8EO brake upgrade confusion. Please help.

[Isztatkof]

Hello,
i`ve been following your forum for quite some time now - most helpful car related forum i`ve browsed through!!!
I bought audi 80 competition in boxes, and after 6 months of assembling it back it underwent 1.8t swap. Stock brakes wont be up to the task (and i am dreaming for them s2 avus wheels) for that matter i bought brembo from e38 and thanks to this forum i manage to find cad drawings and make brackets for them paired with a6 4f 314mm discs for the front. I will be using machined a6 c4 rear hub to go along my v6 82mm bearing carrier and there is no drama for the front end whatsoever.... however for the rear i got really mixed up

AND right to the point of the topic...for the rear i bought b6 s4 300x22mm calipers,carriers and discs but haven`t decided on what 5x112 hub to use.
I went to the far end of the forum, read all that i could find and as far as i understand there are two options:
1. s2 avant/sedan rear hubs
2. A4 b5 quattro rear hubs
First option is out of the question because these kind of parts are hard to come buy and if they do they are very expensive. And it means i`ll have to mix and match CV joints as well...
Second option gives +8mm offset difference per side (total of 16mm wider rear track). <--- can this difference be machined from the hubs to get to stock s2 hub parameters?
A4 B5 hubs accommodate disc with 48mm hat height
80 B4 hubs accommodate disc with 40.1mm hat height
and S4 b7 disc is 36,2 hat height
I am hitting a wall with the calculations, so i`d be really happy if someone shed some light on how to mount these brakes at the back.
as far as i know s4 b7 brakes mount straight up (plug and play) to s2 stock hub (besides hoses and e-brake cable)
What will happen if i try to mount it to an a4 b5 quattro rear hub? Am i needing a 8mm spacers for the carrier to compensate for the different hub and job done?

Bit of a long post...sorry for that!
Cheers, George

[ThatGUY]

I won't be much help with your brake issue...

But Welcome, and I would love to see pictures of your project.

Andrew

[Isztatkof]

Its not anything special...it took me 3 months to put it on its 4 wheels again as the suspension was completely disassembled and a lot of parts were missing.
Fuel tank, transmission, fuel lines, brake lines were not present, a lot of bolts and clips as well. Took me a lot of time to gather all parts from thhe breakers.
Here is how it looks now
The original ACE engine came in boxes with bare block and i thought its not worth putting it back together so it was either 2.2 AAN or 1.8t...for 1/3rd of the money for 20v turbo i got complete a4 b5 which i parted out

I then sourced adr engine mount from the UK, drilled and tapped it to accept stock 1.8t heat shield, made downpipe from 60mm stainless into my original competition exhaust (55mm)
Swapped the aircon compressor, dehydrator ans pipes from the a4, crimped my b4 pipe bend at the radiator for that OEM look, the engine harness was made to fit by one friend without removing the ace one but by using some of it and not removing the dash...i tried my best to pretty it up a bit.
Bought 450/180/65 core size intercooler from germany (not a chinese crap) and yestarday got the upper bracket fabbed from the duraluminium bar inside the a4 front doors...it ended up pretty fansy

I bought s2 3b filter box and made a "cold air intake" from various audi bits upper part is s2 3b...lower part is my stock ACE box, the part with the plastic flap for hot/cold air is from 5 cyl 2.3 filter box...i blocked the flap to be constantly closed and not let hot air in the filter box. I got the 90 degree rubber hose and the plastic bit behind the headlight from a 90 2.3e as well and all assembled pretty straight forward.
I put bilstein b6 struts at the back with stock competirion springs and it became pretty high which was strange....
Yellow adjustable koni at the front....
Bought s4 b5 RARB and 2.6 v6 front one
....lots of other stuff
The 1.8t AEB is completely rebuild and found almost new stock k03 which i bought for peanuts..

Been digging with this car for 6 months now and its almost ready....just turbo pipes to FMIC, few bits and bobs, wrap the downpipe and it should be moving on its own...it starts, revs and idles so engine and wiring is Okay.

Will upload few pics later but i havent documented the build at all

[ThatGUY]

Sounds rad to me; Thanks for the story.

[M2ki]

I then sourced adr engine mount from the UK,

Engine will be under wrong angle. And why did buy the ADR engine mount, if you had whole B5 donor car?
Or did you mean cabrio ADR engine mount?

Bought 2.6 v6 front one

AAH,ABC,ABY,6A,ACE,NG all have the same 26mm ARB.

[Isztatkof]

Yea i bought engine mount from ADR cabrio 80 final edition or something from a breakers on ebay for 40 quid which turns out to be quite the bargain (guess he didnt know what he is selling).
My FARB was smaller than 26mm...maybe it was not original ACE one.
I can source rear 82mm rear uprights from audi 80 2.8 quattro Avant and a friend of told me that i could then use a6 c5 quattro 2.5tdi rear hub to keep stock s2 hub parameters, but i haven't seen it in person and i dont know..
Any help will be welcome.
Here are some pics of my car.

PS: i had to move the vacuum from the back of the intake manifold because it was very close to the brake pump and i didnt like it.
After scavenging a scrap yard i got home with full bag of OEM heat blankets, wraps, etc from various cars and dealt with the oil feed line problem on this engines...pretty happy with the final look. I have prepared a piece of the underbody heat shields from the a4 for filterbox additional "cold air intake" insulation it ended looking quite nice for what it is (it mounts to the existing 2 bolt holes on the s2 filter box)
I`ve put a lot of thought and work in this car ...hope its nice to drive after all is set and done.
My idea is 180-200hp quattro to start with and finish with 280-300ish (safe limit for stock rods i hope)
... i am with the compi gearing 4.56, so it might end up a fun car to drive.

[M2ki]

Yea i bought engine mount from ADR cabrio 80 final edition or something from a breakers on ebay for 40 quid which turns out to be quite the bargain (guess he didnt know what he is selling).

ADR cabrio engine mount is meant for V6 chassis. To use on it on the inline engine chassis you have to make a custom rubber mount or make somekind of extension for bolts.

[Isztatkof]

I dont know about that....i slapped the adr cabrio mount on the AEB block and it lined up with my existing ACE rubber mount without any mods whatsoever, the left mount is my ACE original mount. Maybe i was lucky or my engine is sitting tilted to one side without me knowing but it doesnt seem to be the case as it looks pretty leveled.

[Isztatkof]

[M2ki]

It will line up, but it is tilted and will start breaking the rubber mounts.

[Isztatkof]

I did use a file in the corner of the adr cabrio mount to releave the pressure on the rubber mount stud as it was very tight fit (actually touching it) now all is sitting okay. You mghr be right that it is a bit tilted ...the left gearbox rubber mount on the subframe is more compressed compared to the right one ...maybe because the right(adr) mount is pushing the engine up giving it a tilt to the left.
What solution you advice?

[M2ki]

Some have used Ford Escort 1.8D mount, but i don't know how strong it is and how is the vibration with it.

[ThatGUY]

George, thanks for sharing; it is a cool project.
Sorry I may have encouraged the derailment of this thread.

Hope you can get your original question answered!