Sport Quattro replica

[loxxrider]

Wow, that is awesome, especially with the weight numbers. Now be careful not to offset that with a huge turbo

[PRA4WX]

I'm envious! Nice score!

[PRY4SNO]

Just when you thought the build couldn't get any moar bettererererer

[themagellan]

Wow that weight saving is absurd, amazing. I always like to imagine a very fat child being removed from the front of the engine bay.

[ralleyquattro]

Its here!!!



WH 056 658 it is.






Will have to get some piston jets installed in.



Even though this is 79.5mm block, it already has the new style filler for the hydraulic heads (incl 20v).. no worries there then..


Depending on what I choose for oiling it might not need the turbo return machined.


Zero ridge on the liner, beauty of lazy work as a normally aspirated 1.9L


Looks like 83.. but can not make out the month.

[roortube]

10.

[PRY4SNO]

:jawdrop:

Great find.

[Dave]

are you going to add oil squirters too?

[ralleyquattro]

are you going to add oil squirters too?

Have to if I ever hope to turbo this puppy.

[ralleyquattro]

Another package, another piece of the puzzle..

The last Sport Quattro piston from Audi Tradition. It will make a perfect template for some custom jobies:





Provides nice 8:1 compression.

Also got some original sport rad hoses which they still had for a song!

More to come.

[ralleyquattro]

Rear Sport quattro brake recipe
Ingredients:
1 Sport quattro rear strut housing
1 Sport quattro rear caliper
1 Sport quattro rear parking caliper
1 Sport quattro brake rotor
1 Special parking caliper bolt
1 5 bolt hub
1 75mm wheel bearing kit (with C clips).

#1 press in bearing and hub



#2, install the rotor



#3 install parking brake caliper with special pin bolt (available at Audi Tradition).



#4 Add the 4 piston AP caliper





#5 season with wheel of choice. Repeat for the other side and serve with smile.

[ringbearer]

Served with smile is right!

Fuching cool

[ralleyquattro]

Got a responce from Mahle... the SQ piston is right in between two forgings they have, so the only option they are giving me is a billet piston. At roughly twice the cost.
Anyone have experience with billet pistons?
Also, scored a crank this week, so work on the alloy engine will start this winter.
Just need a block with oil squirters to use as a sample for the machine shop to install some new ones into mine...
Mr Cook offered to lend me one of his AAN blocks for that.

[ralleyquattro]

There has been a bit of a confusion regarding sport pistons on my side, I assumed that KW used 144mm rod, where in fact it does not.

So... looks like I am getting some pistons made and I am given 2 options:
1. Pay $1400+ for a 1 off set of 5 pieces
2. Pay $800 for a set of 5 pieces if I can meet the MOQ
Considering JE’s go for roughly $1200 to $1500 depending on the options I am going to go the Mahle Motorsport route.

Here are the stipulations:
• MOQ of 40 pieces – 8 sets of 5 cylinder pistons.
• Mahle 142 Alloy forging will be used ( a blend between 2618 & 4032 alloy)
• Lead time 4-6 weeks (Could be longer , could be shorter as it depends on when they will be cutting another group from that forging).
• Mahle proprietary Grafal coating applied as standard (no need to farm out for coated skirts and crowns like the JE’s)
• Fixed CC for Dish volume
• Fixed cut out for intake valve diameter – I would probably go with +2mm oversized on the cut outs for those running Ferrea/Supertech larger diameter valves
• Fixed Compression Height – so for those who want to use the 2.5L block will be forced to use a 160mm connecting rod.
• Fixed wrist pin diameter

The only variable will be the bore diameter.

These will be the specs for my set:
• Bore = 79.5mm
• Stroke = 86.4mm
• Block = 7A/AAN/ADU/3B @ 220mm Deck height
• Connecting Rod length = 144mm
• Compression Height = 220 – [(86.4/2) + 144] = 32.8mm
• Piston Dish CC = 12cc
• Wrist pin = 20mm

An Elring AAN 20V Turbo head gasket has a max bore of 82.2mm and a thickness when fully compressed of 1.6mm = 8.49cc
A Stock 7A cylinder head with flat Ferrea/Supertech Standard Size valves has a volume of 44cc in the valve pocket area.

