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Thread: Another hybrid conversion thread....

  1. #801
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    im going to try and get ashley exhausts to develop a manifold down-pipe and full system and then sell them at discounted rates on here... if anybody is interested
    S3 Stage 1 Map, Forge 007p, Jetex filter, JE Forged pistons and scat rods, ARP bottom end bolts + stud and nut kit fited with race ported head, 3" Downpipe + Full Ashley system, lowered on ebaich pro springs, white RS6's, HID headlights n fogs, dewipered..not bad for a few weeks modding .. Hertz Mille 3000 + Audison SR1DK, + coilovers coming soon!

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    Hi Robbie
    what tools are you using to port the manifold?

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    Quote Originally Posted by The Stig View Post
    Hi Robbie
    what tools are you using to port the manifold?
    A high powered drill and standard grinding wheels, nothing as fancy as Bills, the draw back is it takes a whole lot longer.
    I use something along the lines of below, you can get them in woodies.
    Faithfull Mounted Stones (Grinding) Set of 5 - FAIGWSET5 - New Products - Faithfull Tools - DIY and Tools from DIYTools.co.uk - Your First Stop For All Things DIY !
    Mk1 Cupra R Hybrid with goodies @ 318bhp & 314lb/ft and only 2WD

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    Well, a bit of a turn up for the books....

    The car genuinely feel quicker with the ported OEM than it did with the 034.

    Also, getting the same, if not slightly higher g/s readings than I was with the 034.

    Not an acid test, but a good indicator. Should be on the rollers for some comparison runs on Sunday....
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    WOW, i am completely discombobulated by this result, Do you plan on doing any logs? i bet it feels nice to have her on the road again.
    Mk1 Cupra R Hybrid with goodies @ 318bhp & 314lb/ft and only 2WD

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    Quote Originally Posted by RobbieRolex View Post
    WOW, i am completely discombobulated by this result, Do you plan on doing any logs? i bet it feels nice to have her on the road again.
    I will as soon as I get 5 mins dude, yes.
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  8. #807
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    Sweet nice one Bill and Welly!
    Ive been Badger 5'd

    Can we break the magic 300?????? In a word Yes 314 BHP 249 lbft at Badger 5

    Quote Originally Posted by badger5 View Post
    steves is way quicker than any stock turbo'd s3 i have driven
    I only date skinny Women! They keep my power to weight higher...

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    That's put a large moggy amoungst the birds that always crap on my car..

    I have just sent my log mani in to be skimmed, and now i don't know whether to use it or go OEM again..

    Tho i dii fit mine in an aid of keeping EGTs down, and seeing you had a glowing mani before it must have offered some resistance.

    Sunday you say?

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    Quote Originally Posted by Welly View Post
    Well, a bit of a turn up for the books....

    The car genuinely feel quicker with the ported OEM than it did with the 034.

    Also, getting the same, if not slightly higher g/s readings than I was with the 034.

    Not an acid test, but a good indicator. Should be on the rollers for some comparison runs on Sunday....
    Sounds good mate... I suspect the smaller runners could be helping with earlier spool giving the feeling of enhanced quickness... be interesting to see the results Sunday though.... and of course to see what colour we can get the mani to glow ;P

    <tuffty/>
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    i bet white!
    Ive been Badger 5'd

    Can we break the magic 300?????? In a word Yes 314 BHP 249 lbft at Badger 5

    Quote Originally Posted by badger5 View Post
    steves is way quicker than any stock turbo'd s3 i have driven
    I only date skinny Women! They keep my power to weight higher...

  12. #811
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    Quote Originally Posted by Welly View Post
    Well, a bit of a turn up for the books....

    The car genuinely feel quicker with the ported OEM than it did with the 034.

    Also, getting the same, if not slightly higher g/s readings than I was with the 034.

    Not an acid test, but a good indicator. Should be on the rollers for some comparison runs on Sunday....
    Quote Originally Posted by JD09 View Post
    The same, based on the graphs thus far.

    I take it we're taking the manifold as the only variable, and the rest constant? i.e. Bill's 3" TIP etc?
    Hi.

    What do I win?

    Thanks.

  13. #812
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    OK, after a brief technical hitch.... lol.... my pictures are now working again.

    So for the benefit of those who missed it, here are the pics of the damaged 034 manifold:



    You can clearly see daylight through this one when held up...



    The second crack...
    Last edited by Welly; 19th November 2010 at 09:07.
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    Welly - I can't see them.....
    Imteyaz.

  15. #814
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    Quote Originally Posted by Imteyaz View Post
    Welly - I can't see them.....
    Grrrrrrrrrrrrrrrrrrr. It's not you dude, my hosting company decided to switch my hosting from Windows to Linux for no apparent reason, shagging everything completely in the process!! lol.

    I shall keep working on it...

    EDIT: Should be fixed.
    Last edited by Welly; 19th November 2010 at 09:08.
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    yeah, i see them anyway, wow cracked all over the place. How loud did it blow? can you hear it really easilly?
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  17. #816
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    Quote Originally Posted by Cookstein View Post
    yeah, i see them anyway, wow cracked all over the place. How loud did it blow? can you hear it really easilly?
    Yes mate, it was REALLY loud indeed. Most of the noise was coming from the crack on the top of runner 4, the first picture.

