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Tom's Garage, Audi A4 BT-Quattro Project from Greece

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#1 · (Edited)
Audi A4 BT-Quattro Project from Greece

Hello from Greece. My name is Mike. I have been following Detailing World, for some years now, without writing.
Cars are my love, my passion, like most of the people who are in this forum. I was mostly into Studio, Showroom, and of course, in the Projects and Restorations area.

The purpose of this thread, is to show you the progress of my own project. Well one of my projects, the one that takes most of my time.
The car itself is an Audi A4 B7 (8E) Model, 1800cc 20valve Turbo engine inside, and ofcourse, Quattro.

I started modifying it, from the minute I got it in my hands, and the story starts from June 2008. It is a long story, and some of you in here, may know this car already, since it is featured in more fora here and there.
However, I will show progress from start to finish, little by little, so that it has interest to all followers :)

So, let us begin.

It took me not a whole lot of time to begin the mods - First was the exhaust to be modified.

Old exhaust



New cat back exhaust



(the car was initially going for a big turbo, therefore, i chose a 76mm pipe)













Some photos of me when i took the car from my dad [wrench]





with my friend's big turbo MKV GTI, Tom, who is also in charge of my whole build of this car :)



gauges installed









My man who made the gauges work, XM Vaggelis Xaitas at Greece



Ready for suspension, Custom PSS9 racing @ Kirlagkitsis Greece (u can see on the right a racing Impreza)











Gauges almost finished







On the road to Athens


 
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#33 ·
So here is another update

Received the Short Shifter Kit from JHM...The waiting was long but I believe it was worth it. I would like to thank Jason who was always there when I wanted something.

So some pics from the kit...













Now the difficult part was to put it on, as I had no previous experience with this...

And what to you know, I did make it happen

Some pics from the process



































 
#34 ·
And then I took some more weight off the car (small pics are clickable and will expand)

Was in a mood this morning and decided to take some more weight off the car....




Before:



And afterwards...



And the bolts that were holding everything in place...24...LoL... [:)]



And this is how the car was standing out at November 2008

 
#35 ·
UpDates and some more diet for my car...4 more KGs gone home... [:D]



UpDates:

Received my BRAILLE LightWeight B106 battery today.

Weighs 2,8 kg, less than 6lbs, whereas the stock weighs 20kg which is 45lbs...

So yeah, that was a good weight reduction once more...

Here are some crappy cell phone pics. Better ones will come if wanted as well



Some pics of what I've been doing today



[:)]​
 
#36 ·
Started building my first home garage and some more things arrived too

Some updates, both from the car, and from the Garage project I am doing also...
Some 3M masking tapes, and Vallet-Pro Wheels' Cleaner, Apex-I AVCR Boost Controller, and a place to store some things by Keter.

Let the pics speak for themselves...




At that time, car was about to enter its first trackday - more on that on the next update
 
#37 ·
Onto the track event

Some photos of the preparation of the car...that took place on the newly opened back then, 4 years ago, Dazzle Detailing Center of my good friend Andy, whom I thank for all his tolerance throughout the years :)



Some track-pics



And some random pics



And some pics from the problem I had with the exhaust, which I fixed myself...



 
#38 ·
Some more updates:

1. We cleaned the car after the track race, again @ DAZZLE Show Car Promotions with Andy's help

Pics from before:



And after:


And some more changes in the car...



Some more updates of todays work...I started a new project...



Roof....

Before...



And afterwards, almost finished...

 
#39 ·
Some engine work -



Ok Jeff...

Todays Update:

First for the interior job:



Removal of air pipe...



Getting started...



Went to the front seats...



And then back again...



Then onto the footrest



And then for some hardware updates:



While yesterday I ordered this from Integrated Engineering...



I think I have to buy wider wheels before than the turbo however...
These wheels are way too small to fit 265 tires that are necessary for the car's weight...
So I have a great potential at the track even with this power...
Dont forget the car is a lot lighter now...And pretty faster than a lot of tfsi's out there...

Well here's some more, and thanks for the support.





Before:



During:



Finished:



Whereas the air pipe from the driver's side was also removed...



