The Project Pad

This project has already progressed and changed shape a few times.
It started because I was looking for a test mule , basically just needed some quattro B2/B3/B4 body to use to put together an 07K/01E setup. I would then get the body work and paint done on the URQ and transfer everything in.
The URQ is fully stripped with no engine /interior/harness/glass, and I don't have the funds yet to get all that work done, so its too far from driving to be a good test car for an engine. Now once everything is done and running I can't say that I will swap it over, or if I just will leave it as is. As the wide car is just a whole different project with its own challenges and questions.

I was looking for a 4000 but this CQ turned up with a no start issue. Basically the oil pump failed, engine was bad, car sold as is. It went to a guy who sold the rear seat and some parts to Kirk to the Quattromog. He then sold it to someone else who swapped in a junkyard engine but it wouldn't start, he swapped the distributor and a few things.
So I wanted to be able to drive it and see what issues the chassis and suspension have, make sure the wiring works.
Then proceed with swapping and getting the engine dialed out . Figure out what (or if it) works

First step was to re install the distributor, set the timing, reorganize the plugs wires to 1-2-4-5-3. Timing was off 2-3 teeth and the car sounded like a diesel. Set the timing, ran the car for a few heat cycles, changed the oil. And now its running decent. Has a huge exhaust leak (stock exhaust). Only issue I see yet is that i believe it has a bad knock sensor and more importantly I found out that if I rev it to redline the fuel pump fuse pops. Hopefully I can drive it for a bit. Since I need a commuter but soon it’ll come apart

Paint is not in great shape but with some help it’s looks decent










Here she is today

Here are the engines . I was planning on looking for a newer one due to some changes in the pumps but with how cheap they are it doesn’t really matter what I test fit and what I end up with .
06&07 Engine

GBE 6 speed trans

Oil adapter deal. I still have a way envisioned to run without this but we’ll see..


I used one of them (better one) to test fit the trans and put the other engine in the car engine bay without a transmission so I could make the exhaust and intake .
How’d I get it in there with stock subframe ?




For comparison with my other coupe

The exhaust :
There is more trial and error than what’s shows here . 3 different fixture designs just to cut it but after some amount of work I found what works to cut the collector using a band saw.

Intake is what I’m currently working on . I’m only just learning how to draw things in CAD so it’s taken a lot of trial and error. I first was going to make a paper copy of the flange then somehow import into the computer in a 1:1 ratio but I could not figure out how to do it. So it just ended up being lots of careful measurement and triangulation .



First I cut just the flange to make sure the bolt holes and ovals were good








This is the design I have right now . I might change it to have about 15 degrees “downturn” on it so that the runners are not pointed up due to the angle of the engine .





One cut left on this which will be the injector holes .
The runners should fit right into it

This is awesome and I love everything about it.

It should be good . If not I can apply all this to the tried and true 20V

So next ill need to get a clutch and I ca start looking at the timing cover and the starter .
I can trim the timing cover , and use the holes for alignment . It should need to move “out”.
I thought that I would start with the old school sr10X and see about making a spacer for it but I would figure it how thick I need to go then draw it in cad . Or make it and then write down the numbers .

Is this the accidental coupe? Nice start, I’ll be watching its progress.

Like where this is going, nice to see some more of the fabrication you've been doing.

Definitely following this one too. Two 07K CQ treads! Ha!

Love the fab work. It's amazing the amount of custom fab work is needed to fit hese engines in an old skool Audi Quattro.
I thought a VR swap was hard, this is another level.

Well the factory intake is plastic so that’s a no go, but there is one that can be cut apart and used from IE , it’s just expensive, but probably the best /easiest route to go, when you consider the time and resources to make one.
the exhaust, I don’t think that there is any log manifold for any other application that would work (that I know of) . (But who wants a log manifold )

Looking great Pat!!


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FFF wrote:Looking great Pat!!


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Thanks but remember nothing in my shop is as clean as your project

I’ve only had a few minutes to spare this week but I’ve test fit the intake flange last night . I have a couple areas to re do but it’s going to work and the holes and ovals line up perfectly . Injectors are good .


Clearance issue


Here’s a piece of the extrusion , perfect match.



Next thing I need to do is to figure out how to take an extruded aluminum oval tube and bend it . I want to put I think about 15 degrees of bend in it .
I’m considering maybe bringing the entire piece then cut it to equal length pieces . But they all have to be the same so I need to do some thinking on how to bend without crushing it .
This is the “vision”

I’m afraid if the tubes are straight it may put the intake up too high . But I could always try it that way and see how it looks first .


This is the next step is making the plenum end

Oh heck yeah. Pat this is sick. looking forward to updates on this. And did you have access to that milling machine to cut that flange yourself? It looks awesome.

dougkehl wrote:Oh heck yeah. Pat this is sick. looking forward to updates on this. And did you have access to that milling machine to cut that flange yourself? It looks awesome.

I don’t have a milking machine but I have access to one . The machine was originally a 3 axis that has a 4th added, but I still need some training /practice. Not fully capable of cutting the part myself yet .

At some point way down the road I would like to either wall off a section of my shop or add a small piece where I could have a clean room. A lathe, maybe a mill and a spot to build engines and keep the metal dust out of things .

Afterthought wrote:

FFF wrote:Looking great Pat!!


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Thanks but remember nothing in my shop is as clean as your project

Hah! That’s only because you have so many cool projects on the go!!


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I don't know if the runners are the same size, but it looks awful close to AEB runners.
You could buy two AEB IMs and cut out what you need.

EDIT: Outside dims: 41x58mm approx.

Everything is looking AWESOME! I love this so much. Does that oil adapter have a check valve built into it? Have you pulled the pans to confirm they have forged cranks? Also, per Jim Green's path, I also modified a main crank cap to take an AAN thrust bearing to have a full 360deg bearing. I'll put some pics in my post and I think Jim has links to a video of the maching of his cap.

I haven’t even pulled the pan yet on the ‘06 engine! pretty sure it has a forged crank, but I’ll Have to check . I do need the 6 bolt .
The oil adapter that is pictured in the car for fit up is missing some threads but more also there are a couple of ports I don’t see (for example filter bypass) which I think COULD present a problem. don’t know what’s up with it. But the new INA one pictured does have all of the ports I think and it does have a factory check valve in it also
which if I understand it right should keep the head from Draining down .

My plan with this intake manifold was to make one that looks similar to my BST one which is in my URQ. The reason for this is looking though all the Audi sport cars they seem to all run dual plenum. Only after I came up with this vision did I realize it’s not going to be very easy to do . I tried the first test today of mocking some things up.
This is what I’m trying to make .








Looks promising but I think the “slot” through the middle for the airflow is supposed be the same the whole way across .
So if I can figure out how to compress the end more and get it to bend around , I’d be close .




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The slot should be the same the whole way across, otherwise the benefit of the dual plenum is somewhat lost. I'm very very excited to see that manifold come together though. Before I came across my cast plenum I was going to make one. Certainly an intricate piece to make, so hats off to you!

dougkehl wrote:The slot should be the same the whole way across, otherwise the benefit of the dual plenum is somewhat lost. I'm very very excited to see that manifold come together though. Before I came across my cast plenum I was going to make one. Certainly an intricate piece to make, so hats off to you!

What he said!

Hats off, if nothing else... nobody can fault you for lack of ambition!

I'm sure you've read Bufkin's pages on the manifolds...you're better off designing a standard manifold for a street car.