    It sounded awful, which is why I wasn't hanging around in getting it done.

    It's also left carbon residue all over my bonnet to give you an idea of how much gas was coming out...
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  18. #817
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    so welly mate where are the logs of the ported oem mani? cant wait to see the results lol

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  19. #818
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    Quote Originally Posted by DaveA3 View Post
    so welly mate where are the logs of the ported oem mani? cant wait to see the results lol
    Not done them as yet dude, have been off work the last 2 days and left my laptop with VCDS at work.... D'oh.

    Will get them done tonight and post for all to see....
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  20. #819
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    Wow, I can only imagine how after getting nice and hot, them cracks will expand from the heat and make a racket as a result. Seems like the only manufactures of manifolds that will last are OEM and JBS.

    Cost-wise, with the OEM manifold being cheaper (and more readily available) the ported OEM manifold looks to be a winner.

    Welly, I salute you - I would have sold up if it was my car a long time ago, you have persevered throughout and kept us updated with regular pics. I don't have an S3 but your thread (and attached banter within) is one of the few I keep my eye on when I'm on this forum.
    Imteyaz.

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    Quote Originally Posted by Welly View Post
    Not done them as yet dude, have been off work the last 2 days and left my laptop with VCDS at work.... D'oh.

    Will get them done tonight and post for all to see....
    sweet lookin forward to it dude!

    Audi A3 1.8T Sport (AGU) - 2000
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  22. #821
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    Quote Originally Posted by Imteyaz View Post
    Wow, I can only imagine how after getting nice and hot, them cracks will expand from the heat and make a racket as a result. Seems like the only manufactures of manifolds that will last are OEM and JBS.

    Cost-wise, with the OEM manifold being cheaper (and more readily available) the ported OEM manifold looks to be a winner.

    Welly, I salute you - I would have sold up if it was my car a long time ago, you have persevered throughout and kept us updated with regular pics. I don't have an S3 but your thread (and attached banter within) is one of the few I keep my eye on when I'm on this forum.
    Thanks dude. What can I say, I'm just a sucker for punishment, and like a challenge.... lol.

    Anyway, the dyno will be the acid test on the performance of the ported manifold.

    The dyno doesn't lie at the end of the day.

    Figures thus far are encouraging however, and driveability is much improved, which can only be a good thing, if it also encompasses reliability.
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  23. #822
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    Quote Originally Posted by Welly View Post

    It's also left carbon residue all over my bonnet to give you an idea of how much gas was coming out...
    How did you notice against you current colour scheme :-P

  24. #823
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    Quote Originally Posted by Byzan A4 View Post
    How did you notice against you current colour scheme :-P
    LOL, the underside of the bonnet is still yellow!!
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    was yellow
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  26. #825
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    Quote Originally Posted by Cookstein View Post
    was yellow
    ^ What he said....
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    Quote Originally Posted by Welly View Post
    LOL, the underside of the bonnet is still yellow!!
    I know, just couldn't think of anything else constructive to say,LOL

  28. #827
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    Quote Originally Posted by Byzan A4 View Post
    I know, just couldn't think of anything else constructive to say,LOL
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  29. #828
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    Following from SCN thread on similar subject matter..........



    also as a handy ref..
    Garrett suggest 10bhp for every lb/min flow

    265g/s is 35lb/min ~350bhp airflows where my dyno has seen 332bhp

    Plausable!
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  30. #829
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    That's a really interesting plot.

    Off hand Bill, do you remember what Matt's A3 was putting out g/s wise, as a basis for comparison to the above?
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  31. #830
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    if I can find logs (you know what I may struggle with here) yea.. will do
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  32. #831
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    Quote Originally Posted by badger5 View Post
    if I can find logs (you know what I may struggle with here) yea.. will do
    Lol, yes indeedy, look on your External HDD....

    If not, don't fret about it, it was only from an interest point of view.
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  33. #832
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    its there somewhere - i know - its been restored a couple of times so far
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  34. #833
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    Quote Originally Posted by badger5 View Post
    its there somewhere - i know - its been restored a couple of times so far
    Nothing like having it there for emergencies.... lol.
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  35. #834
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    redownloading revo files now on the spare remote drive... big ole file
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  36. #835
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    OK, logs as promised.

    Ambient temp outside tonight is 8.0 degrees Celsius.

    Results - surprising... Displayed below are Blocks 002 and 020.