 
#40 ·
Well I decide I didnt want the new year to find me with a dirty air filter, so heres what I did today although I was pretty bored...

Before filter



A little comparison



And then ready to go to the car



Last updates for this year
Received the Integrated Engineering Block-Off plate today



And then some more orders





I cant help it sometimes hehehehe

Today I decided to take the project of a thing I had not before been familiar with...To take off some vacuum lines, and unnecessary stuff from the car....

Ι did start with a good DIY in my hands,,but it was from the B6 so due to some differences we did have some problems in the way....
Either way we fought it, and we did manage it....
Even though in the end, I did do a major stupidity, and I almost destroyed the Engine's ECU...But lets take it one at a time...

Some photos from the whole procedure :whistle:



I left my bones...



Here is the block-off plate from Integrated Enginnering



Continuing to work....



Purge Valve



More stuff off...



Initially out...



Removal of the lower pipe of the SAI system



Putting on the pipe of the CAI...



Check out the final stuff removed....Not bad heh...



And in the end everything nice and more empty....



And now for the mistake I did....
Wanting to go as fast as possible for a test run after all this was over, I left something on here...pretty warm....



Believing they would stand the heat...
I drive, everything ok, and while I reached home, the car went off on its own....Plus it could start no way....
I opened the hood and saw smoke coming off...I totally blacked out....
Whereas the guy that helped me, told from the first moment it was a melting of the wires, and there was a short circuit...And some fuse was off...
Luckily it was only the fuse and not the ECU...
Then we had to sort the pile or melted wires and fix everything again...Sad...
Luckily it was done and well...

And a photo... Pretty bad...



Conclusion is, not to be lazy to do something right the first time...Otherwise u might be in bad trouble...really bad...Luckily Tom was there :D:D

Well onto a new project I had in mind...

I decided to take the valve cap off, paint it, and change the valve cover gasket as well just cause it would be a good chance....

here are some pics of the process, which was something new for me, I hadnt done it before and it was nice...for the moment at least cause I havent finished it yet....

First I had to disconnect some stuff of the cover...
(the PCV system and SAI were already off, so it saved time)



Me into action with some light :p



Disconnecting the hose from the crank breather



And here is the valve cover



A look at inside



(the gasket will be changed even though its not torn in any way)

Then I had to clean the cover inside out...

Before



And after



Due to some Megs stuff, and Bilberry as well



i then used this to paint the cover



From this



To this



And a final touch with these as well



The final results . . .

Here is the finished thing...



And onto the car


 
#41 · (Edited)
Some todays updates:

The boost controller itself



The place where I put the new boost controller valve





Whereas, there is somewhere waiting for me to pick it up

Thanks to Kyriakos that helped me buy it



For fun





Tow Hook by Ruff is on...



Tidying up on some wires and setting them nicely...



And then a pod that had been on the list a long time ago....




PS: Pic quality is very bad, my camera's light (flash) is off

UpDates:

-Killer battery Switch from Hella



The pod is on the way...



-Then I decided to remove the front doors' interior part....
The weight was significant...
They will be done the same way as the rear ones really tidy.

Some fast photoz, the good ones will follow...





Pod almost there...

Time for killer switch





To the interior





The red wires will be wrapped and not be visible at all

here is some more...

-The pod



The switch, not yet finished totally...



I think they are nice...

Switch is ready



Some refreshments needed...



While doing more work on my interior towards weight removal

Some photos of today's process...
Not easy to say the least....







I may cover some bolts...maybe not...like the racing look...However...I liked the finished result....



Some more updates...

1. Passengers side front door ready (again very difficult project this one, took a lot of patience)

Some pics



What I do like especially, is that nothing from the OEM things is destroyed in any way, and will be ok once i decide to return the car to stock...well someday....[eek]

2. Removed some more weight and cleaned as well....

Some photos from the process...

Rear Wheels



Front Wheels



 
#42 ·
Then, all of the sudden - happened a big change on the car. Plans for big power were never abandoned- however - I changed it back to oem factory things inside- luxury and all, due to my everyday movement with it, a movement that was not so easy with all the racing components . So sold some things . . . and here it was at the end of January 2009





Proof [:p]

New Hitachi CoilPacks...

