- Post is under moderation/ #S14-swapped / #BMW-2002 . In the wastelands of postapocalyptic Sweden, one man and his extraordinary 2002 fight for survival amidst the ruins of civilisation… Words: Elizabeth de Latour. Photos: Patrik Karlsson.
Supercharged S14 2002 rat rod
The future. Mankind has destroyed itself. The earth is barren. Pockets of survivors remain, scattered across the globe. They travel the desolate landscapes of a ruined world they once knew in search of food and shelter, driving machines created from the scavenged remains of cars from the past. In the charred remains of postapocalyptic Sweden the silence is broken only by the howl of the wind and the whine of a supercharger. A flash of orange through the trees. The bark of an exhaust drifting across the ravaged landscape. Then, the smoke parts, and something ungodly and terrifying thunders across the lonely tarmac, a man at the wheel with fi re in his eyes, and then it’s gone as quickly as it appeared and all is silent once more. That man is Thomas Nyman. This is his 2002. This is their story.
You will already know if this is your sort of car. You will have looked at the pictures and made a decision about whether or not you want to read this feature. You don’t need us to tell you that it’s not for everyone, but we will anyway, because it’s really not. For some of you, this might be the greatest crime ever committed against BMWs. Even those of you who normally love this sort of anarchic approach to modifying might be struggling a little. But if you get, really get it, you’re about to enjoy a car that’s really unlike anything else out there.
Browsing his automotive history, it’s clear that Thomas is a man who is obsessed with cars, to put it mildly… “I have owned and worked with several cars in my short life (he’s only 28) and right now I have nearly 100 vehicles on my conscience.” 100 cars. What can you even say to that? Unsurprisingly there have been some wild builds in amongst that lot and a huge variety of machinery, from the 1974 Beetle that served as his first car, to his first #BMW , a 1988 E34 530i, and the car he never finished and still regrets selling. “It was an E12 528i from 1978, light green with a #BBS front spoiler and chrome bumpers, ” Thomas reminisces. “I bought an S38B36 M5 engine that I rebuilt and was going to fi t in the car, and my vision was to build a 100% sleeper with perfect patina. But I was young and impulsive so the car was sold before it was done…” In that case it may have worked against him but, in the case of this 2002, his impulsive nature was definitely on his side.
“I knew about this car for a long time, a friend of the owner had told me about it, and one day in spring of 2010 the owner himself came walking past the garage I rented in the city at the time. I asked him if he wanted to sell the car, and he said yes, so we actually walked over to his garage together to take a look at it then and there. It was in terrible shape at the time; it had been standing outside with smashed windows so the weather had caused some very big rust holes in the body and many parts were missing, like the engine, gearbox, rear axle, the whole interior and the windows. The next day I picked the car up and put it in my garage instead,” grins Thomas. On paper this project sounds like a nightmare and the sort of car that no one in their right mind would have dreamed of touching, which does make us wonder about Thomas’ mental state…
The initial plan, he says, was to make the whole body rusty and give it even more of a rat-look than it’s ended up with, but he realised he couldn’t bring himself to do it. “My conscience became too strong,” he says, “and I felt I could not destroy an historic collector’s car that the 2002 Tii really is today, which is way I kept the original paint.”
So if you don’t like how this car looks now, just bear in mind that it could have looked a whole lot worse… “Our first goal was to get the car finished in one month for an event so we welded and fixed all the rust on the undercarriage in three weeks and fixed what we needed to so it was actually road legal. Then, after that, the whole thing escalated,” he says, and he’s not wrong.
With the decision made to continue down the rat route, Thomas got stuck into the mods and set about getting some stiffer springs, cutting them down by about 50% to get the car down on the ground, and combined them with a set of Bilstein Sport shocks. This was followed by the addition of the four wonderfully retro Marchal driving lights mounted on the front bumper and then came the roof rack, filled with what Thomas describes as “curiosities,” which include an S14 air box and valve cover and an old suitcase, naturally. The four-speed gearbox was swapped out for a five-speed Getrag ’box from an early 5 Series and he also changed the exhaust, both mods carried out specifically for a road trip to southern Sweden and Denmark. Then the time came for the serious business of building that engine…
“I think my vision was to do something no one had done before,” muses Thomas. “You’re probably wondering why I chose the S14 out of an E30 M3, and I’m wondering the same thing! I thought that this engine will fit well in the car and would probably get many types of reactions from people and BMW enthusiasts,” and he’s certainly right about that. “Initially I thought that I would just fit the engine and leave it at that, but then I started thinking about it and decided to add a supercharger on top to ensure that I was doing something new and different,” he grins. The supercharger is a rebuilt GMC 471 positive displacement Roots unit from the 1940s but impressive as it looks, there’s a lot more going on with this engine than meets the eye, and it’s the reason why the build took him one and a half years rather than six months (little more than a Swedish winter, he says) as he’d originally anticipated.
