Bobby Singh's Audi A4 3.0 TDI Project car

[Misikee]

Thank You Bobby


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[Bobby singh]

June 2017
Macan Big brakes

Added TTRS wheel vents & Modified my fog grills



Managed to source Macan turbo brake set up (front, rear, pads, discs and lines)

Fronts - 360 x 36
Rears - 355 x 28



To keep the OEM look they were professionally painted black by Adrian From Project Paint (Cardiff) AdrianSmith617@gmail.com - Totally recommended.

Soda Blasted and epoxy primed









Sourced Macan hub carriers for oem style install



Other side was bought from main dealer at cheaper than expected price which was good news

On to the install (what a nightmare)

First the top suspension arm pinch bolt was completely siezed - tried many methods to pull this bolt out but in the end one of the lugs broke as I tried to wind the thread out.
Out came the angle grinder
(I was changing the carrier's anyway)



Then my next problem was trying to remove the lower (rear) suspension arm from the carrier. Again this was completely stuck in the steel bush - in fact the ball joint bent under the force that my spliter put on but it still wouldn't move.
So again I just cut this out to save time (it was ruined anyway).



First test fit:



At this stage I tried my stock wheels but they would not clear the calipers (ET47)

Carried on with the install and discovered the Macan carriers have a M14 ball joint and my old ruined ones were M12 (both have 65mm bush)
In fact all Audi's made from November 2009 have M14 arms

TRW arms:



The back plate was trimmed to provide heat protection for abs sensor, ball joints, track rod end only

Backs were a direct fit:





Coming back to the wheels - I decided on a set of S line alloys from an Audi A5.
Benefits:

Same look as the A4 wheels
ET29 off set
8.5J rather than 8J
15mm clearance (from caliper)
No spacers required
OEM wheel bolts






Brake feel like OEM but work very well its a very impressive set up.
To aid cooling I've added Macan air baffle plates, I've ordered some braided line which will go on soon.

[Bobby singh]

Hybrid testing time....
So my turbo guy sent me a hybrid to test. Objective was to see what power is possible with 'decent' compressor wheel and turbine in the stock 2260vk...not the usual AMG turbine.

Removed the S200, fitted a gutted dpf unit, stock exhaust - PCV behind the headlight haha



Results:

426hp / 870nm



Looking at the log I had a lot of torq correction based on egt's due to the hot weather so on a colder day I would expect better power

Nice daily unit with great response.

[Alex jb]

Bobby, what transmission do you have?


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[Bobby singh]

Its in the build thread Alex - but its a TIP 6hp 28

[Alex jb]

Thanks, couldn't recall.
Was assuming it had to be the ZF6HP, as the DL501 would be on the limit with this power and your other setups were even higher I think

I am just jealous, my CVT couldn't handle anything like this torque.

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[Bobby singh]

DL501 handles 730nm - I've done a few between 710nm to 720nm without issues

[baracad]

Hi Bobby, impressive build.

I have the CCWA on my Jan 2009 A5 and TIPtronic. I have been quoted recently by Darkside Developments for a remap of around 300bhp as a safe limit with stock 2260vk, intercooler upgrade and free flow exhaust aparently with original map sensor.

Would you be willing to run a better map on my car if i come to you please?

And if so what other prerequisite hardware would i need apart from going down the higher flow older fuel pump route?


Kind regards

B

[Bobby singh]

Hi Bobby, impressive build.

I have the CCWA on my Jan 2009 A5 and TIPtronic. I have been quoted recently by Darkside Developments for a remap of around 300bhp as a safe limit with stock 2260vk, intercooler upgrade and free flow exhaust aparently with original map sensor.

Would you be willing to run a better map on my car if i come to you please?

And if so what other prerequisite hardware would i need apart from going down the higher flow older fuel pump route?


Kind regards

B

Hi - sure but you don't need exhaust system.
I'll drop you a private message to arrange things. Cheers

[Bobby singh]

July 2017

Still using the hybrid unit but will have a version 2 hybrid to test soon
Braid lines have been installed and the braking is very powerful now.

Suspension wise I had one of the rear springs break on me recently so I put in H&R springs but the ride quality has been poor.



Looked ok though:





I've now got the Eibach Pro kit in







The ride quality is now perfect. The car does sit higher compared with the H&R's but thats ok.

From the ground to the arch I made the following measurements:

H&R's - Front & Rear - 655mm
Eibachs - Front - 666mm - Rear - 663mm

As you can see even though both kits are 30mm there is a difference in height.

On the engine side I've installed some high flow injectors - details of which I will not be releasing but they are working very well with 100deg egt cooler for same amount of fuel.
And I've installed version 2 2260 hybrid with a larger compressor wheel - Hopefully I can get on to the dyno soon.

Cheers
Bobby