3.6 Litre's O' fun

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  • v8 coupe
    S2Forum Fanatic
    • Aug 2006
    • 93
    • Country: United States

    #1

    3.6 Litre's O' fun

    Alright Thought it was time to let you all in on my project. What I have is a Standard US spec 91 Coupe Quattro with the stock 7A engine and 01A. The motor has seen better days, It's at 275k miles and has lost a ton of power and is on the way out. The project came to be over a year and a half ago when a friend called My dad and said there has a V8q at the local junk yard. Well after 4 days in the july sun fighting the motor I had myself a 195k mile beaten up PT motor. Took it home where it sat till august when I decided to take a look see at it and popped the intake manifold off. The inside of that manifold scared me. It was filled with oil and gas(after sitting in the yard for a month and sitting in my garage for another) so I continued to remove the heads and found the pistons covered in about an 3mm's of black carbon. SO a newer much cleaner PT was sourced.

    So that brings me to the newest motor a 130k mile PT. Well that came out of a very clean 91 V8q that got t-boned. So I then began looking into transmission options and suspension, brakes, turbo's you now the fun stuff. I found a guy online that was in the process of bringing over a bunch of 01E 5 and 6 speed transmissions. I did my reasearch and decided that a DQT code transmission would be about the right gearing for me, 8 months later I had my DQT 01E and it sits in my storage unit awaiting it's new home. In the mean time of waiting for the transmission to arrive I picked up some Porsche 996 rear calipers from Billzcat1 when he had a big clearing house sale. So I made up some hats to work with wilwood 328 by 25.5mm rotors. For the rear I had planned on running 04 S4 calipers, but after looking into the costs of maching brackets and fittings I decided on S8 carriers with girling g43 calipers clamping down on a 2 pc. wilwood 300mm by 22mm rotor.

    After sorting the brakes I turned to the fact that all the brakes were setup for 5-112 hubs. I got those from a GB on them through another forum. So that brought me to the suspension, my car was in need of a rebuild as I had completely bone stock everything on the car. I got myself some coil-over sleeves and hardware, the springs are still to come once a spring rate is picked. I basically am just using the stock body and interior as I am redoing everything else. The rear will get just as much attention as the front does with a torsen going out back to feed power to the 255-40-17 rubber that is soon to reside on all four corners. Also with all the fun bits in the drivetrain I had to address some of the cars cosmetics that had aged or been damaged. The tail lights got replaced with Treser units, the head lights with Vortex daul round conversion units. The front bumper will be a fiberglass RS2 unit with S2 foglights and signals. completeing the look the upper turnsignals will be deleted and used as inlets to a set of custom airboxes to feed the V8 monster soon to breather under the hood.

    Now that I have out lined the basics of my project now comes the parts I need a little help filling in. I have been having a very hard time finding the shift linkage I need for my car. I have nothing for it considering the 6-speed came from a a6. If any one has pictures that would help out a ton. Also if there is one for sale that some one knows of please let me know. The next hurdle I face is the fact that my local government (city/town) has been all over me this year for vehicle violations. In our town it is illegal to have a vehicle on your PRIVATE property that is not licensed insured and capable of running under it's own power. Hopefully I'll have a shop in a week (leasing argeements in the works).
    Sean
    91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.
  • v8 coupe
    S2Forum Fanatic
    • Aug 2006
    • 93
    • Country: United States

    #2
    And for the picture lovers I bring you pictures.
    Attached Files
    Sean
    91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

    Comment

    • ~Delta
      S2Forum Maniac
      • Apr 2005
      • 797

      #3
      Are you using a TDI 6 speed quattro tranny? I'd ay it's a bit high-geared for the 3.6 PT motor. I'd have opted for an S2 / S4 6 speeder.
      Never show a fool a half built house.
      Never underestimate the power of stupid people in large groups.