There’s a special head gasket and ARP head bolts for the cylinder head, four Siemens 688cc injectors fed by a Nuke fuel rail while the supercharger itself is cooled and lubricated by a water/ethanol system using a Bosch 988cc injector. The blower itself sits on a custom 4mm steel intake manifold and there’s a custom exhaust manifold connected up to a custom 3” stainless steel exhaust with three silencers, though Thomas says that they really don’t do much silencing. Peer into the 2002’s engine bay and you will notice a small problem: there’s no room for a radiator, which is kind of important if you want to have a fully functioning engine.
The solution? Stick all the cooling gubbins in the boot, which is exactly what Thomas has done, building a custom cooling system consisting of an electric water pump, cooling fan and a massive aluminium rad, which sits in a custom housing that seals tightly up against, and is fed cooling air by, the louvred boot lid. The boot is also where you’ll find the aluminium fuel cell with an Aeromotive A1000 fuel pump located inside, and assorted fuel supply components. As you can see, it’s a comprehensive engine build, but it almost put Thomas off the car altogether. “After one and a half years of building the engine, I was so tired of this car and the project,” he sighs. “If I had been younger at the time, the car probably would have ended up being sold, just like my E12 project. But then I fired it up and rolled out of the garage for the first time and I was totally in love again! I cannot describe the feelings I had on the first test-drive…” he says with a massive grin.
Along with the aforementioned five-speed gearbox swap, Thomas has strengthened the drivetrain to be able to deal with all the power and torque being put through it by the S14 and supercharger combo, fitting an uprated clutch and homemade cardan shaft. The rear axle is a custom affair, constructed from a concoction of various different BMW components. “The original axle didn’t last long so I decided to build a bullet-proof one,” explains Thomas. “I took the 3.07 diff and joints from an E34 535i and ordered custom shafts made from spring steel and the hubs are also made from special steel. I made the wishbones thicker by adding 2mm of steel to every area and on top of this I also deleted the bushes between the body and the axle.” The brakes, meanwhile, are from a 2002 Turbo, with larger, vented discs up front and bigger 250mm drums at the rear.
As far as styling is concerned, Thomas has definitely stayed true to his original rat rod vision and while he may not have taken things quite as far as he originally planned, aside from the welding and repairs required to get the 2002 road worthy in the first place, the exterior has received no special attention. This makes the fact that the original Inca orange paint, where rust or repairs haven’t obscured it at least, remains as bright and vibrant as ever all the more impressive. If you’ve made it this far without choking on whatever you might be currently eating or drinking then Thomas’ wheels might just push you over the edge…
“I decided to go for BBS RS splits,” he says, gleefully, “because these are very expensive wheels today for those of us who collect and drive ’70s cars. The ones I have are in very bad shape, with loads of scuffs and scrapes all over them, so they’re a perfect match for the car!” As for the interior, it’s also a perfect match for the exterior and, just like the rest of the car, looks like it’s just about survived the apocalypse; the 2002 Turbo seats that he’s fitted are torn, a bank of auxiliary gauges juts up against the centre console, while the massive gear lever was chosen as it resembles an old tool.
So, there you have it. We’re not really sure what to say. We could definitely do with a sit down and a cup of tea after that. One thing we’d like to think is that, despite how Thomas’ 2002 might make you feel, you can at least summon some modicum of admiration or respect for what he’s created because he really has put so much into this car, and proved a lot of people wrong along the way. “The engine is my favourite part of the whole build because no one believed in my project and told me that this engine would never run, but they were wrong!” he exclaims with a smile. “I’m also really pleased that I managed to fit my homemade rear axle without cutting the body. The ‘experts’ told me there was no chance in hell it would work because they had ‘tested’ it without success, but I proved that it could be done.”
