Track car project - Part 1

We thought it would be a lot of fun to build an affordable HPDE/track-day car that could also double as a spirited daily driver.   We also thought it would be fun for our readers to be able to follow along and watch our project progress to a track day finale.

We chose one that would reflect what we see with many of our customers who have dual use cars of this type.  We looked for a car that would accommodate a range of drivers comfortably, retain key amenities like air conditioning and a full interior to allow the vehicle to be driven comfortably to the track or to function as a second car when needed.  We felt it should be mid-sized,  turbo charged, and preferably all-wheel-drive (AWD) for more predictable traction and handling under a wide range of weather and surface conditions.  We also felt that a passenger (or instructor) should fit comfortably, and the car should have ample storage for tools, gear, and maybe even the occasional bag of groceries.  With all that in mind we set our sights on finding an affordable Audi A4.

A search of local classifieds netted a number of Audi A4 B5 or early B6 models that are inexpensive, and enjoy a wide range of aftermarket options that can improve acceleration, handling, braking, safety and reliability.

Our project car was previously involved in a minor off road event that damaged the bumper cover, radiator, AC condenser, side mount inter-cooler, and several engine and transmission mounts.   Since we planned to change out many of these items in the process of the build, this was a limited concern to us.  That meant that we purchased it at a bargain price to boot!   Others of you out there might want to start with an undamaged vehicle for slightly more money and have less things to return to undamaged condition.

Our project build will be performed in multiple installments focusing on upgrades to the engine, suspension, brakes, wheels & tires.  The body and interior mods are expected to include some carbon fiber panels, roll bar (or semi-roll cage), seats and harnesses.  We want our approach to reflect the journey an enthusiast might go through as they build their own dual-purpose track car.  Suspension, engine, and brake components often need to be updated in stages as improvements in other areas such as power create an imbalance in the factory equation.  For example,  significant power increases will dramatically increase  speed entering a corner, resulting in the need for improved grip from the suspension and tires, and larger brakes to slow things down and dissipate the heat effectively to avoid brake fade or warped rotors and may overpower other drive train components like the factory clutch.

For our initial work, we are disassembling, assessing damaged and worn out components, then ordering replacements  along with our first round of upgrades to the suspension and engine.  After raising the car on a lift, we  removed the bumper cover and bumper assembly, the damaged AC compressor, condenser, radiator, headlights and various mounts and sub assemblies.  This gave us a list of things to consider for upgrades as well as replacements.  This also gave us a view of vehicle components and structure that is not usually seen.

The damaged side mount inter-cooler and piping were removed, along with the cross pipe and radiator mounts.  The oil pan needed to be replaced along with several engine, transmission and sub-frame mounts.

Note the shattered aluminum mount – this provides the the driver side mount points for engine mounts, anti-sway bar, and connection to body and sub-frame.  The damaged loop of tubing provided minimal factory cooling for the power steering system.  This will be replaced by a dedicated cooler as the build progresses.

A used replacement bracket was sourced for less than $30 online.

The driver side transmission mount bracket was also replaced for about $20.  There are a number of websites that sell used parts from salvage vehicles.  This was the most cost effective way to source these parts.   We also replaced the associated bushings and mounts with new pieces as these were readily available from our parts suppliers.  For many of you an alternative would be a pull-it-yourself auto recycling yard such as LKQ.

Note the blue numbering indicating the inventory numbers from the salvage vehicle this bracket was removed from. When inspecting a used vehicle for purchase, look for these type of tell tale numbers which can alert you to parts that may have been replaced as the result of an accident or complete failure (as with engines, transmissions, differentials).

The oil pan had a hole in it and needed replacement.  With the oil pan removed, it is an opportunity to visually inspect for any other issues including signs of sludge and carbon build up, and ensure to the oil pickup screen is clean and undamaged.

This was also a good time for a bit of research as we consider engine mods once the initial restorative work is done and we have a baseline to work from .  We found a helpful resource in Integrated Engineering’s website, covering the variations in the five valve 1.8L VW / Audi engines.   For now we will keep the stock bottom end, but if we want to increase power significantly while maintaining reliability, it may be time to build a fresh engine with stronger rods,  and hardware.

With the new oil pan in place, we’ll take a break and be on the lookout for the UPS and Fedex trucks. Our upgraded suspension parts are starting to arrive, so in Part 2 of the project, we will begin our upgrades – focusing on the new coil over suspension, larger sway bars, new control arms and tie rod ends. Stay tuned!