Yetti this means YOU!
034Motorsport GTI-RS
034Motorsport is in the business of building fast exciting cars for our customers. When it comes time to build our promotional and competetive cars, we want to show the world just what we’re capable of. The beginning of the GTI-RS project was no different. After sweeping the EuroTuner Grand Prix 2009, we decided to retire the A4 and build a new concept. Our Time Attack A4 project featured an Audi Chassis with a VW motor, we decided to flip this concept on its head.
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In 2006 we campaigned a heavily prepared Mk4 Jetta in SCCA World Challenge Touring Car Class. Though we managed to make this car incredibly fast, we always felt that the car was too nose heavy - causing it to push and not want to turn in. What if we could build a VW that was well balanced w/o a big motor hanging out over its front axle? This led us to consider a mid-engine configuration, mounting a motor and trans in the rear seat area, and ultimately to the Audi V6 due to its very short length. In early 2010 we sourced a 2001 GTI with a salvage title and the project was underway.
The first thing we did was gut the car, all interior came out, the motor, drive train, suspension, axles, everything. The chassis was inspected, straightened and reinforced in preperation for the extensive modifications. The rear floorpan was cut out from the rear hatch to the area in front of the rear seats. Chassis reinforcements were welded in to take the place of the missing structrue. Wheel wells were cut out as well to make room for massive 11" wide Porsche 996 Turbo hollow spoke wheels.
Next we made room for the Audi V6 motor, bolted to a 6-speed front wheel drive 01E from a European Audi 100 diesel. The trans was sourced and built by our friends at Advanced Automotion. Inside the trans all gears and moving parts were treated by WPC. A Guard clutch type limited slip differential completed the mods to the trans. The custom gear set we use is incredibly tight to allow fast lap times on track. To attach the engine and trans, we looked to SPEC Clutch for a solution. We’ve been offering SPEC’s multiplate clutches for a while which hold over 1000 ft/lbs TQ with ease, but once we heard they were working on a full carbon-carbon clutch we knew we had to have it. SPEC supplied us with their new carbon billet clutch kit which not only holds over 1200 ft/lbs of TQ but also offers smooth, streetable drivability due to the carbon construction.
With the trans bolted to the motor, we set out to install this in the car, the only thing we were missing was a rear suspension. Since we have a company 996 Turbo, we started poking around at that and it quickly became apparent that it would make the perfect rear suspension for our GTI-RS project. A complete rear suspension with 996 turbo axles was sourced from Los Angeles Porsche Dismantlers, we knew it was serendipitous when the stock porsche axles bolted right up to the Audi trans, we didn’t even need to change the axle length. We built a cradle to attach the engine/trans/suspension to, with 4-bolts the entire assembly attaches to the car making any engine related work much simpler than a B5 S4 for example. The Driveshaft Shop performed an upgrade to the stock 996 Turbo axles including a stronger and more flexible chromoly shaft.
Shifting was going to be tricky and required a clever solution. Pulling from the Porsche parts bin yet once again, we used Porsche Boxster shift cables and shift box. Custom 034 CNC machined brackets adapt the Porsche cables to the 01E transmission.
With the engine sitting in its home, suspension locating big Porsche wheels, it was time to do something about the fenders. The way it sat the Porsche 18x11" rear wheels with 325 series tires on them sat over 2" past each stock fender, that wasn’t gonna work! We set out to widening the stock fenders - front and rear were widened over 2" on each side. Our partner Rolf from Rolf By Design artfully, not unline Micheal DeAngelo, went to town on the steel fenders. Widening involved carefully cutting the stock fender lip off and moving it to its new position in space. Then the fender was cut and sectioned, spaces artfully filled in and welded back up to created the final shape and profile. Though we didn’t need as much room up front for tire, we did want to widen the front track to match the rear. Cars that handle best have a front track as wide or wider than the rear. In the front we run a 255 series tire. Front and rear VW R32 bumpers have been modifed to fit up to the wider front fenders, and Votex side skirts tie everything together. Its all covered with deep metal-flake silver paint.
