I’m always building/welding cool stuff for other people’s cars, so it’s about time I built something cool for myself.
The car I’ve had for a while, it’s a 1994 Audi S4, UrS4 (“original” S4). With the 2.2l 20valve turbo 5cylinder engine (AAN engine code). I haven’t really started modding the car until about a year or so ago. Last year the car made 357awhp on a GT3076, 630cc injectors, VEMS standalone, and other supporting mods.
I switched to a GT4294R with a Tial hotside housing for the upcoming year. So, of course, the car will be built with all the supporting mods for that (fuel system, motor/head build, intercooling, blah blah blah). Whatever. Alot of fabrication is needed, so I figure I’d post some of the progress I’ve made so far.
First, had the head flange for the exhaust manifold designed:
(034 Motorsport sells this flange for $145.00, this ended up costing me about $60.)
Then had is waterjet cut:
The finished product:
Since the motor sits at a slant toward the passenger side of the car, I welded these 1.00inch long (1.50in sch10 316L stainless pipe) “extensions” to the flange to make the rest of fab a little easier:
Had the collector designed in solidworks, and cut on a 5axis CNC laser. (The fitment of the pieces are 2nd to NONE, very precise) This shows the finished part all welded up, bolted to the turbo:
Then I started on the manifold.
Needed an engine hoist to position the turbo into place (thanks Zero5672 for the hoist!):
Two runners done and in place (one is fully welded, the other is just tacked up):
Three all done:
I should have this all finished sometime on Tuesday, I’ll post up some hi-res, non-iphone pics once it’s all finished.
