Introducing Project B6 420-TS Avant.

[Nollywood]

I discovered that what I thought were B6 A4 2.5 V6 TDI front axles, were actually the originals from my 2000 B5 2.8 Quattro, before it got a V8, and an 01E swap. That meant inner flanges of 108mm.


I managed to get hold of the correct ones, with the 130mm inners. So, Tripod, rather than the regular Lobro units.

[Nollywood]

B6 420-TS spec. Final spec may be subject to change, and subsequent revision:


Audi B6 420-TS Spec.


Powertrain:


Rebuilt 2004 RS6 (BCY) 4.2 V8 40V BiTurbo.
OEM steel laminate head gasket, 1 extra leaf added.
APR Rod Stud kit.
APR Cylinder Head Bolts.
RS6 cylinder heads ported, exhaust ports polished.
Intake manifold ported to match cylinder head ports.
Custom exhaust manifolds with V-bands.
C5 S6 (ANK) crankshaft, cyro treated.
Rods and cams cryo treated.
Throttle body ported to match intake.
OEM C5 RS6 intercoolers.
Vibra-Technics aluminium billet Motorsport mounts.
2 x Magnaflow 200 CPI CATs.
OEM B7 RS6 cat-back with rear active muffler valves.


Fuelling:


Bosch 0280150672 injectors, 800 cc/min (74 lbs/hr).
OEM 4 bar FPR.
Fuel pump capable of 365 L/H at 6.0 bar.
D3 A8 4.2 MAF housings, C5 RS6 MAF units, scaled accordingly.
Intake trumpets machined to accept larger MAF's.


Management:


Bosch Motronic ME7.1.1 stage III remap by MRC Tuning.


Drivetrain:


Built 01E 6-speed manual, from 2002 C5 A6 2.5 V6 TDI Quattro.
B6 A4 2.5 V6 TDI rear 4.11:1 differential.
TTV / B7 RS4 single-mass steel flywheel.
OEM B7 RS4 241mm clutch pressure plate.
OEM C6 A6 3.0 V6 TDI 241mm clutch friction disc.
B6 A4 2.5 V6 TDI front driveshafts.
Vibra-Technics transmission mounts.
Vibra-Technics differential mounts.


Braking:


Porsche Cayenne S 6-piston Brembo calipers (fronts).
Alcon 2-piece 365 x 35mm slotted rotors (fronts).
Porsche Boxster 4-piston Brembo calipers, custom brackets, OEM calipers for parking brake (rears).
Alcon 2-piece 330 x 32mm slotted rotors (rears).
Stainless steel braided hoses all round.
Dot 5.1 hydraulic fluid.


Rolling stock:


OEM B7 RS4 9" x 19" wheels, powder coated anthracite, diamond cut faces.
255/35x19 Continental Sport Contact 2 rubber.


Suspension:


Bilstein PSS9 adjustable coilovers.
OEM B7 RS4 lower and upper arms.
OEM B7 RS4 front and rear ARB's.
OEM B7 front ARB links.


Exterior:


OEM B7 RS4 rear quarter panels, grafted onto B6 rear quarters.
OEM B7 RS4 rear door bulges, grafted onto B6 rear doors.
OEM B7 RS4 side skirts.
OEM B7 RS4 rear bumper, B6 upper section grafted on, to match B6 tailgate and tail lamps.
OEM B7 RS4 fender bulges, including skirt attachment area, grafted onto B6 fenders.
OEM B7 RS4 front bumper flared sides with "gill slits", grafted onto B6 "Votex" bumper, smoothed into 1-piece.
OEM B7 RS4 brushed / matte aluminium trim around the side / door windows.
OEM B8 S5 satin-effect aluminium door mirrors with LED repeaters, mounting "triangle" modified to fit B6 doors.
B6 "RS4-look" hood grille, to match mesh in B6 Votex bumper.


Finished off in Ford Ultimate Green Pearl.

[Nollywood]

As one of the issues encountered, when having a large engine in a relatively small engine bay is heat, this is one of the issues I'm going to be addressing with B6 420-TS.


You can add as many fans as you can physically fit in the available space. But it's useless, if the hot air can't be drawn out of the engine bay. Typically, the heated air sits at the rear of the engine. I'm going to be addressing this with real researched hood vents, shrouding, carefully selected fans and oil coolers.


I will also have a pair of scavenge ducts built into the false firewall, where heat can be drawn out from the scuttle area. The battery will be in the luggage compartment. Unlike in my previous V8 swaps, I'm going to run an OEM B6 S4 or B7 RS4 radiator. Aluminium aftermarket radiators sure look good, but I doubt their research budget is even a third of that of an OEM radiator on a Hyundai.


Every cooler will be painted satin black. Silver under the hood merely serves to reflect heat, and keep temps higher.

[Nollywood]

I took advantage of the brilliant weather today, to cut out the B7 RS4 rear "bulges" from the rear quarters. This has definitely ruled out any chance of my B6 having the B7 swage lines, that run from front to rear, above the door handles.


It'll soon be time to start cutting the actual car, once I get a new daily, and a shop to work in.