      Life is like a **** sandwich
      The more bread you have, the less **** you eat

      Comment

      • v8 coupe
        S2Forum Fanatic
        • Aug 2006
        • 93
        • Country: United States

        #4
        Originally posted by ~Delta
        Are you using a TDI 6 speed quattro tranny? I'd ay it's a bit high-geared for the 3.6 PT motor. I'd have opted for an S2 / S4 6 speeder.
        Yes sir, I am using a DQT TDi a6 transmission. I don't feel it is to low of gear considering 1st through 3rd are the sam as the S2 4th-6th are the cruising gears. The DQT code is the lowest TDi transmission with 4.11 that I could find.

        Gear ratio's are
        1st=3.5:1
        2nd=1.89:1
        3rd=1.32:1
        4th.87:1
        5th=.67:1
        6th=.56:1

        Final=4.11:1

        My PT after all won't be stock it won't be run on motronics. I'll be getting a set of reground cams to increse from the crappy ~230/243 (intake/exhaust) to 264/264. I'll also be using waste spark and wb02 for tuning. Some other goodies this motor may get depending on how I play my cards are true equal length headers to go with the full daul 2.5" stainless steel exhaust system. The exhaust will have plenty of flow for any of the V8's with a low angle x-over pipe, to high flow (over 400cfm ea) after market cats, and a set of Borla XR-1 mufflers it will have that V8 rumble and still have the flow and look of a preformance car.
        Sean
        91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

        Comment

        • v8 coupe
          S2Forum Fanatic
          • Aug 2006
          • 93
          • Country: United States

          #5
          Ok can any one on here help me? I spent the better part of 10 hours on here, motorgeek, and audiworld. What I am looking for information on is adapting B4 front control arms to the rear of my T89 CQ. I have been thrown through loops of yes and no, with no straight forward it won't work unless you do xyz. If I had a tube bender and enough machinery I would build up some tube control arm's but I don't have the means to at the moment. Maybe a few years down the road.

          So am I pipe dreaming again or is this actually do able? I could possible make up a custom set of balljoints if need be.

          Also what are the options for RARB on a CQ?

          TIA
          Sean
          91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

          Comment

          • PeterS
            S2Forum Addict
            • Jul 2003
            • 423
            • Country: United States

            #6
            I think that Alex Van Gerbig put the cast arms on the rear of his 90QTQ..

            Have not heard it done on a CQ or S2....
            Peter S

            1990 ErsatzS2 - track toy
            1991 Coupe Quattro
            1991 Coupe Quattro
            1995 S6 Sedan
            1995 S6 Wagon

            Comment

            • v8 coupe
              S2Forum Fanatic
              • Aug 2006
              • 93
              • Country: United States

              #7
              Yes I remembered reading that about a year ago when I bought these arms, but couldn't find it. I have emailed him directly, but it may take him a while to contact me back. As far as I know the rears on the sedan and the CQ should be interchangeable correct?
              Sean
              91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

              Comment

              • v8 coupe
                S2Forum Fanatic
                • Aug 2006
                • 93
                • Country: United States

                #8
                Alright I think I should up date this with the fun parts I am ordering this week.

                I have been calling around to very driveshaft shop in my area and a few across the country and found that to make the axles I want for my 6-speed would cost me almost as much as the 6-speed did. I then went looking for RS2 axles as I am going to need something soon so I can get a good portion of the car down on the week I have off from school for spring break.

                So I am ordering all 4 RS2 axles for a good price and the guy also has a RS2 front swaybar. I hadn't planned on getting on for the car, but after reading the rave reviews on how it's a great improvement over the stock unit I had to order it. So now I'll basically have an RS2 coupe drivetrian and body wise and a V8 engine powering the thing.

                I also got a box of brake parts in the mail that I ordered a while ago. In the box are 2 Euro S8 caliper carriers for the 300mm rear discs I have selected (actually 11.75" by .81"). The other thing is a set of very nice looking SS brake lines from a place called earl's preformance I think. They are very nice quality with steel ends so I can run them during the salty winter months.