With room for tires it was time to suspend the car. Since we had a 996 Turbo rear suspension it was as simple as bolting in an off-the-shelf solution. We chose an Ohlins Motorsport kit with 3-way adjustability and external canisters. Bruce and his team at PSi were incredibly helpful, advising us on spring rates and modifying the front struts for us. Since we had a full Porsche kit on hand, we did some measurements and quickly realized we could modify the front Porsche struts to fit the Mk4 front wheel bearing housings - wala. Front spring rates are 550 lbs and rears are 850. Final weight split on the car is 45% front and 55% rear. Other mods to the suspension include H2 Sport drop spindles in the front, Ground Control adjustable camber strut mounts, Eurosport front strut tie bar, stock 996 turbo rear sway bar and upgraded front sway bar. Since the car is now RWD, the front axles have been removed, a massive 1" bolt replaces the CV Stub axle to hold the wheel bearing and hub together.
To stop the car we are using stock 996 Turbo rear brakes, in the front is a custom 034 13" brake kit using 034 2-piece rotors and 993 Turbo Big Red calipers. Cobalt Friction brake pads are used all around, stainless brake lines and the OEM ABS has been programmed to work using the new Porsche wheel sizes and custom 034 rear wheel speed sensors. We also employ proportioning valves for the rear brakes as we’ve found we have more than enough rear brake on the car, we needed to shift some braking bias back to the front.
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An extremely important area of the car we need to discuss is the motor - the heart of the beast. We knew we were working with a twin-turbo 2.7t S4 motor, but the measly 250HP of the stock engine was not even in the same galaxy we were looking. Even with a Stage 3+ configuration it would not even be 500 crank HP, still WAY off our goals. We quickly decided to build some long tube headers, secondaries and use a single turbo setup with twin scroll technology. One turbo is actually more efficient than two, is more compact and greatly reduces installation complexity. The other benefit is fast and easy turbo changes for different car setups. For the track we want to run a smaller 6-700HP turbo (Precision GT35R), for drag racing or outright HP exhibition a much larger 1400HP (Garrett GT45R) turbo is on hand. 4-bolts, a few oil and water lines and we’re good to go.
Dealing with heat on a high HP car like this is critical, for the intercooler system we engineered an air-to-water setup that will deal with the rigors of the dyno, road course and drag racing. A massive Bell Intercooler core is mounted between the turbo outlet and the S8 throttle body, through it flows water pumped by a 55 gallon-per-hour electric water pump. Up front a 4-gallon water tank ensures lots of thermal capacity, can be filled with ice to bring intake temperatures well below ambient.
[LEFT] To hold all this power we chose Pauter rods wtih ARP Custom Age 625+ rod bolts and JE Pistons with 9.0:1 compression. 034Motorsport coated rod and main bearings keep everything spinning. The bottom end assembly was balanced within 1 gram. For the top end breathing, Supertech supplied 1mm oversized intake and exhaust valves. To prevent valve float Supertech supplied high rate valve springs and Titanium retainers. Our partner CAT cams supplied a set of custom billet cams made to our specifications. Our Stage 3 porting job finsihed off the mods to the head. The heads are big port Audi 2.8 heads for maximum flow, to match the ports an RS4 intake manifold is used, everything port matched to ensure smooth flow.[/LEFT]
None of these parts or labor are worth anything if it all can’t be controlled harmoniously. GTI-RS is a maserpiece in control, a symphony of systems that all work together seamlessly. It all starts with a 034EFI Stage IIc ECUfor engine controls such as ignition, fueling, boost control, launch control, rev limiters, map switching and hundreds of other engine related controls and tuning parameters. This system is fully standalone and allows us to easily tune the engine in GTI-RS quickly and easily whenever needed. We also employ a “Push to Pass” feature which allows a steering wheel button to control a higher level boost map. For example, we run 10psi as that’s all the traction the rear tires allow in corners, but on straights we can run over 20psi which is only the push of a button away.
Since we had moved the engine so far back running a throtle cable would have been cumbersome. Also considering we would need the stock ECU to run the ABS system, we decided to fully remap the stock ECU to control our new S8 throttle body. We’re not talkng about tricking the ECU, or paying a major chip tuner to do it, we did it oursleves in-house. The throttle body is controlled by the stock ECU which has been custom mapped to make the throttle body act exactly how we’d like it to - all whilie keeping the ABS system working as well. In fact, plug into the GTI-RS OBD2 port and you won’t find one fault code, you won’t find any systems not readied, this car would pass a California OBD2 DMV check.