If you think that, after pouring so much time and effort into this 2002 over so many years, he’s done with it, you’re really rather wrong as there’s a lot more to come. “I bought the car in 2010 and I’m still not finished; it’s 2017 now, right?” he laughs. “My next plan is to build an air-ride system for it and I also need to build a new exhaust system as well as a new intake with a front-mount intercooler to get the intake temperatures down, then new wiring inside the car, maybe a new ECU. I’m also thinking about a mounting a turbo under the rear bumper…” But Thomas doesn’t finish his sentence. The light is fading and, if there’s one thing we all know, it’s that you don’t want to be caught outside at night after an apocalypse because that’s when the “things” come out of hiding… Thomas fires up the 2002 and, just like that, he’s gone, tail lights fading into the twilight, supercharger howling, S14 roaring, headed for the security of his bunker, safe in the knowledge that he lives to mod another day.
DATA FILE DATA FILE #Supercharged-S14 / #BMW-2002-Rat-Rod / #BMW-2002 / #BMW-2002-S14 / #BMW / rebuilt 1940s #GMC 471 Roots supercharger / #BMW-2002-E10 / #BMW-E10
ENGINE AND TRANSMISSION 2.3-litre four-cylinder #S14B23 / #S14 / #BMW-S14 from 1988 E30 M3, rebuilt 1940s / #GMC / #GMC-471 / #Roots-supercharger, custom 4mm steel intake manifold, special head gasket, #ARP cylinder head bolts, #Aeromotive #A1000 fuel pump, aluminium fuel cell, #Nuke fuel rail, 4x #Siemens 688cc injectors, water/ethanol cooling system for supercharger with #Bosch 988cc injector for cooling and lubrication, #Nira-ECU, custom 3.6mm steel exhaust manifold, custom 3” stainless steel exhaust with three silencers, custom cooling system in boot with electric water pump, cooling fan and aluminium radiator. Five-speed #Getrag gearbox, uprated clutch, custom cardan shaft, custom rear axle with E3 2500 and E28 535i components, E34 535i 3.07 diff and joints, custom driveshafts
CHASSIS 15” (front and rear) / #BBS / #BBS-RS three-piece wheels with 195/50 (front and rear) tyres, stiffer springs cut by 50%, #Bilstein dampers, BMW Turbo brakes with vented discs (front) and 250mm drums (rear), thicker rear wishbones, bushes between body and axle removed
EXTERIOR Original Inca orange paint, Marchal driving lights, roof rack, green louvred boot lid, extra rear light
INTERIOR 2002 Turbo seats, auxiliary gauge pod, old toolstyle gear lever, custom short-shift
THANKS To everyone that did not believe in this project, it only made me more determined to complete it and get the car running again, and also thanks to everyone who helped me with the car over the years
“decided to add a supercharger to ensure that I was doing something new and different”Stream item published successfully. Item will now be visible on your stream.
- Post is under moderation/ #Audi RS4 B5 with a 5-cylinder engine / Words Davy Lewis / Photography Andreas S Jansson and Bjorn Eirik Odegård
This track-prepared RS4 is running a #5-cylinder-engine that makes 939hp – now there’s something a bit different…
RS4 B5 940hp 5-cylinder swap
Doing things differently is a risky business. Get it right and you’ll win the respect and admiration of your peers. Get it wrong however, and people will tear you apart on social media. This couldn’t be more relevant than in the car scene. From choice of wheels, to the tricky subject of rear wings – an upgrade that wins the internet with its ingenuity and originality is only a hairs breadth away from a total balls-up that incites derision and hate. People are funny, eh?
So where am I going with this? Well, one of the most fiercely loyal of all Audi enthusiasts are the RS4 B5 guys. Many view this as the only true RS4. The real deal. The big kahuna. The daddy. And you know what – I’m inclined to agree. There’s something about that wide arched, 2.7 biturbo-powered avant that is bang on the money. Never mind the fact that most of them will spend an inordinate amount of time in the garage, simultaneously emptying your wallet and making you cry into your Aldi value beans (cos that’s all you’ll be able to afford as a B5 owner). But, they’re a passionate, dedicated bunch and I applaud that.
So what on God’s earth are they going to make of an RS4 with a naughty secret under its bonnet? You see, this track-focussed RS4 has a cylinder missing. Or, to put it more clearly – it has one less cylinder than it should. But why would anyone remove a perfectly good V6 biturbo and replace it with an old five-pot?