                The last thing on the ordering block this month was a set of exhaust flanges for the V8. I have decided to build my own race style headers for the car. With a run length of 30" and a 1 5/8" runner diameter the headers should flow enough for the motor to easily make 15HP more over the very restrictive stock headers. These are going to be mild steel as I am not going to be turboing the car with these and 321 stainless steel is very expensive. I am still considering ceramic coating the headers, but do to the expense and out lay I am also more likely to skip it for now. I will do one of my favorite things which is to use "old Skool" header wrap to wrap the runners and give it a hot rod style look. Fitting a 30" runner in that tight of a space is going to be tough as is keeping the runners within 2" of each other. The 2.5" v-band collector will make exhaust connection easy. I am hoping to queeze 300-320HP out of the V8 with all the modifications I am doing so if I do get to that power level it will be a very powerfull car.
                Sean
                91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

                Comment

                • S2central.net
                  Retired OG Mod
                  • Jul 2003
                  • 16590
                  • Country: Northern Ireland

                  #9
                  Sean,

                  Checkout the other thread on rear brakes... The S8 carriers will not accomodate the 300mm discs on the rear of the Coupe. I measured up last night and posted an update.

                  I was thinking of a carrier adapter for the rear to give it the reach required but its kind of pointless as the S6/RR Girling caliper and pad combo does not have the span on the inside to use the entire disc space available.

                  So I'm gonna skim my nice 300x22 8E0 discs down to 280mm and finish this damn job. Only other thing needed is 5mm spacers with a 10mm hole to get the carrier offset correct. The S2 handbrake cable is a perfect fit on that caliper and so are the S2 brake lines.

                  Sounds like a mighty project you have running there though - good luck with it.
                  Paul Nugent
                  Webmaster http://S2central.net
                  Administrator http://S2forum.com

                  1994 S2 Coupe ABY - aka Project Lazarus
                  2001 A6 allroad 2.5TDi - family tank
                  2003 S4 Avant 4.2 V8 - daily burble

                  Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                  There are only 10 kinds of people that understand binary - those that do, and those that don't

                  Comment

                  • dub007
                    S2Forum Buff
                    • Dec 2006
                    • 29
                    • Country: United States

                    #10
                    Where did you manage to find just the manifold flange? Normally that’s something you have to waterjet, or cut the old manifold to pieces. I’m betting it would almost be more cost effective to make your own adapters for a drive shaft that is the appropriate size. The custom shops tend to charge a lot because they know that without them you’re not going anywhere.

                    Comment

                    • v8 coupe
                      S2Forum Fanatic
                      • Aug 2006
                      • 93
                      • Country: United States

                      #11
                      At S2 central I Understand that for your rotor there is wasted space, but I\'m running 2 pc rears. Yes that\'s right my rear\'s are going to be lighter then the stock 269mm by 20mm 200 20vt rear vented rotor. Lighter by almost 2 lbs per rotor and will cost 35 a rotor new. Also my disc is actually only 298.45mm as it\'s a 11.75\" rotor not a factory unit. and the hat hieght is spot on with my hats I got for pennies.

                      At dub007 got the flanges from 034Motorsports IN cali. Call Javad he\'ll hook you up. That company is quickly becoming one of my favorite places to shop. I have decided not to get custom axles as it would cost me almost 400 just to have them balanced to 7k.

                      The RS2 axles I am going to be getting are a perfect match fro my cars drivetrain. 6-speed in front with 108mm flanges (once installed since DQT has 130mm) and 108mm in the rear thanks to the torsen conversion. I am bascially going to have a RS2 CQ with a V8 as I said earlier. the car will never be under 300HP once I get there, which should be the first time. I am working on porting and polishing the large lump of cast aluminum the factory said is an intake. If I get the flow numbers I can hope I should get 8-10HP out of that easy enough. I am also considering getting theABZ (A8Q) manifold which is a 2 stage manifold.
                      Sean
                      91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

                      Comment

                      • S2central.net
                        Retired OG Mod
                        • Jul 2003
                        • 16590
                        • Country: Northern Ireland

                        #12
                        Understood on your custom 11.75" rotor, but the S8 carrier will still not work with it - unless you build some form of extension bracket to bolt it onto stock location of rear carrier.