All stock GTI creature comforts are still there except for air conditioning which got shelved. There are so many other mods and specifications to GTI-RS we could write for days. See the spec list below, and browse through the gallery as we documented this process quite well. Enjoy and look for GTI-RS at national events, on You Tube in videos and in magazines world wide!
DETAILED SPEC SHEET - GTI-RS 
Technical Specifications (modifications list):
Engine:
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[Fully Built 3.0L](http://www.034motorsport.com/engine-components-27tt-bottom-end-build-package-27tt-p-19906.html) Audi 6-cyl turbo engine, (2.7tt architecture) featuring: -
[Pauter Rods](http://www.034motorsport.com/engine-components-27tt-pauter-rod-set-audi-v6-p-18630.html) with ARP 625+ Rod Bolts -
Custom [JE Pistons](http://www.034motorsport.com/engine-components-27tt-piston-set-je-27tt-p-566.html) with 83mm bore and 9.0:1 compression -
034Motorsport [Coated Main](http://www.034motorsport.com/engine-components-27tt-main-bearing-set-coated-27tt-p-808.html) and [Rod Bearings](http://www.034motorsport.com/engine-components-27tt-rod-bearing-set-coated-audi-v6-and-27t-p-1270.html) -
2.8L large port cylinder heads, 034Motorsport Stage 3 port work -
Supertech [1mm oversized intake and exhaust valves](http://www.034motorsport.com/engine-components-18t-valve-set-oversized-valve-audivw-motors-p-533.html) -
Supertech [high rate valve springs and Titanium retainers](http://www.034motorsport.com/engine-components-18t-valve-spring-set-valve-high-rate-and-lift-wti-ret-p-555.html), engineered for more valve lift without coil bind -
[CAT Camshafts 264/250](http://www.034motorsport.com/engine-components-27tt-camshaft-set-audi-v6-cat-billet-cams-264250-p-21255.html) high performance cam set, [OEM lifters](http://www.034motorsport.com/engine-components-18t-lifter-set-valve-hydraulic-p-18089.html) -
RS4 intake manifold -
Custom Air to Water intercooler with a Bell Intercoolers core, large front mount heat exchanger, 5-gallon water tank, electric high flow water pump -
034Motorsport [Track Density Engine](http://www.034motorsport.com/chassis-components-audi-a4s4-motor-mount-density-line-b5-b6-b7-c5-and-many-others-p-772.html) and [transmission mounts](http://www.034motorsport.com/chassis-components-audi-a4s4-motor-mount-density-line-b5-b6-b7-c5-and-many-others-p-772.html) -
[Main](http://www.034motorsport.com/engine-components-27tt-main-stud-kit-27tt-p-690.html) and [Head studs](http://www.034motorsport.com/engine-components-27tt-head-stud-kit-audi-27tt-p-660.html), Main Bearing Cap Girdle -
Upgraded cooling systems for all fluids. -
Custom 034 long tube headers with secondary pipes to allow divorced turbine housing use. -
Garrett GT35R Turbo with Precision billet high flow wheel for track use -
Garrett GT45R Turbo for drag racing and dyno use -
Twin Tial [V38 V-band Wastegates](http://www.034motorsport.com/turbochargers-acc-wastegatesparts-tial-mv-v38-wastegate-38mm-band-p-18960.html) and Tial [Q-Vent Blow off Valve](http://www.034motorsport.com/turbochargers-acc-blow-offrecirc-valves-tial-blow-off-valve-50mm-band-p-13874.html) Cooling System: -
4 gallon water tank -
55 gallon per hour electric water pump for intercooler system -
Bell Engineering air-to-water intercooler core rated for 1500HP -
All [aluminum replacement radiator](http://www.034motorsport.com/engine-components-18t-radiator-high-output-mk4-vw-all-aluminum-p-20180.html) with larger capacity for engine cooling -
Custom heat exchanger for intercooler system, 18"x2"x12" tall -
