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Thread: Another hybrid conversion thread....

  1. #1281
    <tuffty/>'s Avatar
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    Good work mate... hoping to start mine in the morning and have the head and turbo off ready to port the wastegate... if I don't waste any time gassing I may get it all done ready for fitting on Monday!.. although I doubt it tbh lol...

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  3. #1282
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    Welly, I have some serious respect for you! you seem to be able to do everything yourself! and Im guessing your not a mechanic by trade, mentioning fixing computers?
    In all honesty, how difficult is it to remove and refit the head? I would have a go on mine as i need to drill out a broken mani stud in the head, but get slightly scared when it comes to refitting and a small issue of timing the thing!
    I've fitted turbos etc but timing scares me! :S

  4. #1283
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    yeah Welly should open up shop & fix cars & computers

  5. #1284
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    Patience of a saint.
    Last edited by Essflee; 6th February 2011 at 13:36.
    revo'd

  6. #1285
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    how do you reset the belt tensioner welly as ive got the head off at the moment and it will be going back soon as I've got it pressure tested.

    sorry for the off topic
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  7. #1286
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    Quote Originally Posted by Mpathe View Post
    how do you reset the belt tensioner welly as ive got the head off at the moment and it will be going back soon as I've got it pressure tested.

    sorry for the off topic
    Using a vice or a G clamp mate. Put pressure on it gently, then it will slide back in. Use something as a pin through it, and then it's good to refit.
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  8. #1287
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    So far today, good progress....

    Photo of the head last night ready to fit...



    Started today with taking the engine mount off, resetting the tensioner and refitting.



    That's all sorted now, combined with the new belt on waiting to be fitted.

    Took my intercooler pipe up to Bill so he could weld in a boss for my WMI... (thanks Bill - again ). Anyway, he had that done in a very short time indeed, so I was off home before long.





    Refitted the intercooler pipe to the car, and threaded in the WMI nozzle and check valve with a bit of instant gasket to help it seal.





    I started running the pipes then, and fitted the WMI pump to it's new home. Made a bracket to make it fit, and bolted it in to see how it fits. Really pleased with the result





    Then decided to see how easy this head would be to get back on with the manifold bolted up, and more importantly, how hard the nuts would be to get onto the studs...

    Difficulty - easy. Time taken - ages.

    This was easy once I had devised the right tool for the job. I went and mangled an old 17mm spanner into the right shape for the job... Photos below for reference.





    One of the nuts is very hard to do up as we know, I have got it as tight as possible, however only time and the engine running will tell if it's tight enough... Fingers crossed.

    Finishing up the night, the engine bay looks like this:



    There is tons of space where I modified the heat shield, so I am really pleased with that. Tons of room, but it's still protecting all the important stuff... Shibby

    Shouldn't take long to get it to the point where she will be able to run, but then I've got to drop the sump afterwards and change the pickup pipe.
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  9. #1288
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    impressive

  10. #1289
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    Very nice work dude, looking forward to seeing how it performs compared to the INA mani and what figures you will be running with WMI
    Last edited by S3 Nattie; 7th February 2011 at 00:29.
    For sale

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  11. #1290
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    What is a WMI

  12. #1291
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    Quote Originally Posted by cecilthesausage View Post
    What is a WMI
    Water injection (engines) - Wikipedia, the free encyclopedia

  13. #1292
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    busy weekend for u mate glad its sorted and fingers crossed everything is ok for ya. top work mate.

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  14. #1293
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    nice work pal and good look
    350bhp & 316ftlb BBT new k16 7+7 blade hybrid turbo, Welly cooler, jetex filter, relentless ported v3 manifold 3" downpipe & de-cat, liquid gauge, r32 rear arb, AGU ported and polished Head, 550cc injectors, kw v2 Coilovers, s3dave tie bars & heat sheild, milltek cat back, I.E forged rods, brembos, inline fuel pump, v3 badger 5 tip, devils own WMI kit, AGU pistons, rear grooved discs & brembo pads, ds2500 pads & EBC ultimax disc, stack boost gauge

  15. #1294
    RIP S3dave

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    wellys now fitted his Xs Power tubular manifold..
    WMI to come tomorrow..

    Ran it tonight to check afr's ok...
    Impressive gains.... above and beyond 034 hi-flow mani, faster spool by 400rpm, more power more torque.. and without WMI running

    hopefully tuffty can upload the video.. much glowage




    Best Number before:
    331.7bhp / 277.4lbft
    Tonights run:
    343.8bhp / 302.1lbft

    12.1bhp gain and 24.7lbft gain over and above best previous 034 ex mani

    WMI comes tomorrow..
    350+bhp within reach now.

    Well done Welly.
    fingers crossed the mani lasts. It certainly works flow wise. better spool than 034 is nice.
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  16. #1295
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    Thanks for your time dynoing it dude. Again. lol.

    ^^ What Bill said - the graphs speak for themselves. Tired out, even after 2 cans of Monster Energy but f**k me I am sooo happy with that output.

    Few bits to finish up tomorrow, then will take some photos of the manifold fitted and the water meth install.

    I'm a very happy boy
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  17. #1296
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    Way hey! Nice results there, you must be well chuffed

  18. #1297
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  19. #1298
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    wow

  20. #1299
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    Yeah, she gets a bit hot.... water meth will help that thank god.

    To be fair, that's how hot the OEM mani used to get. The stainless mani's heat fades so much faster then the cast item used to, as you would expect.
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  21. #1300
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    Holy glow sticks batman.


    Good to see it fade so quickly and awesome results well deserved mate!
    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...

  22. #1301
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    Thats some cracking work there Welly, well done!!

  23. #1302
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    Properly awesome Welly!

    Never throught 340bhp+ would be possible from a ko4 hybrid to be honest, that's some pretty mental power.

