Project B7 420-R. Base Car ‘12 Seat Exeo ST Sport Tech.

[Nollywood]

Since I start doing B5 V8 swaps back in 2008, I have had a lot of enquiries, mostly regarding converting the C5 RS6 to manual.

As many may know, the C5 RS6 block is unique to it’s application to automatic transmission. It runs a much larger torque converter than regular V8 engines, similar to that fitted to the W12 engines.

This means a larger diameter flexi plate, and a larger rear mounting surface to bolt to the larger RS6-specific automatic transmission bellhousing. The RS6 block will bolt to a regular 01E 6-speed manual, but some machining, drilling and tapping is required, to ensure all bolt holes are used. Without this, only 4 bolt holes line up.

I encountered this issue with my last swap, a BFM 4.2 V8 40V from a 2005 D3 A8 into a 2000 B5 A4 2.8 Quattro, married to an 01E. A days worth of measuring, marking, machining, drilling and tapping got all 10 bolt holes used.

So, I will split the 077-series 40V blocks into 2 groups:

SMALL BLOCK.

D2 A8 3.7 / 4.2 V8, 1999 - 2002.
D2 S8, 1999 - 2002.
C5 A6 4.2 V8, 1998 - 2003.
C5 S6, 1999 - 2003.

BIG BLOCK.

D3 A8 3.7 / 4.2 V8, 2003 - 2005.
C5 RS6, 2002 - 2004.

Identification of the blocks are simple:

The starter motor aperture on the “small blocks” forms a continuous hoop.
The starter motor aperture on the “big blocks” forms a split hoop (like a “C”).


SMALL BLOCK.

BIG BLOCK.

 

[Nollywood]

Not much different between the B7 and B8 platform, in terms of dimensions. B8 wheelbase is quite a bit longer, though.

Hmmm...

 

[Nollywood]

There’s one car that never failed to impress me with its handling, due to its rear wheel steering, was a pretty obscure, and underrated car from the 1980’s...

The Honda Prelude.

And I’m not referring to passive rear wheel steer, whereby the rear axle bushings are set up with compliance to allow some degree of movement. I’m talking about Active Rear Wheel Steer. The Honda Prelude was pretty advanced for its time. No other sport Coupé or Sedan had such a set up, not even cars from the premium sector.

The result of RWS on the Honda Prelude was two fold: Tire wear was greatly reduced, gas mileage improved due to less friction and tire scrub, and handling on the limit was sharper and more neutral than that of similar vehicles in its class.

I had long forgotten about this, until now, as I’m now an IRTEC-certified large goods vehicle technician, working on big rigs.

A lot of these trucks with more than 8 wheels have steering mid or rear axles. The mids I’m not interested in, as they utilise a mechanical connection between the front axle and the middle one (just behind the front one). This is just an extra drag link, cumbersome and crude, and steers the mid axle wheels in the same direction as the fronts, and with the same degree of steer.

The rear steering axles is my interest here. The struts are not mechanically linked to the fronts, they are linked by a fluid medium. So, hydraulics. There is a master hydraulic ram attached to the front steering axle, and a similar slave one at the rear. Linked by hydraulics, so steering the front axle forces fluid to the rear ram, extending or retracting the piston.

Think of a master and slave clutch cylinder arrangement, and you’ll get an idea how this works. Different front to rear cylinder ratios will produce different results and feel.

The rear wheels steer in the opposing directing to the fronts, just like the old Honda Prelude did. And with just about 20% of the front turn angle too.

I am looking at incorporating a similar setup in the rear of the 8E rear end. With the old type 85 / B2 Quattro models, it was much easier, due to the very simple rear arrangement. Effectively, a mirror of the front subframe, struts and trackrod setup.

Working on big rigs has its advantages.

 

[Nollywood]

G’day ladies and gents!


I have been looking at different rear differential solutions, for my B7 build.