Well, for starters the V6 wasn’t perfectly good. The owner had been through numerous turbos and frankly he was sick to the back teeth of removing the damn thing to fix it. The B5’s engine may be a masterpiece when working well, but get a recalcitrant unit that has frequent issues, and you too could grow to hate it. Add to this the fact that Aslan Eshanov is based in Norway and it becomes clear. These guys don’t think like us.
They go their own way, which is why so many insane cars appear from the frozen lands of northern Europe. Anyway, when you’ve got a nice five-cylinder sitting in the garage, it would be rude not to make use of it. But there’s more to this story than a simple track project build…
The RS4 was actually impounded by the police after they discovered it had a false chassis number. Aslan was prosecuted and fined 23,000 euros (the price of the car’s import tax to Norway). Gulp. So, he hired a lawyer and fought the case in court, proving it was the previous owner who had committed the fraud. However, after a total of 60,000 euros had been spent, Aslan was told that he still could not use the RS4 on the road unless he paid a further 23,000 euros. “I could not afford to do this, so I decided to build a full track car,” he says. So before anyone shouts, “what a waste of an RS4” – it was either build a full-on track weapon, or it would never be used at all.
The project began in July 2014 in Aslan’s basic, unheated garage with only ordinary tools. “I worked a lot in the summer, but not so much in the winter as it was -20 outside and still -10 in the garage.” He spent around 14 months on the car, having to work much of the details out for himself as well as fabricating many bespoke parts.
You can read the full engine spec on the last page of the feature, but it’s based around a 2.5 TDI block, with forged rods and pistons. There’s an AAN cylinder head and CatCams that allow this strong bottom end to withstand a 10,000rpm rev limit. Everything needed to be strong, because Aslan likes to give it a serious kicking. You may have seen videos of it being nailed sideways around the track at various Gatebil events.
Watching this RS4 performing brutal four-wheel power slides never gets old and with 939hp on tap, it’s some crowd pleaser. Listening to that beefy, Precision turbo snorting and chuffing away, accompanied by the roar from the 3.5in exhaust really is something special. It’s a raw, unrestrained sound that is all the better for being produced by an engine with an odd number of cylinders.
Thankfully, the outside has been left pretty much OEM. The only additions are a Leon Cupra front splitter, some tow straps and US-spec side marker lights. The fact it isn’t covered in some crazy livery or emblazoned with sponsor’s logos, only adds to the appeal of this RS4.
Inside it’s a different story. The dash remains, but pretty much everything else has been removed to make way for a comprehensive roll cage and the fuel system, mounted in the boot. There’s even a rear-mounted radiator, inspired no doubt by the Group B cars of the ’80s. Sensibly, Aslan has installed a firewall, to keep himself away from the fuel system.
The wheels are as wide as possible to allow for maximum traction – they measure a girthy 10.5x19in all round, wrapped in 275/30 semi-slick track rubber. However, a set of 18in Rotas are used for drifting with smaller 235/40 tyres.
There’s plenty more to come from this rather immense RS4. It’s an unconventional car, with a chequered past, but there’s no denying that it is 100% savage. Aslan reckons there’s another 200Nm of torque to be had, so it’s set to become even more of an animal on track. It’s a shame it can never be used on the road in Norway, but I guess that means that it’s never going to be a compromise. This RS4 is all about going insanely fast (often sideways) and for that, I give it a big nod of respect.
