# 1st Generation Audi S4 exhaust manifold & more **URL:** \ **Category:** Builds\ **Created:** [November 9, 2009, 6:45am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899 "2009-11-09T06:45:21Z")\ **Posts on this page:** 20\ **Page:** 1
**Author:** ![LowlyOilBurner](https://avatars.discourse-cdn.com/v4/letter/l/a6a055/32.png) [@LowlyOilBurner](https://forums.speedlife.net/u/LowlyOilBurner)\ **Post date:** [November 9, 2009, 6:45am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/1 "2009-11-09T06:45:21Z")
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.) ![http://img.photobucket.com/albums/v406/LowlyOilBurner/cadflange.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/cadflange.jpg) Then had is waterjet cut: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/IMG00536.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/IMG00536.jpg) ![http://img.photobucket.com/albums/v406/LowlyOilBurner/IMG00537.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/IMG00537.jpg) The finished product: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/photo2.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/photo2.jpg) 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: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/flange1in.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/flange1in.jpg) 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: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/collectordone.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/collectordone.jpg) Then I started on the manifold. Needed an engine hoist to position the turbo into place (thanks Zero5672 for the hoist!): ![http://img.photobucket.com/albums/v406/LowlyOilBurner/hoist1.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/hoist1.jpg) ![http://img.photobucket.com/albums/v406/LowlyOilBurner/hoist.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/hoist.jpg) Two runners done and in place (one is fully welded, the other is just tacked up): ![http://img.photobucket.com/albums/v406/LowlyOilBurner/2runners.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/2runners.jpg) Three all done: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/3runners.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/3runners.jpg) ![http://img.photobucket.com/albums/v406/LowlyOilBurner/3runners1.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/3runners1.jpg) I should have this all finished sometime on Tuesday, I’ll post up some hi-res, non-iphone pics once it’s all finished. ---
**Author:** ![newman](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/newman/32/7569_2.png) [@newman](https://forums.speedlife.net/u/newman)\ **Post date:** [November 9, 2009, 6:48am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/2 "2009-11-09T06:48:42Z")
looking good. ---
**Author:** ![boardjnky4](https://avatars.discourse-cdn.com/v4/letter/b/96bed5/32.png) [@boardjnky4](https://forums.speedlife.net/u/boardjnky4)\ **Post date:** [November 9, 2009, 6:49am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/3 "2009-11-09T06:49:22Z")
that’s one large turbo any bracing planned? ---
**Author:** ![bigtymer7463](https://avatars.discourse-cdn.com/v4/letter/b/7ab992/32.png) [@bigtymer7463](https://forums.speedlife.net/u/bigtymer7463)\ **Post date:** [November 9, 2009, 6:56am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/4 "2009-11-09T06:56:45Z")
awesome, bet they didn`t have manifolds like that in the trenches of nam… ---
**Author:** ![TRP951](https://avatars.discourse-cdn.com/v4/letter/t/b77776/32.png) [@TRP951](https://forums.speedlife.net/u/TRP951)\ **Post date:** [November 9, 2009, 7:11am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/5 "2009-11-09T07:11:53Z")
Awesome work as usual this thing is going to be siqqqq ---
**Author:** ![LowlyOilBurner](https://avatars.discourse-cdn.com/v4/letter/l/a6a055/32.png) [@LowlyOilBurner](https://forums.speedlife.net/u/LowlyOilBurner)\ **Post date:** [November 9, 2009, 7:55am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/6 "2009-11-09T07:55:48Z")
> [@boardjnky4](#): > > any bracing planned? YES. ---
**Author:** ![MPD47](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/mpd47/32/7383_2.png) [@MPD47](https://forums.speedlife.net/u/MPD47)\ **Post date:** [November 9, 2009, 8:05am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/7 "2009-11-09T08:05:22Z")
Awesome Matt! :tup: You going to be around Friday? I think I’m going to come hang out for a bit. ---
**Author:** ![LowlyOilBurner](https://avatars.discourse-cdn.com/v4/letter/l/a6a055/32.png) [@LowlyOilBurner](https://forums.speedlife.net/u/LowlyOilBurner)\ **Post date:** [November 9, 2009, 8:16am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/8 "2009-11-09T08:16:59Z")
> [@MPD47](#): > > Awesome Matt! :tup: > > You going to be around Friday? I think I’m going to come hang out for a bit. Should be. > [@bigtymer7463](#): > > awesome, bet they didn`t have manifolds like that in the trenches of nam… Let me tell you about NAM, boy…you know what what we use to do in them trenches… ---