In the late 1980’s - early 1990’s, I was pretty much into the B2, B3 and B4 drag scene, going on to win trophies with my RS2-engine spec’d B2 Coupé Quattro. Final output of 420hp and 437 ft-lbs from a 2.5L built version of the Audi 2.2 20V I5 turbo. The “Big 5”!


Quarter mile times with the same power output, but different rear differential fitted:


017 locker, differential open - 12.38 secs.

017 locker, differential locked - 12.33 secs.

017 TORSEN - 12.26 secs.


The upper 2 differential were the stock B2 / B3 Quattro versions, with 4.11 FD.

The lower differential was the stock TORSEN D11 Quattro version, with 4.11 FD.


Launching with the stock rear differential, and the differential lock disengaged produced a lot of front and rear wheelspin, more at the front though. For those too young to remember, locking the rear meant the centre was locked too, though the centre could be locked independently, the rear could not, unless the vacuum lines to the actuators were reconfigured.


With the rear differential locked independently, after I reconfigured the vacuum-operated actuator lines, my times were better. Though I must say, I did not launch the car as hard as with the differential lock disengaged. I was conscious of the fact that the lock was mechanical, a simple pawl arrangement. I was not sure how it would react to a full launch with 437 ft-lbs of torque. It could have been quicker, but I never tried it.


When I installed the TORSEN / LSD rear differential foam a 1992 Audi V8, things were different. Besides being quicker on the drag strip, handling on the limit in corners was different too. Much more composed than with the stock 017 run in “open” mode.


I have a spare V8 torsen rear differential, for my build. I am now wondering if I should acquire an 017 lockable differential from a B2 Quattro. And try beating on it with the rear differential lock engaged? Just try it closer to home, in case it breaks. And have a stock 8E (01R) and tools in the trunk to swap back in if the mechanical locking pawl in the 017 snaps.


So, have any of you guys tried a different rear differential, even if it’s an aftermarket LSD? How was the experience?


Thanks all.

 

[tom t]

Sounds epic! Will be keeping an eye on you're build m8! Good luck

 

[Nollywood]

Thanks Tom!

 

[Nollywood]

Another item turned up today:

 

[Nollywood]

Just ordered these BiXenons. Comes with ballasts and bulbs. Left hand headlamp was back ordered from Audi, with the expected delivery date being the 6th of December.

I’m not willing to wait that long, so I found an alternative source:

 

[Nollywood]

I’ve just dropped a deposit on a 2012 Seat Exeo ST Sport Tech, thanks to EA. I’m away on vacation, so I won’t be seeing it in the metal until I get back home.

It’s a black on black, and being a 2012, it’s a facelift model, which gives different wheels, honeycomb grille, LED DRL’s and Xenon headlamps.

 

[Leeoncupra]

I actually really like that , looks better with the xenons

bagged fr , k1 rep , 19s

 

[Nollywood]

Thanks, LC.

 

[Nollywood]

I haven’t owned a 2WD VAG model in the last 20 years. Besides, deploying 700hp / 720Nm through the front wheels would be akin to driving on ice.

Phase 1 will be the installation of Quattro AWD, using the rear subframe, gas tank, differential, rear axles, driveshaft from my B6 Avant, and my built 01E.

This is an 01E I have never let go. It has been in 2 of my cars till date. 6th ratio is geared to do 37.2 mph in per 1000 rpm in 6th. It was originally in a 2003 C5 A6 2.5 V6 TDI Quattro.

 

[Nollywood]

My original plan was to replace the entire Seat Exeo ST wiring harness, with one from a B6/7 A4 Avant, as the Seat is a 2.0 TDI. This will make the integration of my custom C5 RS6 engine harness much easier.

But...

After spending an hour poring over the 2012 Seat Exeo ST dash (main) harness, this will really complicate things. If it was a pre-facelift car, built 2009 - 2011, it would be easy to yank the entire harness out. But not the facelift from 2012 - 2013. Especially as it’s a Sport, with the Tech Pack. It’s just too highly-specified.