SPECIFICATION / #Audi-RS4-B5 / #Audi-RS4 / #Audi-A4-B5 / #Audi-A4 /
Engine Self build 5-cyl 2.5 20v Turbo, 2.5 TDI long block from 94-97 A6 (same block as Transporter T4) with custom CP-service pistons and #Rosten-Performance H-profile rods, #Audi-Ur-S4-AAN cylinder head from S4 C4 91-94 rebuilt to mechanical lifters and #CatCams for higher lift on valves and can run 10,000rpm, modified #AAN intake manifold from 2.2 20v S4 C4, Nuke fuel rail with 1600cc #Bosch injectors, custom exhaust manifold for B5 with 5-cyl engine, #Precision / #Precision-6466CE turbo, Tial 60mm wastegate, #Tial Blow-off valve, 3.5in exhaust all the way and 2x 3.5in tailpipes (Diesel look), 4in intercooler, big oil catch tank with return line for oil back to the oilpan, #Autronic-SM4-ECU , Audi R8 coils, #Accusump oil accumulator (stabilizes the oil pressure in engine)
Transmission OEM RS4 B5 transmission, OEM drive shafts, Tilton 2-plate clutch good for 1500hp
Power 939.8bhp and 983Nm at 2.3bar of boost on E85 fuel
Brakes RS4 B7 brakes in front, OEM rear brakes, hydraulic handbrake
Suspension #Øhlins 3-way coilovers, #H&R ARBs front and rear, #PowerFlex bushings / #Öhlins / #Ohlins-Racing
Wheels & Tyres #BBS-CH / #BBS 10.5x19 with 275/30x19 semi slicks, OEM RS4 and Bola B1 (Rota grid) drifting wheels with 235/40x18
Interior OEM dash, #Sparco / #Sparco-Pro-2000 black seats, Sparco 4-point red belts, full “rally” roll cage, rear mounted radiator with water pump in boot, 3x #Bosch-044 fuel pumps for E85 fuel, 60-litre fuel cell, Nuke fuel catch tank, 2x #Nuke fuel filters, firewall between boot and rear of cabin
Exterior Leon Cupra front spoiler, US side marker lights, tow straps, tinted windows, OEM paint
Tuning contacts/thanks Tuned by #RFS-Performance in Norway. 939.8bhps and 983Nm at 2.3bar of boost on E85 fuel (not finished with the tuning, need to adjust cams to push out around 200Nm more)
Top: Cheeky on-road shot of this epic track car
Below: The plate gives the game away...
Left: Rear firewall and extensive roll cage Below Left: Interior is driver focused.
Bottom: Just a regular RS4...
Above: Aslan kicks the RS4’s arse on track.
Action photographs: Bjorn Eirik Odegård
Below: Rear-mounted cooling system.
“The RS4 was actually impounded by the police...”
Below: View through the rear window gives the game away.Stream item published successfully. Item will now be visible on your stream.
- Post is under moderationPUT IT DOWN / KRB #Audi-S1-Quattro replica / / #KRB-Audi-S1-Quattro-replica / #Audi-S1-Quattro replica / #KRB-Audi-S1-Quattro / #Audi-S1-Quattro / #KRB-Quattro / #Audi-Quattro / #Audi / #KRB
With a rear wing the size of Belgium, and tyres wider than J-Lo’s backside KRB’s ’80 Coupé puts down all of its 1061whp very effectively! Never has the word ‘want’ been so appropriate as now! KRB Audi-S1-Quattro replica. Over 1000bhp and wings to die for. Words: Brent Campbell. Photos: Kid A.
Pop quiz; if you had the chance to add any car from VW/Audi’s motorsport catalogue to your garage, which one would it be? We’re talking no-holds-barred, any car, be it a rough-and-tumble rally racer to a ’ring regular, a Le Mans legend to a DTM demonstrator. While we’re sure you needn’t any help making up your mind, let’s talk it through, just for the sake of conversation. First off, we can probably go right ahead and dismiss anything from the VW side of the family, as the only memorable racer VW has ever produced had two pin-stripes and a 53 painted on the side (and it’s probably landed in some California impound lot after all those DUI convictions, no?)
So forget that; let’s take a look at Audi. Lots of fine, sporty cars to choose from, eh? How about the diesel R10? It would add a nice pep to your commute to work, not to mention return excellent fuel economy, though it does get a bit dodgy around those speed humps. What’s that, weather too unpredictable for a car with no roof? Well, how about the A4 BTCC racer of the mid- ’90s? Instantly recognisable, modern and with that Quattro grip you’ve been after. Too pokey? I knew you’d say that. Well if it’s speed you’re after, we’ll need to roll the clock back a bit further. What you’ll want is one of the legendary Group B cars of the mid-’80s. Relentless power, go-anywhere Quattro capability and people will be cheering from the kerb whenever you roll by.
So you’ve decided then? Sign here… Alright, alright, sorry. Enough messing about. We all know that these cars don’t just pop up for sale and even if they did, you couldn’t afford one and neither could we. But there is another option. All of these cars are based on production cars, right? Sure, not the R10, but for the most part, the touring and rally cars were. So you’ve got some time, some skill and maybe a little spare change in your pocket; why not build your own take on that rally favourite of yours?
