'87 4000cs quattro Challenge Build

I have been making headway the last few weeks. figured out my high rpm issue was my crank sensor mounting bracket vibrating and loosing signal. wound up adding a gusset and tying in to another bolt on the oil pump. funny that I was bragging about it not being some ugly welded piece on the previous page. . . live and learn I guess.

I also added a bigger oil catch can and bracket which seems to work ok. . .

im not happy with the internal design of this particular can and I plan on adding a baffle and some stainless wool inside to help grab the oil out of the air. I may change up the plumbing a bit after talking with keith yesterday at our last track event of the year. still a little smoke out of the tail pipe every so often so im just not satisfied yet.

otherwise the car is running well. still working out the high rpm tune but once I am happy with that I will put in my stiffer wastegate spring and step up to 14lbs of boost

Today I added a baffle plate inside my ebay catch can It always amazes me when a company will spend a great deal of time making a part look great on the outside, fully cnc'd, and then short change the functionality of the thing on the inside like this catch can. I know its ebay but the amount of time they put into this beautiful piece. . . just seems crazy that they didn't add a baffle plate.
I took a few measurements with my calipers, rough cut the shape with a cut-off wheel then did the detail work with a flap disc and a hand file. it has a .300 gap at the bottom of the can and I added some holes so the air can still flow as the bottom of the can fills up. then put in some stainless steel wool I picked up at the dollar store. once the work to the can was finished I kept the momentum going with a factory audi pressure regulator valve on top of the valve cover and I re-plumbed the pcv system so I am always pulling a vacuum thru the catch can on both the intake plenum and pre turbo. It would be difficult to improve the crank case ventilation system beyond what I have now and I think my smoking days are finally over

Looks like you are making some nice progress. You will be quite happy to bump up to 14psi. That's what I am running now, and its fun to mess with cars on the highway.

I'm looking into cutting a flywheel with a 60-2 trigger, so I can avoid having the sensor hanging out in mid air like that. Other than buying one of the $400 main seal triggers, I figure that is the safest way.

got the tune better but still not great. put it into winter mode last weekend and drove it to crested butte (4+ hr drive) for opening day. I'm still shocked at how well the cold start system works considering I haven't touched the cold start enrichments and im not running any type of ISV right now. well below freezing and above 8000ft she fires right up and idles smooth

today id like to finish up what I can on my license plate wind fairing for the roof rack and I'm going to go ahead and make a low-buck wheel storage rack for the garage. pics coming soon

2K4Kcsq wrote: got the tune better but still not great. put it into winter mode last weekend and drove it to crested butte (4+ hr drive) for opening day. I'm still shocked at how well the cold start system works considering I haven't touched the cold start enrichments and im not running any type of ISV right now. well below freezing and above 8000ft she fires right up and idles smooth today id like to finish up what I can on my license plate wind fairing for the roof rack and I'm going to go ahead and make a low-buck wheel storage rack for the garage. pics coming soon

Which part of Colorado are you in again? I almost went to CB last weekend for some opening day shenanigans as well. Been sticking with Loveland and Copper these days though.

sobe_death wrote: Which part of Colorado are you in again? I almost went to CB last weekend for some opening day shenanigans as well. Been sticking with Loveland and Copper these days though.

I am way out west in grand junction, about 30 miles from the state line. Closer to the mountains that most people from Denver have never been too like telluride, silverton, crested butte, monarch, powderhorn. That being said I will drive anywhere to ride. . . we should meet up sometime. . . vail or copper has got to be a good midway meeting spot. . . maybe even squeeze in some quattro donuts in the parking lot

Haha, I need some quattro first! It's hard to find AWD cars for sale for decent prices out here after the first snow has fallen. That, and trying to buy property in Denver before it's out of reach for the common man seems to be an exercise in futility.

We are planning on a long St. Patty's day weekend at CB, and my Loveland pass gets me days at Monarch too. Might as well use them! We should for real get together if you get as far out as Copper.

sounds good. im pretty much up for anywhere as long as the snow is good. too expensive to pay for bad conditions anymore. as far as the quattro donuts, we can use mine till we find yours. . . patience is key when looking for the right car around here. . still plenty of good old quattros, just one cold day and a hard start away from being "upgraded" then sold to guys like us

not really quattro content but I finished the double wide wheel/tire rack today.