Will be getting two more later on....



Today I relocated the engine's general electric switch and moved it to the engine compartment....

Removed...




And everything is back in order inside....



Received the D1S lamps I had ordered a couple of weeks ago...

They arrived....



And decided to put them on...





Ready



Had fun in the snow



On a side note, here are the pics with the new coilpacks on....

Check it out...





 
#47 ·
Well some news today.

If you've read the thread, you will know I had 76mm (3") catback.

Today I had a 76mm(3") downpipe too...(stock was 55mm , 2")

Some pics from the process....

Arriving at the shop



How it was before



Here is the stock downpipe, 2"



And the stock cat



As well the 2" to 3" connector



Removed all that, leaving us with this



and then onto the new one...Some pics of the process...







Some wholes were made for the Defi EGT, and GReddy A/F Ratio



Then it was polished, and back onto the car







I also changed the HKS air filter with a new one



[wrench][drive]

The car sounds GREAT, I had an 0.1 boost increase...Not that I care with the stock turbo on, but hey, it was nice.....
Now onto some more tuning....

Time for some injectors today. 630cc.
Large for now but will be useful soon....

Some pics of the process.

Removing the injectors and installing the new ones





 
#48 ·
More updates today.
Received my tires from Germany.

2 sets, one, 245.40.18 Toyo Proxes R888 (semislick tires)
one 225.40.18 Sport Contact 3 for the family Golf GT.

Couldnt be happier.

Some pics.

Received the package....



Managed to get all 8, tires into the car, B7 rulez [:)]



The tires themselves



And the man that helped me through the process of purchasing them



And here onto the car.....







Which got a little happier too hehehe...



On a side not, I cleaned the engine bay yesterday, by myself


 
#49 ·
Got this Cupra Lip



Well some minor touches on the car...

First I fixed the rear trunk interior panel, which was damaged in the past not by me, and instead of bying a new one, I thought of doing it myself, so I did the following...

Before....



During....



After....


It came out perfect....

Today I bought this...



And installed it as well...



Well some more updates for today:



Installed....



And a general photo of the current status....



I think it came out really nice and tidy...

Well some minor stuff, in terms of looks...

1. Once, I've read a "Penny mod" in a signature, and said, WTF is that...? once explained by someone, I thought it was fun, and did it myself to see how it looks, hehe

So, one Penny Mod, complete (actually in euros, it is €0,02 [:p] ) :



2. Then did something to my mask, with my Golf's United Gray colour



3. And then took something off the engine bay:



Prepared it, cleaned it, masked it



And went from this:



To this:



I think it looks nice. [:)]

As for yesterday night, I wish I had my good camera with me...I liked the lighting...



Well some minor mods done:

-VAGged the display to show me lights on, and the Clutch message, thanks guys, hadnt found this one



Oh, I had totally forgetten one more cap...I found it...LoL



-Time for some caliper love, as the original colour was destroyed, more like oxidized by some wash foam, so decided to make it much better (will paint the letters in the future as well)

Before:



During



After



Some random photoz...



A problem I had that luckily didnt give me a flat tire...Love those R888s



-And then I decided to remove the old cf trim vinyl and replace it with a much better one, from 3M, the one i have put in the interior trim as well...

My friend Andy was more than happy to help me get rid of the old one.



And then the car looked really weird....Really really awkard...



Time for 3M CF vinyl



This time I decided to do the B-pillars as well...



And two funny pics:

One :p



And another one, of a car parked behind me...Sort of like the before and after situation....Hehe...



PS: My friend Andy, had this DahlBack Racing intake manifold on his 1.8t 20vt Golf MK4. The air intake, is on the other side. Do you think I should take it from him and do some new pipework, so as it fits properly...?
Here are the pics to explain


 
#50 ·


Well, today some work was done in the car....



And I started taking the door card off, and generally everything off....

Pics of the process...



I always wanted a door like this one, like Imprezas, without the upper part



Getting there...



And, what went wrong...