With all the advancements in technology over the years, not to mention the off-the-shelf attainability of performance parts and materials that once only factory-backed race teams could afford, the proposition doesn’t sound all that outlandish.
But there is a fine line. There’s a difference between building a modern take on a hero car and taking a bone-stock 80 GT and slapping a bunch of stripes and stickers on it like some motorsport wannabes. We’ve all seen them; base-model Audi repmobiles with tawdry spoilers, brushed-on livery, cut springs and no back seats. Oh, and still on stock wheels no less. What was intended to be a tribute can sometimes do more to invoke the gag reflex than inspire pride in your brand’s heritage.
Fortunately, some people do get it right. A satisfying mix of modern performance wrapped up in a retro motorsport shell; it can be done. Just look at some of other cars we’ve featured: Perry Mason’s blood-red BTCC ’banger back in the October issue; MTM’s S1 rep from 10/09; Autoparts Veghel’s V8 Sport Quattro from 08/08 and Andy Krink’s 20v rally rep from 05/08.
And that leads us to this car (finally…), which we spotted while covering a Gatebil event at Rudskogen, which we featured back in January 11. While it has the look and the presence of the greatest of the Group B and Pikes Peak-era Audis, it isn’t at all a replica, at least by conventional standards. No, this Audi has taken on the look of a bewinged S1 more by functional necessity than by choice.
It was built by Kai Roger Bokken and the boys at KRB Trading, a Norwegian-based tuning firm with an affinity for giant snails and Audi’s potent 20v five-pot. In fact, such is the affinity for this motor that they’ve fastened it in to just about any car with four wheels at some point, Audi or not! But before we get into that, let’s get to know the man behind the plan a little better first… “While I’ve always had a passion for the Quattros, I actually got started by driving Volvos,” explained Kai. “I grew up around motorsport and my first car was a Volvo 142.
Not long after that, I started racing in a budget class called Car Cross using an old Skoda with a 2.2-litre Volvo motor in the rear.” It wasn’t long before he started building up full-on race cars to compete. “I stuck with Volvos for a while due to their rear-drive dynamics and relatively low weight,” he said.
“I competed in a number of events with the cars, including a 242 built up for rallycross and a 343 track day car that I eventually stripped out and converted to tube frame.” His involvement with the racing scene from his early teens eventually led to opening his own tuning and parts-supply business; KRB Trading. “I started that back in 1994 as there was a big demand for racing parts and with my connections, I knew I could do a better job than the other suppliers,” he said. The business’ primary focus was supplying turbochargers and components, which, not surprisingly, typically found their way on to a turbo’d five.
By the early 2000s, Kai was one of the most knowledgeable Audi tuners in the country and he was ready to finally do a fullon build on an Audi. “I’d always wanted a Ur- Quattro, but the price of entry was so high, it took me about 20 years to finally have one of my own!” he joked. He built up a red Quattro from scratch, taking everything he’d learned to achieve the highest level of power he had reached with a five-cylinder so far, nearly 850whp. After successfully putting that motor to work on the track, he took the spare motor for that car and used that in his 343 tube frame racer and competed with that as well.
Now that he’d fully built a Ur-Quattro and had successfully converted his 343 to a tubeframe race chassis, the next logical step was to take what’d he’d learned from both builds and construct the ultimate Audi track-day car. “With this build, there weren’t going to be any compromises. Not only did I plan to take the five-cylinder as far as it would go, I was designing and building the chassis and drivetrain to my specs to show what the car was capable of,” he explained.
Kai picked up the donor shell for this car, a lowly 80 coupé, back in October ’07. “There wasn’t much that we were looking for in a donor since it was all coming apart anyways, but you’d be surprised how hard it is to find one of these things without a sunroof!” he laughed. “But once we had that sorted we went straight into it. There was to be no Phase 1, 2 and 3 with this build, we were intent on turning it into a race car from the start.”
Unlike many of the privately-owned Audibased motorsport cars, Kai was willing to make significant changes to the structure of the car to enhance drivability, not to mention lower the car significantly. “The primary improvements I wanted to make by going to a tube frame design, besides reducing weight, were to improve weight distribution front-to-rear and to lower the center of gravity. Typical Audis of this era have more than 65% of their weight hanging up above or in front of the front axle. This makes the car prone to understeer. By building a custom transmission and designing my own chassis, I’d be able to move the motor lower and further back, hence improving its balance.”
