6 bumper and made a mold. The only difference is that I deleted the headlight washers.

After going through the process I would say "What a PITB!" and I would buy a factory bumper skin for $1200. Having said that the CF unit with paint only weighs 9 lbs

Nice work Haydn. Love the head shielding. Nice attention to detail on the whole concept really.

Hank wrote:Nice work Haydn. Love the head shielding. Nice attention to detail on the whole concept really.

Thx Hank

where did you score that oem looking heat shield on the turbo?

Summit Racing, not cheap at $90 a piece but its nice. Ill look up the part number

I cant wait to see this thing running, truly incredible work. The rear mounted intercoolers are epic and severely missing in most other rear-mount builds I've seen

I wish I could find a way to work with the similar material used on all the newer OEM VAG stuff, and the heat shielding that has been used on MotorSport Audi stuff for a while. It is crazy how well it does at keeping heat out in while not exposing metal to degrading moisture traps and extreme heat lock on stainles.s

awesome work H... those heat shields are nice

Here ya go Hank

Turbonetics Turbocharger Heat Shields 31040

http://www.summitracing.com/parts/tnt-31040

$93.49

Did a little more today

Finished heat shields ready for ceramic coating


Mounting detail for the heat shields



Finished the heat shields up


Gold, shiny gold


Super high temp stud grease, stainless hardware and stainless conical lock washers



Some beauty shots







I moved on to some thermal insulation. The material is DEI Boom Mat, its about 1/2" thick and is self adhesive backed. i added stainless rivets too to make sure it stays in place





First layer of protection I modified the stock heat shields. These will get cleaned up and the really hot areas will get a silver mylar layer on top




next job is to fit all the front end exhaust work, wrap the main 4" pipe and then its ready for final install. Also coming up is powdercoating brackets etc, finish and get annodized all the boost plumbing and run all the lines for real. fire up soon!