OK so lets preface this post with saying that I am a mechanical engineering student and i have a fairly good background in fabrication. I do not; however, have a whole lot of experience with cars. I have a friend who will help me out on this project who has a pretty good knowledge of cars. That being said, "the boss" wants to know exactly what I am intending on doing in order for me to procure propper funding for this project. I want to break the project up into logical steps because that is just how i am. I do want to be able have the car pass emissions. Although, I'm ok with running a test pipe the rest of the time.



I want to start with an S5 TII.



1. Intake/exhaust - any suggestions would be helpful, maybe just buy the mufflers and weld it up myself?

2. fuel pump and bigger injectors to accept a future turbo upgrade - with the injectors will i be able to use them with the stock ecu?

3. Front mount intercooler

4. Engine rebuild/clutch/flywheel - i saw atkins rotary had a video and a couple of manuals on rebuilding a rotary and they had a full rebuild kit. Do you think this would be eneough for me to be successful in this?

5. Turbo upgrade - a T04E mounted on a HKS cast manifold and a HKS wastegate. o, and a standalone to control all of it (ill use whatever brand that i can find someone to tune on).

6. Coilovers.



I want to do everythign right the first time so i dont have to do it again.



What am I missing?

If you had to give a rough estimate of how much each step would end up costing?

The money tree is not infinite so if you have any suggestions on where I can save money without skimping on quality that would be awesome.



Thanks for all the help

 

sounds expensiveIMO. . .

1.i believe u could get away with $100-$200 if u went to a junkyard to get parts and fabbed the intake and exhaust up yourself.

2. $250-500 depending on fuel pump and if u replaced all 4 injectors or jus secondaries.

3. honestly this u can get away with much cheaper then usual too. if u get yourself a cheapy from ebay or such, and are able to bend your own piping u might be able to do this for $200 litle more little less dependiong on the intercooler. u also could use the stock top mount intercooler and mount it up frount, then this step would only cost u piping.

4.now rebuilding the motor could be a little tough, if it runs fine u might want to let it go. clutch and flywheel u can prolly get the pair second hand for around $300, if going new itll be way more. and the price of the rebuild kit and videos (not sure how much those r)

5.now in my opinion i would copmpletey skip this step if based upon a budget and doesnt intend to be driven performance whise. the absolute lowest can imagine this step getting done for would be about $500 (highly unlikely for only $500) but i would expect much more like $2000. the s5 turbo is better then the s4 and not a horrible turbo, i have seen big numbers and fast cars still using those turbos b4. i would say keep the stock turbo and get an safc, if you did that, u could get away from the worst step by far, for only about $200.

6. if u wanna do this one cheap cut the springs , jk dont do that. if u can find a used set maybe $100-$200 depending on where and tear, new id say around $3-400, but if your good and think u can get away with it, make your own and cut costs way down.

now something u didnt add that i would, would be a boost gauge and boost controller. an upgrade intercooler, bigger injectors, to4, all that would be basically uneeded if running the stock boost, so ull need a cheap boost controller to turn boost up, u could get one of the cheap underhood ones for $50, and i say boost gauge because the stock one isnt so hott/accurate.

so id say your lookin at $1500 absolute minimal, and dont mess anything up. alright it took me like 10min to think about and write this, hope i didnt forget anything, feel free to message me anymore questions, goodluck

 

Before I built my car I don't think I even changed a set of sparkplugs - if you've a background in mechanical engineering you'll be fine so long as you have your facts straight.

 

what are your intentions with the car... drag.. road course.. etc..

 

+1



Building up these cars is not cheap by any means if you want the best quality products. Rebuilds if done yourself can be relatively cheap, but if the rebuild is done by a professional, it will be done right the first time.

 

Atkins video sux and so do there seals IMO. Atkins video cuts so many corners and use the FF button when they shouldn’t. Save your money on that. The RA video is good however and use OEM seals. Also the new one I think the name of the video is RE or something it is a 3 disk set very good.



Research your project more before coming up with a plan because some of the stuff you have will not work.



Stock ECU on a large turbo will not cut it. Just mufflers will not do you any good. Emissions will be hard to make with anything over a T04E.

 

I didn't realize once the car hit the pavement everything had to be absolutely perfect.



I'd roll it around and try stuff out. Try the stock ECU with tubby injectors, try generic mufflers, try emissions. Then fine tune what you want. Projects aren't suppost to be perfect the first mile they make, that's why they're projects! If something isn't working out the way you wanted, put more R&D and cash into it. You'll get what you want.

 

+1 for colin

 

Yeah, Colin knows well. His project has been how long in the making now, and it still is'nt right?

 

Well college for completing my technician certification has been keeping me busy.



I suppose all my projects were complete, I just never posted results. The stock 6 port with megasquirt was fun. I upgraded that to TII intakes to fit a 6 port block. It was interesting. So was the TII block N/A, full exhaust with megasquirt and an FB dizzy. My same car is on it's 4th engine setup. That doesn't mean the other ones failed, it means I had my fun and I'm on to something new!



It might have sucked if I spent the entire time designing one big scheme. But really, it's alot of fun to slowly turn the car into a monster piece by piece. You begin to not even notice it's really happening.



But go about your business whichever way you like, but if you got the time, I'm just saying it's tons of fun trying different stuff out!