Now, waiting for the Precision Cooler....cant wait....

Well some more updates....

First...I got something from RECARO....

Here it is....



But more on this later...

I also got my garage a bit more tidy



And now to something good....

I got something today from USA...



Noooo...this was not the good one...[confused]

However, this was...[:D][:D][:D][:D][:D]







Look at the size of it....





[drive][drive][drive][drive]



the front bar will have to go propably...but then where will the bumper's height will be...?​
 
#52 ·
Well some more updates....

-First I had some light problems, which I sold by buying a new license plate bulb holder, i dont know how it is called...

Here are some pics during the change....


Some random pics too....during my changing horns to the MKv Golf GT....



I ordered some things from GT3 Turbo
which are the following

1. Oil Return Flange with integrated -10 Flare for GT15 Through GT35R


2. Lower Adapter Flange - 18T Oil Pan Drain


3. Oil Return Line -10 - 14" ST/90


4. 45 Degree 1/2" NPT to -10 AN


5. Oil Return Gasket - GT Series


6. Oil inlet fitting for GT28/30/35R with built-in restrictor


7. Oil Feed Line -4 - SS Braid 4 Ft.


8. 45 Deg 1/8" NPT to -4 AN


And I also bought some stuff needed from the stealership...
Exhaust Manifold gasket and nuts...



As for the exhaust manifold, this is coming from Mike2ptZero...



Something fresh....

1. Waiting for this (in blue color) from Mike2ptZero:



2. And something like....this...also from the states :

Got some more things today....



[happy]
 
#55 ·
Well at last some things are here, it seems ages since the cooler arrived...

So onto the pics from GT3 Turbo, England









Little things, that are so important, and not cheap as well....

Now waiting for the next nice packages... :)

And some random pics of the car, with some dirt from a week's unstoppable rain :p









As for the car, it is feeling a bit sorry for itself, waiting for the turbo, mani, and WG to arrive at last....





A trip with friends, to Araxwva, Parnassos, a famous winter destination...
Some pics











It was great, both the place, and the road trip.
 
#56 ·
I had the opportunity to do a little project I've been meaning to do for some time now, but I was always bored to..Today though, I wasnt...

I'll let the pics talk for themselves...





So I went from this:



To this:



But that was not all there was to it...I wanted no chrome at all @ my car, and since this was the lasti bit that was left....







I liked it, and now time for the second one [:)]



Hope this little DIY helps someone who wants a stealth look too...

On a side note, I polished my cooler, and did for the focus I had forgotten, black rear badge :p



AC REMOVAL TIME

First of all, once again I opened the top end of my motor so as to change a gasket, because of a small leak i noticed...

Pics of the process...











Installed the new gasket, cleaned the cap



and then it was ready.

Then, my friend Tomas who is looking after my mechanic stuff, persuaded me (like I didnt want to) to remove the A/C system. So onto the pics of this process as well:

Removed the air/liquid (it is called freon in Greece, not sure in english, sorry)



Removed the CAI, and MAF



Then we remove this 13mm nut



And have something like this





Then pull it out slowly and carefully...







This has to go as well...



It is held in place by a plastic bracket, and two metallic tubes are also held there.





Gone



Time for the AC radiator to come off
So from this



To this





Now you must get yourself under the car, and unplug a fuse from the AC compressor and get the two lines out







So eventually you will have removed all this pile of junk





(notice that my cold startup pump has already been removed in the past that is why there is nothing on the passengers side :p )

So you end up with something like this





Note: The AC compressor which is really heavy, will come off too in the future when I get a smaller belt.

Next time the car gets in for some work, will be hopefully in a week or so for the BT.
Fingers crossed to finally get the things from USPS...

A huge thanks to ToMaS for his help.
 
#57 ·
Some more little things bought today....

Again, from DEI Thermal Tuning Products, two Heat Protective Sleeves, for the hoses that will run from the AVCR's Boost Controler, to the External Wastegate, so as to protect them.







Well, major update today....Santa was a bit late, but what the ****....At least he came after all.... :

First package I received was this:















(I wish treadstone hadnt forgotten some hoses i had ordered....)
 
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