This car has:

Bi-Xenon headlamps.
LED DRL’s.
LED tails.
240V AC socket in the centre console.
AUX input in the centre console.
iPod input in the centre console.
Power folding mirrors.
Rear PDC.

And more I’m still trying to get my head around.

I’m fully aware that most modern vehicles have separate harnesses, connected to the central system (in the case of the B7, the dash harness) making them easy to replace. But the dash harness of the 8E chassis cars is unique to the original customer’s order. This means the RNS-E, and most of the audio options are incorporated in the central system.

Slapping in a B7 A4 harness will require a lot of reworking, a B7 S4 / RS4 with Bi-Xenon headlamps and a similar spec level to the Seat would be ideal, but they don’t come up for sale often, and I don’t really want a heavily-reworked dash harness.

Interestingly, the B7 Seat Exeo ST is a mixture of B6 and B7. The early cars up to mid 2010 have RB6 instrument clusters, while later cars, including mine are RB8. The CCM is also the same as fitted to all B7 S4 models. Dual-stage airbags too.

So overall, it would be easier to incorporate the gasoline-specific wiring into the Seat Exeo ST’s harness. This includes the fuel pump relay socket. It’s in the diesel-engined cars too, but a couple of the slots are vacant. Same goes with adding the secondary fuel level sender, which will reside in the quattro’s fuel tank.

I love wiring!

 

[Nollywood]

It’s not often a brand new Audi instrument cluster turns up on eBay. RS models even less frequently, or when they do, the seller wants as much as buying direct from a dealership.

But, a seller came up trumps. I have purchased a brand new B5 facelift climate control panel, as well as a brand new RNS-E for a friend, from the same seller. I wsn’t expecting a German seller to have this cluster in km/h and mph either. Looks like the seller has a few for sale too.

I bagged 1.

 

[Nollywood]

I haven’t done a great deal since, other than keep an eye open for more parts. Still after a pair of Recaro Wingbacks.

I haven’t even gone to pick up the car, as we’re in the middle of a move (country change). So thinking of getting the car trucked to new place, or embark on a long, long road trip.

I also have to move my stash of parts in a big truck, as well as all my shop tools, so super busy with it all. It’s too cold to start the basic part of the build right now anyway, installing quattro drive to my B7, so I’m looking at spring before embarking on this project. Meanwhile, the acquisition of parts continues, some from mainland Europe.

 

[Jimbobcook]

I haven’t done a great deal since, other than keep an eye open for more parts. Still after a pair of Recaro Wingbacks.

I haven’t even gone to pick up the car, as we’re in the middle of a move (country change). So thinking of getting the car trucked to new place, or embark on a long, long road trip.

I also have to move my stash of parts in a big truck, as well as all my shop tools, so super busy with it all. It’s too cold to start the basic part of the build right now anyway, installing quattro drive to my B7, so I’m looking at spring before embarking on this project. Meanwhile, the acquisition of parts continues, some from mainland Europe.

Sounds like you've got some serious lifting to do lol hope the move goes well and it's always nice finding parts waiting for a big build. I wouldn't want to be making this beast in winter haha

Keep us in the loop with how you get on.

 

[Nollywood]

Will do, Jimbo.

 

[MATT RILEY]

Sounds like you won't be needing the towbar Noll's, want to sell it?

 

[Bedlam]

I haven’t done a great deal since, other than keep an eye open for more parts. Still after a pair of Recaro Wingbacks.

I haven’t even gone to pick up the car, as we’re in the middle of a move (country change). So thinking of getting the car trucked to new place, or embark on a long, long road trip.

I also have to move my stash of parts in a big truck, as well as all my shop tools, so super busy with it all. It’s too cold to start the basic part of the build right now anyway, installing quattro drive to my B7, so I’m looking at spring before embarking on this project. Meanwhile, the acquisition of parts continues, some from mainland Europe.

This sounds expensive ......a move from where to where ?

 

[Nollywood]

This sounds expensive ......a move from where to where ?

From the UK to elsewhere in Europe.