A Bluestar from Germany...

[levi]

[SyncroGhia]

Well despite moving along slow with the S8/996 setup, something else has turned up and swayed my hand...

I've been looking for a donor Audi RS6 ever since I owned one in 2013.

I just can't get away from that torque and never ending stream of power.

Eventually one popped up that fitted the bill.

It's a 2004 Black RS6 Avant with 118,000 miles. The gearbox is dead (no surprise there!) and it has a chequered history having been written off back in 2014 due to being uneconomic to repair. I have no history as to where the car was damaged but the engine is good (I did a compression test) and that's pretty much all I care about.

The gearbox will be a G50 based 4WD but I'm trying to introduce a Torsen differential into it to create the first Porsche Quattro 4WD system. Sounds simple doesn't it...

The current plan is to complete the S8/996 engine conversion and have the RS6/G50 in the background ready to swap in at the right time.

I already have the gearbox and an adapter plate (it's actually for a small block chevy to G50) which will need modifying to match the RS6 engine and a flywheel made to suit, probably to accept a 996 Turbo clutch.

Oh... one more photo to be going on with...

MG
_________________
T3 Syncro 16 S6 Westfalia Limey SOLD
T3 Syncro 6x6 SOLD
T3 RS6 Bluestar
T3 Tristar Syncro 16 SOLD
T3 Tristar Syncro RHD SOLD

[SyncroGhia]

I took a day off work and pulled the engine/gearbox from the RS6....

I don't know why people go on about it... it's really simple!

You just unbolt a few things... and puuuuuuuuuuuuuulll

It's a bit 'busy' at the business end!

The turbos have a bit of play in them so I'll probably buy some cores and rebuild them myself.

Then it's onto removing the gearbox and offering up the adapter plate for the G50 gearbox.

I picked up an Audi S4 B7 gearbox cheap for some internals for modifying my G50 gearbox. This'll be fun

MG
_________________
T3 Syncro 16 S6 Westfalia Limey SOLD
T3 Syncro 6x6 SOLD
T3 RS6 Bluestar
T3 Tristar Syncro 16 SOLD
T3 Tristar Syncro RHD SOLD

[SyncroGhia]

A couple of up to date photos of the van sitting on it's wheels. I'm so used to seeing it up in the air that I'd forgotten how low it sits... that said there is around 500kg of junk inside it right now

I hope to pull the gearbox off (means removing at least one turbo!) later and putting the engine on a trolley for mocking up the adapter plate.

On a side note, the Tristar Syncro has gone and Limey is now in storage so I can finally get on with this!

MG
_________________
T3 Syncro 16 S6 Westfalia Limey SOLD
T3 Syncro 6x6 SOLD
T3 RS6 Bluestar
T3 Tristar Syncro 16 SOLD
T3 Tristar Syncro RHD SOLD

[blaze80]

the width of rear wheels is awesome!!!
_________________
/// '89 Syncro Sport Joker, Reimo Hightop, mTDI
/// '90 Carat (SOLD)
/// '06 Audi A4 Avant S-line (SOLD)
/// '92 mk2 Jetta GL 8v (SOLD)
/// '89 'Bluestar' (SOLD)
/// '04 Audi S4 (SOLD)
/// '99 Jetta GLX VR6 (SOLD)
/// '84 Vanagon GL (SOLD)

[SyncroGhia]

[SyncroGhia]

I have grabbed a front differential to go along with the 4WD gearbox.

As I'm putting a lot more bhp/ftlbs through this setup that standard, I've already upgraded the output flanges on the gearbox to 108mm and now I'm doing the same with the front differential.

Standard...

Bigger

Last thing before I forget... my gearbox is missing one part. The slave cylinder for the LSD. Yes, it has an adjustable rear LSD in the gearbox. It's usually operated by an ECU (or 3!) as in the 964 via hydraulics but I don't have the slave cylinder.

Does anyone have an old one kicking around?

Thanks

MG
_________________
T3 Syncro 16 S6 Westfalia Limey SOLD
T3 Syncro 6x6 SOLD
T3 RS6 Bluestar
T3 Tristar Syncro 16 SOLD
T3 Tristar Syncro RHD SOLD

[scottz]

[SyncroGhia]

[MsTaboo]

[SyncroGhia]

[Christopher Schimke]

[Christopher Schimke]

[SyncroGhia]

[MsTaboo]

[brad131a4]

Just wondering if this has progressed any farther? I see the last post is 2017.

[SyncroGhia]

I've just realised that I haven't updated this for some time.

I'm afraid to say that not much has happened due to various things going on in my life and other projects.

I did however had an adaptor plate made to mate the G64 gearbox to the RS6 lump. Also, I had an adaptor sleeve made from the remains of a dead G64 centre diff so I can run the gearbox in 2WD or 4WD. I am planning on running it 4WD but it'll be nice to be able to actually get it driving without having to do everything at once.

I also bought the necessary parts for the clutch control.

Then past several years, a divorce, house move etc...

Then I got some time spare and mated the gearbox to the engine.

Moving it around was always going to be entertaining as my workshop is in the corner of the garden. So... I used my box trailer to move it onto the drive... yes my sons decided that underneath the Bluestar is the place to be!

I've had to cut the centre of the gearbox cross member out entirely so that the gearbox will sit up high enough. I'll be adding in strength underneath when I fabricate the gearbox mount.

It's quite a snug fit under the engine lid but it does it.

Then a lot more time passed by as I concentrated on other projects and it went into storage.

I've just (yesterday) got it back onto the drive and intend on getting the engine/gearbox mounted properly asap.

It IS chuffing freezing here atm. 1-2°C during the day and -7/8°C overnight which doesn't help.
_________________
T3 Syncro 16 S6 Westfalia Limey SOLD
T3 Syncro 6x6 SOLD
T3 RS6 Bluestar
T3 Tristar Syncro 16 SOLD
T3 Tristar Syncro RHD SOLD

[11BC2]

Mein Gott im Himmel!

[Schnippzle]

Welcome back! Looking forward to the next round of updates!
_________________
1988 Caravelle - FB25B - Syncro converted
2016 MB E63 AMG S - The daily driver
2019 Harley Davidson FXFBS Fat Bob - The leisure

[Crankey]

Cool project. Looking forward to the wheel fitting chapter 😀
Nice shorty sinka back there too !