Vc = 4cc + 44cc + 8.49cc = 56.49

79.5mm bore x 86.4mm stroke = 2144.4cc : Vh = 2144.4 / 5 = 428.88 cc / cylinder
81.0mm bore x 86.4mm stroke = 2226.1cc : Vh = 445.20 cc / cylinder
81.5mm bore x 86.4mm stroke = 2253.7cc : Vh = 450.74 cc / cylinder
82.5mm bore x 86.4mm stroke = 2309.3cc : Vh = 461.86 cc / cylinder
83.0mm bore x 86.4mm stroke = 2337.4cc : Vh = 467.44 cc / cylinder


Based on my math a 79.5mm bore piston (for me) will yield the following:
E (compression ratio) = (Vh + Vc) / Vc
= 428.88 + 56.49 / 56.49
= 8.6:1 CR

For sample if I went to an 83mm bore the CR would be:
= 467.44 + 56.49 / 56.49
= 9.27:1 CR

So the range of CR will be from 8.6:1 to 9.3:1 depending on the bore size chosen.

Now these are the possible combinations for the order:

(1) 79.5mm bore x 86.4mm stroke – Martin Pajak
(4) 81mm bore x 86.4mm stroke – for the AAN users with a good bore
(2) 82.5mm bore x 86.4mm stroke – for anyone that wants to overbore the block
(1) 83mm bore x 86.4mm stroke – for 2337cc

The remaining 7 sets can be any number of combinations for the bore size. Without meeting the MOQ this will be a custom order.
If you are interested, let me know

[loxxrider]

Hmm... let me get back to you.

[ralleyquattro]

Hmm... let me get back to you.

Let me know, 4 sets are semi-confirmed, half way there!!

[PRY4SNO]

I might have a guy interested. I'll put out the offer/recommendation and let you know.

Would these work with a 92.8mm crank in an over bored 7A block?

[ralleyquattro]

I might have a guy interested. I'll put out the offer/recommendation and let you know.

Would these work with a 92.8mm crank in an over bored 7A block?

They are designed for 86.4mm stroke with 144mm rod.
If you go to 92.8mm crank you will need to alter your rod length to compensate for the extra stroke.

HTH

[PRY4SNO]

Yeah, that's what I figured from reading the info you provided.

Know what would work? 160mm rods?

[ralleyquattro]

Yeah, that's what I figured from reading the info you provided.

Know what would work? 160mm rods?

Shorter I believe, 137.6mm.

[loxxrider]

Hi Martin, it looks like these aren't going to work well in my aapplication. Sorry! Will be getting something specd by FRP specifically for my goals.

[AngryTaco]

May be interested in the group buy. I'll want 81.5mm pistons for the AAF block. My problem is with a 12cc dome, that will put me in the 11.8:1 compression area....little too high, but I do plan to do a bit of chamber work. Doubt I could do enough to shave it down though.

Not an issue if I need to use 160mm rods, gonna need to get a custom set anyways

Does anyone know what the compressed thickness of the MLS 20v headgasket is?

[ralleyquattro]

May be interested in the group buy. I'll want 81.5mm pistons for the AAF block. My problem is with a 12cc dome, that will put me in the 11.8:1 compression area....little too high, but I do plan to do a bit of chamber work. Doubt I could do enough to shave it down though.

Not an issue if I need to use 160mm rods, gonna need to get a custom set anyways

Does anyone know what the compressed thickness of the MLS 20v headgasket is?

No problem, just let me know if you decide.

As per above:
An Elring AAN 20V Turbo head gasket has a max bore of 82.2mm and a thickness when fully compressed of 1.6mm = 8.49cc

[AngryTaco]

Martin, I think I'm interested pending finances. I was planning on a CR of 10.0 - 10.5:1 since I plan to run e85.

These pistons will be a perfect fit and I will achieve that desired compression after I deshroud the valves in the head and round off all the hard faces.

Any pictures of these mahle pistons?

[ralleyquattro]

Any pictures of these mahle pistons?

No, they are custom and I can take pictures only after they are made, but for that to happen I need 7 others to pull the trigger, with you on board it would make it 5 including me..
Email me
martin at quattro.ca

Thanks