So... Have you turned up the boost yet?

And are you coming east to play in the snow? :P

still at 7lbs I had a mishap with an oil cooler hose, luckily I shut it down before the engine got hurt but I will say this, I'm never using that PTFE hose for my AN fittings ever again. I knew they weren't right when I struggled to make the connections. should have trusted my gut and not used that crap. fixed now though.

car is running well, I just have this subtle miss above 4000rpm that I haven't figured out yet so I'm still hesitant on doubling the boost.

as far as coming out east I would say right after the new year. . . maybe the 2nd of January?? not sure what works for you

oh I did get a chance to put this car on a scale the other day. 2880lbs without driver and a full tank of gas. my friend's B3 audi 80 was about 120lbs heavier. both cars are 10v quattro

I actually lowered my boost, from 17psi to 10psi. I will be setting up my electronic boost control soon.

I also had an oil cooler line fail. Funny how that works. Mine was my fault, the hose was rubbing against the body, and I didnt know it. New cooler and lines fixed that porblem though. I also had the head gasket I installed go out. Now I have a MLS gasket, and a bunch of other new parts. Things are better now. Well, all except for the tune. That basically had to be started all over.

Got any tips on setting up the MS for the 60-2 rigger wheel? I picked 1 up, and plan to install shortly after the new year.

Nice pic with the 4k and the 80.

I would just suggest doing plenty of research on the cam input for your particular ms. I thought I had my board set up correctly 3 different times before getting it right because there are so many different ways of doing it.

otherwise I know you do machining so im sure you have some ideas on concentric mounting and all that stuff. my dad and brother were laughing at me while I centered that wheel up un clamps before drilling and tapping but I felt it was time well spent

I'm thinking I'll send my MS back to the person who built it for me to have it modified for this setup. Electronics aren't exactly my thing. He told me it would be quick and easy, but I would rather him do it, than me screw it up.

The trigger wheel I picked up came from a recently blown track car. I plan to check the concentricity of the trigger myself, but the fact that is came from a 500hp+ tarmack car, makes me pretty confident its OK.

Are you running a VR or hall sensor on your?

mine is a hall from DIYautotune. sounds like your install will be much more trouble free than mine was given all the prep work will be done.

The hall from DIY is what I will be running as well. I'm not a huge fan of the Audi VR sensors, as they are somewhat problematic. I'll just be happy to have a more reliable timing method.

Just wondering, but what size hose are you running on your breather system/catch can. The factory size is somewhere in the 19mm/.75" range. I have a 1/2" hose on mine for now with no catch can, and am starting to have oil build up on the turbo inlet. I'm thinking of upping the hose size back to 3/4" and getting a catch can to keep things cleaner.

my hose starts as 3/4 from the valve cover then down to 5/8 or so on everything else. catch can must be working as it seems to fill relatively fast.

Interesting. The larger the hose, the less oil is actually supposed to make it to the catch can. Any clue why you are pushing so much oil out of the breather?

mini update: finally solved my hesitation issue with some small adjustments to my dwell time. she revs clean all the way up to 6k now wooWOO! might not have time this weekend but I plan on installing my forge manual boost controller soon. . . . then we will finally start to see the potential that I have envisioned since I fist laid eyes on this car and heard my friend wes talk about the turbo motor sitting on the floor of his dads shop for so many years.

Where did your timing map end up? I remember you saying the one I sent you was pretty harsh for your setup. We have actually increased the timing on some points for mine.

finally getting around to updating this thread. I mounted up the manual boost controller and am currently running about 12 lbs. what a difference that made! this car is running very hard now. took a trip to Denver and had a great night tuning with a good friend of mine named Jason. getting faster by the day, soon I plan on switching over to E85 since I cant really give it any more boost without adding octane. all that said its a blast to drive now. I would probly be out flogging right now if I hadn't broke the already worn out clutch master push rod assembly today new parts are on the way and I cant wait to post a small vid. there is plenty more to come on this build I assure you all. just been busy enjoying the new boost!

It's awesome to see how far this build has come. Your patience is impressive lol, I'm not sure I'd have been able to stick with it...but then again, if I had as fun a project, I guess I coulda hung in there too. Congrats, glad to see the hard work paying off!

Good to see you are still at it. What made you go with a manual boost controller?