Custom 1.25" aluminum tubing to connect engine coolant to front radiator -
12"x12"x1.5" thick oil cooler Drivetrain: -
6-speed 01E 2wd transmission from Euro-spec Audi 100, custom matched gear ratios, assembly by Advanced Automotion -
Prototype SPEC triple carbon clutch kit with light weight aluminum flywheel -
All transmission friction surfaces treated by WPC for reduced friction and strength -
034Motorsport custom Clutch type Limited slip diff -
Porsche 911 Turbo Shifter box and cables Front Suspension: -
Ohlins 3 way adjustable dampers with remote reservoir, with custom valving for weight and wheelbase of GTI, from Performance Shock in Sonoma, CA -
H2Sport front sport spindles and spherical control arms -
[Ground Control Adjustable camber plates/strut tops](http://www.034motorsport.com/chassis-components-volkswagen-cambercaster-mounts-vw-mk4-chassis-p-556.html) -
Eurosport front strut tie bar -
5x100 to 5x130 wheel adapters for the front hubs Rear Suspension: -
Custom tubular rear subframe with provisions for engine and trans mounts as well as pickup points for all suspension links. Complete 996 turbo rear suspension. -
Ohlins 3 way adjustable dampers with remote reservoir, with custom valving for weight and wheelbase of GTI -
Stock 996 Turbo rear sway bar Wheels/Tire Size: -
Porsche 996 turbo Twist “Hollow Spoke” wheels 18x8 Front and 18x11 Rear, custom painted body color with black added. Brakes: -
Porsche 996 turbo Front brake Calipers and custom 034Motorsport Rotors Porsche 996 turbo Rear brake calipers and OEM rotors -
Cobalt Friction Pads -
Stainless Steel brake lines through out Chassis: -
NHRA Legal roll main roll hoop and rear chassis reinforcement -
Custom metal widebody, widened 2” front and rear fenders -
VW R32 Front and rear Bumpers Modified for wide body -
Custom metal flake silver paint Fuel System: -
ATL 10-Gallon Fuel cell Mounted in front engine bay -
1 Gallon Surge Tank and Intercooler reservoir mounts in Engine bay, twin Bosch [044 Fuel pumps](http://www.034motorsport.com/fuel-injection-solutions-fuel-pumps-fuel-pump-bosch-044-motorsport-pump-p-347.html) integrally mounted to surge tank, pumps capable of 1400+HP -
034Motorsport custom modified [Bosch 850cc injectors](http://www.034motorsport.com/fuel-injection-solutions-fuel-injectors-850cc-bosch-ev14-fuel-injector-p-19844.html) -
034Motorsport [Fuel Rails](http://www.034motorsport.com/engine-components-27tt-fuel-rail-pair-audi-27t-with-brackets-p-19793.html) with adjustable [Fuel Lab regulator](http://www.034motorsport.com/fuel-injection-solutions-fuel-pressure-regulators-fuel-lab-fuel-pressure-regulator-dual-inlet-p-415.html) -
-10AN fuel feed line splitting to each fuel rail into dual –6AN Interior: -
NHRA Drag Cage -
R32 Steering wheel and Seats Mobile Electronics: -
[034EFI Stage IIC](http://www.034motorsport.com/034efi-engine-management-034efi-systems-upgrades-stage-iic-ecu-p-38.html)Engine Management with full control over injection, ignition, boost control, idle, etc -
034Motorsport [direct acting boost control valve](http://www.034motorsport.com/034efi-engine-management-engine-management-accesories-boost-control-valve-direct-acting-pwm-controlled-p-19292.html) -
[034EFI Custom engine wiring harness](http://www.034motorsport.com/034efi-engine-management-plug-in-harnesses-stage-iic-plug-in-harness-p-364.html) with Mil-Spec materials -
[AIM Sports MXL Pro Dash](http://www.034motorsport.com/engine-monitoring-aim-sports-aim-dash-mxl-pro-2005-p-491.html) and data Acquisition, complete Mil-Spec custom Chassis Wiring harness -
Speedcom communications “dual channel” 2-way Radio system for use in competition