**Author:** ![layzie](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/layzie/32/7599_2.png) [@layzie](https://forums.speedlife.net/u/layzie)\ **Post date:** [November 9, 2009, 8:21am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/9 "2009-11-09T08:21:34Z")
we did unthinkable things in the trenches of nam der boy! ---
**Author:** ![zero5672](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/zero5672/32/5255_2.png) [@zero5672](https://forums.speedlife.net/u/zero5672)\ **Post date:** [November 9, 2009, 11:44am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/10 "2009-11-09T11:44:40Z")
Ballin’ Just like everything that you work on ---
**Author:** ![EvilJay](https://avatars.discourse-cdn.com/v4/letter/e/a5b964/32.png) [@EvilJay](https://forums.speedlife.net/u/EvilJay)\ **Post date:** [November 9, 2009, 1:08pm UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/11 "2009-11-09T13:08:38Z")
Those welds look like shit. You suck. ---
**Author:** ![POOPRA](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/poopra/32/7188_2.png) [@POOPRA](https://forums.speedlife.net/u/POOPRA)\ **Post date:** [November 9, 2009, 1:32pm UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/12 "2009-11-09T13:32:15Z")
looks pretty, should be able to get that beast moving ---
**Author:** ![BREETIME](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/breetime/32/5214_2.png) [@BREETIME](https://forums.speedlife.net/u/BREETIME)\ **Post date:** [November 10, 2009, 10:15am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/13 "2009-11-10T10:15:10Z")
nice mat…ill be calling you soon you dirty n ---
**Author:** ![juicedz4](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/juicedz4/32/5051_2.png) [@juicedz4](https://forums.speedlife.net/u/juicedz4)\ **Post date:** [November 10, 2009, 10:20am UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/14 "2009-11-10T10:20:43Z")
In for updates. Looks great. Dan ---
**Author:** ![LowlyOilBurner](https://avatars.discourse-cdn.com/v4/letter/l/a6a055/32.png) [@LowlyOilBurner](https://forums.speedlife.net/u/LowlyOilBurner)\ **Post date:** [November 10, 2009, 4:21pm UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/15 "2009-11-10T16:21:15Z")
Thanks everyone! 4th runner all done: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/turboon1.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/turboon1.jpg) And all finished: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/done1.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/done1.jpg) ![http://img.photobucket.com/albums/v406/LowlyOilBurner/done.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/done.jpg) On the head: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/onhead.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/onhead.jpg) A few with the turbo bolted up: ![http://img.photobucket.com/albums/v406/LowlyOilBurner/turboon2.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/turboon2.jpg) ![http://img.photobucket.com/albums/v406/LowlyOilBurner/turboon.jpg](http://img.photobucket.com/albums/v406/LowlyOilBurner/turboon.jpg) Next up is the downpipe and wastegate mounting/dump-tube. ---
**Author:** ![02NismoSpecV](https://avatars.discourse-cdn.com/v4/letter/0/74df32/32.png) [@02NismoSpecV](https://forums.speedlife.net/u/02NismoSpecV)\ **Post date:** [November 10, 2009, 5:45pm UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/16 "2009-11-10T17:45:32Z")
how many custom parts you even mean? looks awesome man. cant wait to see what it makes on the dyno when its all done ---
**Author:** ![turbominime4door](https://avatars.discourse-cdn.com/v4/letter/t/bbe5ce/32.png) [@turbominime4door](https://forums.speedlife.net/u/turbominime4door)\ **Post date:** [November 10, 2009, 5:50pm UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/17 "2009-11-10T17:50:52Z")
lookin good as always.should be a beast.i hope my mani cory designs comes out tghis well:snky: ---
**Author:** ![brilliantyellowg60](https://avatars.discourse-cdn.com/v4/letter/b/6f9a4e/32.png) [@brilliantyellowg60](https://forums.speedlife.net/u/brilliantyellowg60)\ **Post date:** [November 10, 2009, 6:14pm UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/18 "2009-11-10T18:14:29Z")
I like 🙂 I’ll be doing the same for my 16v soon you have a waterjet? ---
**Author:** ![LowlyOilBurner](https://avatars.discourse-cdn.com/v4/letter/l/a6a055/32.png) [@LowlyOilBurner](https://forums.speedlife.net/u/LowlyOilBurner)\ **Post date:** [November 10, 2009, 7:39pm UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/19 "2009-11-10T19:39:56Z")
> [@turbominime4door](#): > > lookin good as always.should be a beast.i hope my mani cory designs comes out tghis well:snky: I’m sure it will. Cory didn’t design this manifold, he designed the head flange. I built the manifold from scratch with no real “design”, just had an idea of what I wanted and what I had to work with. ---
**Author:** ![Shockwave179](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/shockwave179/32/7496_2.png) [@Shockwave179](https://forums.speedlife.net/u/Shockwave179)\ **Post date:** [November 10, 2009, 8:33pm UTC](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899/20 "2009-11-10T20:33:31Z")
That is awesome, you fabricate some really cool stuff! [Next page](https://forums.speedlife.net/t/1st-generation-audi-s4-exhaust-manifold-more/75899.md?page=2)