Of course, to undergo such a dramatic overhaul, it wasn’t just a matter of getting it up on jack stands and going at it with a spanner. “We started by stripping the car down and then putting it up on a steel jig, kind of like a rotisserie,” said Kai. With the car up in the air, all corners and crevices were now easily accessible. Kai and his mates slowly worked through the process of reinforcing the shell with a tubular frame, cutting away un-needed parts of the body, one portion at a time.
“We started with the cockpit area, building a cage around the driver’s compartment. We then cut away the original floor and welded in a new floor. From there, we built up the front and rear frames to support the suspension and the drivetrain. Since we didn’t have any engineered drawings or schematics to work with, it was often two steps forwards, three steps back, but in the end, we accomplished what we set out to do.”
The unconventional thinking didn’t stop with the chassis. On a quest to get the most power without making sacrifices in durability, Kai built the motor to withstand much more power and boost than even the 850whp from the previous motors. “Rather than using the standard five-cylinder block, the motor is actually based around a 2.5-litre VW diesel bottom end,” Kai explained. “We then overbored the cylinders to 83mm and designed our own rods and pistons.” The original 20v S2 head was used, but modified to fit the new block as well as to increase flow. “We fabricated our own valve springs and camshafts to work with long, stainless valves and titanium retainers,” Kai remembered. To allow for lower placement in the car, a Peterson dry sump system was incorporated.
To allow for placement further aft the front wheels, Kai commissioned Sellholm Tuning of Sweden to design a custom, sequential all wheel-drive five-speed ’box and center diff that would mate to the diesel block. A custom front differential was also supplied, which would now reside in front of the motor, allowing for a more centralised placement and minimal axle angle at the car’s race height. “In all, Sellholm supplied us the gearbox with center diff, the front and rear diffs, the driveshafts, the uprights and the majority of the suspension components, so it was an integral part of the build. We spec’d what we wanted and it built it for us.”
As you’d expect, the chassis and mounts were all custom-designed for the motor, so it fits perfectly. With the motor and transmission in place, the front driveshaft actually sits beside the motor as it runs up to the front diff. With the motor sitting in the bare chassis, the assembly continued, with the custom fabbed intake manifold, upgraded fuel rail and 2200 Siemens injectors now coming into play.
For the exhaust, an equal-length manifold was fabricated, which was originally mated to a GT42 turbo. That has since been replaced with a lighter and more efficient CT43 Comp turbo with triple ball bearings. This was paired with a 60mm TIAL wastegate and, ultimately, an Autronic SM4 for engine management. “We’ve been using Autronic with E85 for years now with a lot of success. The flexibility of the software makes it easy to work with,” said Kai. The remaining intake, intercooler and exhaust system was all fabricated in-house. Note that the intercooler now sits where the radiator originally did, with the radiator now relocated to the rear of the car, using giant fans to pull the air through.
Suspension components were mainly borrowed from previous Volvo projects than from the Audi donor, due to familiarity and known durability. Volvo S80 front spindles were used front and rear, supporting a McPherson-style suspension up front and a custom double-wishbone setup out back. The Sellholm coilovers use Bilstein shocks, and Sellholm supplied the adjustable sways as well as the Volvo 240-style steering rack.
XYZ brakes were chosen for the odious job of bringing the over-powered car to a stop. With the mechanics of the car all in place, Kai and the team then went about re-skinning the car over its tubular frame. Kai took an existing S1-style body kit and modified it, moving the wheel openings upwards and extending the wheel arches three inches per side. This allowed for larger wheels, which were required to fit over the giant brakes. The remaining portions of the body were constructed from carbon fibre, including the fenders, the sills, the hood and, of course, that monstrous rear spoiler.
Inside the car, a Volvo 240 column was used, but is otherwise all go and no show. OMP supplied the seats, wheel and harness, Tilton the pedals and the handbrake, and a Racepak IQ3/Autronic display is the ‘dashboard’. It doesn’t get much more hardcore race car than this!