    Logs with 034 Manifold fitted:

    Code:
    	Group A:	'002				Group C:	'020			
    		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization
    	TIME					TIME				
    Marker	STAMP	 /min	%	 ms	 g/s	STAMP	 CF	 CF	 CF	 CF
    	147.11	840	23.3	2.05	4.06	146.71	0	0	0	0
    	148.3	1240	45.9	3.69	10.92	147.9	0	0	0	0
    	149.5	1440	52.6	3.69	13.25	149.09	0	0	0	0
    	150.69	2360	77.4	5.74	36.08	150.3	0	0	0	0
    	151.9	4040	177.4	10.66	153.31	151.5	0	0	0	0
    	153.11	7480	187.2	15.17	264.14	152.71	0	0	0	0.8
    	154.41	6040	191.7	17.63	254.06	153.93	0	0	0	2.3
    	155.61	7400	188	15.17	265.83	155.21	0	0	0	2.3
    	156.81	5520	191.7	18.45	245.67	156.41	0	0.8	0	2.3
    	158.01	6280	191.7	18.04	258.81	157.61	3	0.8	0	1.5
    	159.21	6840	191.7	16.81	264.14	158.81	3	0.8	0	0
    	169.8	4480	3	0	2.97	170.59	0	0	0	0
    	171.09	4160	6	0	5.64	172.1	0	0	0	0
    With ported OEM manifold fitted:

    Code:
    	Group A:	'002				Group C:	'020			
    		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization
    	TIME					TIME				
    Marker	STAMP	 /min	%	 ms	 g/s	STAMP	 CF	 CF	 CF	 CF
    	240.99	3520	125.6	9.02	93.69	241.38	0	0	0	0
    	242.41	5440	191.7	18.45	244.83	242.89	3	0	0	3
    	243.8	7120	191.7	15.99	267.53	244.28	2.3	0	0	3.8
    	245.08	5480	191.7	18.45	249.42	245.48	0	2.3	0	3.8
    	246.28	6240	191.7	18.04	258.81	246.68	0	1.5	0	3.8
    	247.48	6840	191.7	16.81	267.53	247.88	0	0.8	0	3
    	248.68	7320	190.2	15.58	266.39	249.1	0	0	0	1.5
    	249.99	5840	191.7	18.04	251.94	250.49	0	1.5	0	3
    	251.29	6200	191.7	18.04	255.36	251.69	0	0.8	0	3
    	252.49	6520	191.7	17.63	258.58	252.98	0	0	0	1.5
    	253.78	6840	191.7	16.81	264.14	254.28	0	0	0	0
    	255.19	7120	191.7	15.99	264.69	255.59	0	0	0	0
    	256.39	5640	3.8	1.23	0.19	256.77	0	0	0	0
    	257.57	5400	3.8	0	4.69	257.97	0	0	0	0
    Another section from the same log:

    Code:
    	Group A:	'002				Group C:	'020			
    		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization
    	TIME					TIME				
    Marker	STAMP	 /min	%	 ms	 g/s	STAMP	 CF	 CF	 CF	 CF
    	118.65	3920	55.6	3.69	62.17	117.84	0	0	0	0
    	119.95	4800	191.7	17.63	213.28	119.15	0	0	0	0.8
    	121.36	5840	191.7	18.04	254.92	120.46	3	0	0	0.8
    	122.65	6560	191.7	17.63	260.25	121.85	3	0	0	0.8
    	123.87	7080	191.7	15.99	268.08	123.05	2.3	0	0	0
    	125.24	5720	191.7	19.27	265.94	124.35	2.3	0	0	0
    	126.55	6120	191.7	18.04	256.64	125.64	0	2.3	0	3.8
    	127.85	6480	191.7	17.63	261.44	127.05	0	2.3	0	3.8
    	129.07	5040	1.5	0	0.22	128.25	0	0.8	0	3.8
    As can be seen here, the OEM manifold is consistently flowing more air then the 034 manifold, with similar timing pull.

    Discuss....
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  37. #836
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    I'm totally dumbfounded, basically the highflow mani is/was a red herring. From the looks of the your OEM ported manifold is performing the same if not better, you mentioned the turbo can spool faster/lower down due to the smaller runners, this in itself is a great benefit and from the logs its not choking up top either!

    Is there anyone that can hook you up with an EGT gauge this would be the icing on the cake really.
    Mk1 Cupra R Hybrid with goodies @ 318bhp & 314lb/ft and only 2WD

  38. #837
    RIP S3dave

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    I have a non-contact IR thermograph I could use onto the manifold, but I have no reference data not having tried this on another. Wellys k04 does'nt have egt bung
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  39. #838
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    Quote Originally Posted by RobbieRolex View Post
    Is there anyone that can hook you up with an EGT gauge this would be the icing on the cake really.
    Sadly not mate, there isn't anywhere to put it.

    Can go on two things, firstly the glow of the manifold, and secondly the timing pull. Higher EGTs would normally come with more pull.

    There isn't any.
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  40. #839
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    Quote Originally Posted by badger5 View Post
    I have a non-contact IR thermograph I could use onto the manifold, but I have no reference data not having tried this on another. Wellys k04 does'nt have egt bung
    What color was the mani, this can be an indication of heat range.Still this is some result.Anyway when Welly gets his WMI, they should be in the 800's like mine are, with a bit of luck

    Anyone wanna buy a part used 034 manifold, LOL
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  41. #840
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    It will be interesting to see how Morgan gets on when he's complete on his TT with TSR manifold and same spec hybrid.
    I think I may be seeing a JBS k04 mani come by here at some point also for comparison also
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