                        Photos here - http://homepage.mac.com/nugentp/PhotoAlbum15.html
                        Paul Nugent
                        Webmaster http://S2central.net
                        Administrator http://S2forum.com

                        1994 S2 Coupe ABY - aka Project Lazarus
                        2001 A6 allroad 2.5TDi - family tank
                        2003 S4 Avant 4.2 V8 - daily burble

                        Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                        There are only 10 kinds of people that understand binary - those that do, and those that don't

                        Comment

                        • v8 coupe
                          S2Forum Fanatic
                          • Aug 2006
                          • 93
                          • Country: United States

                          #13
                          I am now happy to report the car has begun it;s tear down stage. Only got 2 hours in as it\\\'s ~35 degrees in my shop with out a heater right now so I am getting a heater before next weekend. I am not really good with posting pictures on this site so I\\\'ll just link to my project thread on another forum. http://www.tdif.com/phpBB2/viewtopic.php?t=68#10443
                          Sean
                          91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

                          Comment

                          • v8 coupe
                            S2Forum Fanatic
                            • Aug 2006
                            • 93
                            • Country: United States

                            #14
                            Well Update on this baby.

                            I\'ve been working every weekend since the last post at least 3 hours. I know have the front suspension removed except the subframe and swaybar, the rear suspension is about the same only the 2 control arms are still attached. Hood is off, air box out, headlights, center of front bumper, rear carpet and interior, driver\'s side outer tierod had to be sawzalled off because it has become one with the nut and no air tools to help in removal. Rear driver\'s side same thing. Suspension appears to be factory stuff and the top mounts are completely dead. The car has been in Minnesota it\'s entire life and driven in ~13 years of winter. In Minnesota we use tons of salt on the road with no studded tires. The amount of oxidation on the suspension is amazing and some of the components put up a really good fight. Including a wheel that took so much pounding on to remove that I destroyed the wheel bearing. Oh well I have 4 news ones sitting next to me with S2 hubs ready for install.

                            Car is getting rear end removed next weekend. Drive shaft will come out along with exhaust via Sawzall because it has more holes then the fuel lines which is patched 3-4 times. I\'ll also be unbolting the rear control arms for a caustic cleaning and then seam welding them. The rear subframe will get a run along with the rest of the rear end parts through a car wash (manual kind) then caustic bath. The rear diff will go on the bench for torsenication and the rear subframe will get bead blasted to prep it for seam welding. All the strut tubes will be torn down and looked over the rears are quite corroded and are certainly stock. They took the most effort to remove and faught very hard. In the end a can of JB80 2 cans of engine degreaser and a 4lb dead blow hammer won the battle.

                            All this effort is to prep the car for it\'s long and ever going list of mods which now includes an RS2 rear tail lamp center section and hopefully an RS2 fiberglas rear bumper. I am currently working on sourcing another engine as I no longer have the PT that was headed for this car. The motor had a very large chunk missing so the motor has been moved to my house and will get a complete gut for spares for another PT that will get a second chance on life now. Hoping to get into an ABZ then go crazy with the modifications as I figure I am spending money and have set the schedule back months why not. Goal is 350HP+, so 4.2L is the next on the big list of stuff.
                            Sean
                            91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

                            Comment

                            • v8 coupe
                              S2Forum Fanatic
                              • Aug 2006
                              • 93
                              • Country: United States

                              #15
                              I think I should update this thread since I haven't been on here in over 6 months.

                              Well the car is apart now, but I have another project I'm working on before I return to this One.

                              I will be this winter working on the body modifications I want which include flares styled very similar to the ABT C5 coupe and Sport Quattro. The other body modifications will be under workings of the body redone with new undercoating and a rear bumper built.

                              I'm going to have to consider engines since a 3.6L just isn't going to be fast enough considering I will soon have a roughly 400HP 6-speed daily driver (V8 quattro). SO I am considering a few options one of which is a super charged 3.6L with ported heads and lowered compression to ~9.5" on a rebuilt bottom end. I'm hoping I can get some work done on the suspension over the winter and spring and have a rolling flared chassis, by summer. I do have to finish the 6-speed 4.2L daily driver first though.
                              Sean
                              91 CQ Elanor 1.9L compound Turbo build. Fully built internals, full race oval port head, custom race cam. GT2256v and hy35 in compounds.

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