Once the car was at a driveable state, Kai and the KRB team tuned it on their in-house 4WD dyno and gave it its first run at the start of the 2008 race season. Since getting the car running and tuned, the challenges have largely been around in getting the suspension sorted. “We initially had a lot of issues with understeer, but over the past few seasons, we’ve experimented with a variety of roll bars, toe and caster settings to make it easier to handle around corners,” confessed Kai. While running a ‘conservative’ race-tune of 831whp and 659lb ft of torque at 1.7bar, it’s no wonder the car loves the straights. Running a full 2.4bar of boost, the car put down 1061bhp and 753lb ft of torque at the wheels, incredible for an all wheel-drive car.
Competing at Gatebil and other events around Norway and Sweden, the car has already seen a lot of success. It won the Norwegian Time Attack in 2009 and 2010, taking second this past year due to a few hiccups and against a very competitive field. “The car that beat us was a Porsche GT2 that won Le Mans, so we weren’t that upset by the loss. Overall, we’re very happy with the car and have no immediate plans to build something else. We still have lots of work to do perfecting it and we’re looking forward to 2012” said Kai. Should you find yourself in Norway with a craving for some old-skool motorsport action, this is the car you want to see. This is Group B turned up to 11!
Huge twin fans out back suck air through to keep the relocated radiator cool.
ENGINE: 2.6-litre five-cyl, 2.5L #TDI engine block over-bored, milled steel crankshaft, KRB flywheel, billett connecting rods, custom CP pistons, 10.7:1 compression, multilayered steel head gasket, S2 cylinder head modified by KRB, custom stainless steel valves, custom camshafts, #Piper/KRB cam drive system, KRB intake manifold with 3” throttle bodies, #Nuke fuel rail, #Siemens 2200cc injectors, Comp Turbo CT 43 71/79, 31.2psi (2.15bar) boost, #Turbonetics HP #Newgen wastegate,# K&N air filter, #Autronic-SM4 engine management system, MSD direct fire ignition, Magnecor 10mm ignition leads, Bosch spark plugs, #Aeromotive mechanical fuel pump and FPR, KRB fuel cell, #Spearco-based custom intercooler, 4- 5” exhaust tubes made from rolled 0.5mm stainless steel, Ferrita 4” silencer, dry sump lubrication, #Petersen four-step oil pump, rear mounted PWR-based custom radiator, twin #Bosch cooling fans.
Race power at the wheels: 894 bhp (907 PS) at 7224 rpm. Torque: 753lb ft at 6244 rpm. E85 bioethanol fuel.
TRANSMISSION: Three-step Tilton carbon clutch, Sellholm five-step sequential gearbox with integrated centre diff, Sellholm front differential, KRB-modified Ford 9”-based rear differential, Sellholm drive shafts and joints.
CHASSIS: KRB tube chassis, Volvo S80 front spindles fitted front and rear, McPherson front suspension, double wishbone rear suspension, #Sellholm coilovers with #Bilstein shocks, Sellholm knife adjustable sway bars, Sellholm ‘Volvo 240 type’ rack and pinion steering. #XYZ brakes: 380mm discs and eight-piston calipers front, 375mm discs and six-piston calipers rear respectively. #Zito-Grand-Prix 10x18” wheels, Michelin SX 27/68-18 slick tyres.
OUTSIDE: #Audi-Coupé windshield frame, front half of roof and b-pillars, all other body panels carbon fibre designed by KRB, plexiglass side and rear windows.
INSIDE: Aluminium floor below tube chassis, removable transmission tunnel, Audi Coupé dash top, KRB/Volvo 240 steering column, OMP steering wheel, seats and harness, Sellholm/KRB gear change mechanism, Tilton pedal assembly, Tilton hydraulic handbrake, Racepak IQ3/Autronic digital dash logger.
SPONSORS: KRB Trading AS, Nordisk Dekkimport, Elite Bil, Nuke, Drammen Karosseri, Profilbyraa AS
SHOUT: My family, friends and everyone that lent a hand.
EDITORS NOTE: That was a reference to Lindsay Lohan and her appearance in Herbie, Fully Loaded in the second paragraph. It was reaching a bit, we know..
1061whp. We’ll say that again. 1061whp! Power like that kind of makes your Stage 1 remap look a bit silly doesn’t it?
If it isn’t needed to go faster, make more power or lap a track quicker, it’s gone.
Audi RS4 seats? Check. Quilted leather retrim? Check. Highend audio install in Alcantaratrimmed boot build? Check. Oh, no... wait...Stream item published successfully. Item will now be visible on your stream.