    Torque curve looks amazing too! Not typically 20vt like, it just holds so late in the revs!
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  24. #1303
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    It must pull like a frickin train!!!

  25. #1304
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    Thats amazing, cant believe the power and torque your making mate.

    Would you not heat wrap the mani?
    Driving the most secretive S3 on ASN

  26. #1305
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    I hope it proves to a long lasting and fruitful project matey.

    My hybrid is 100BHP down on that, and i am scared for how long it's gonna last.

  27. #1306
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    Good figures dude and nice torque curve. Lets hope the XS mani is bit more reliable than the INA one.
    For sale

    3" Downpipe and de cat (will be going on ebay soon)
    Autogauge boost gauge
    Chrome Audi Number plate surrounds

    PM for info.

  28. #1307
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    Quote Originally Posted by Dani_B19 View Post

    Would you not heat wrap the mani?
    Problem with heat wrapping as I understand it, is that it stops the heat getting out to damage other stuff in the bay, and actually keeps the heat within the manifold, so makes it MORE likely to crack!
    -------------------------------------------------------------------------------------------------

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  29. #1308
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    Excellent figures there welly/bill it makes the labour worth it when you get nice results......

  30. #1309
    "Stick a V8 in it!"

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    Nice work and impressive figures for that diddy little turbo!

    You'll find the manifold wont get nearly as hot when actually driving, as there will be a lot more airflow over it.

    I just hope it lasts, you've taken a huge risk fitting it, especially as you're proper fed up with removing the cylinder head.

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  31. #1310
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    Quote Originally Posted by aragorn View Post
    Nice work and impressive figures for that diddy little turbo!

    You'll find the manifold wont get nearly as hot when actually driving, as there will be a lot more airflow over it.

    I just hope it lasts, you've taken a huge risk fitting it, especially as you're proper fed up with removing the cylinder head.
    you have'nt seen welly drive have you

    "diddy" little turbo which has a 35lb compressor wheel in it..
    GT28Rs..... same flow abiltiy compressor to put things into perspective
    just faster spooling in a k04 wrapper.

    I think we're all hoping it lasts for Welly...
    shows, if you allow the hybrids to breathe they can and will breathe... and unlock their flow potential.

    Its all about the flow - Badger5 Mantra
    Last edited by badger5; 8th February 2011 at 12:58.
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  32. #1311
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    OK, so after last night's happiness, normal service has been resumed... with epic failure. lol.

    WMI installed today... and when I say installed, I use the term loosly. It would seem that this pump being gravity fed for the inbound water is a necessity.

    Pics here:











    Arse.

    So my positioning of the pump above the outlet for the screenwash tank hasn't really work as well as I had hoped... The bloody pressure produced by the pump (with all the water it can't get) is an epic fail. Having tested the theory with a Devil's Own tank held above the pump, it started spraying properly as expected....

    So, a rethink required there then. Have decided now to mount the pump in the empty space left by the driver's side original intercooler. This seems the ideal place as is directly below the screenwash tank, and I can still use the original lengths of pipework I have run, and will require very little wiring modifications. Have decided, based on the new pump pump location, to simply run the pipework across the front of the car, along the intercooler, and then around to the pump.





    Moving on, the pump housing on the union for the water in is cracked, and leaking. Bugger. Bill's words were 'Araldite is your friend'. So thats what I have tried basically. I spanked a whole lot of it on there to produce a nice coat, and will do a second lot after this has dried. Hoping that I will never need to get that union out now, as I don't think it will be coming out easily...



    Lastly, I seem to had developed a water leak from the pipe that mates to the side of the head. I knew the O ring looked a bit gammy, and the pipe is slightly cracked.

    Ordered one from Audi on the way home, to find that when I got home, the leak had decided it wanted to stop... Will keep an eye on this for a while and see what's what...

    Waiting for the pump to dry so I can recoat with more epoxy resin, and then hope for the best....

    Positive mental attitude FTW!
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  33. #1312
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    Keep it goin lad! We all wana see that bumble bee flyyyy!

  34. #1313
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    Good work mate, onwards and upwards... must have been the day for it as I managed to fit the cam belt pretty much first time with no hassle only to find I had forgotten to move the crappy engine mount bracket into place so had to do it all over again... what a PITA that was... then I realised I had left the old driveshaft heat shield in place when I test fitted it before putting the head back on... needless to say everything hit it and its proved to be a PITA to remove... gave up at 7:30pm as I will need to remove the driveshaft to help get it out...not the best day but hopefully start the old girl up tomorrow...

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

  35. #1314
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    Quote Originally Posted by tufftybloke View Post
    Good work mate, onwards and upwards... must have been the day for it as I managed to fit the cam belt pretty much first time with no hassle only to find I had forgotten to move the crappy engine mount bracket into place so had to do it all over again... what a PITA that was... then I realised I had left the old driveshaft heat shield in place when I test fitted it before putting the head back on... needless to say everything hit it and its proved to be a PITA to remove... gave up at 7:30pm as I will need to remove the driveshaft to help get it out...not the best day but hopefully start the old girl up tomorrow...

    <tuffty/>
    One of those days me thinks.... Waiting for the third coating of epoxy resin to dry now.... Leak? I don't think so. May slap a bit of silicone on there for good measure as well!

    Not putting the engine mount back on must be due to doing too much work on Ibizas...
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  36. #1315
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    Quote Originally Posted by superkarl View Post
    Keep it goin lad! We all wana see that bumble bee flyyyy!
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    "Marriage is like a coffin and each kid is another nail."
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  37. #1316
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    Is the new target 400bhp? lol
    3.2 V6 with Custom Code VVT Attack Software


  38. #1317
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    Quote Originally Posted by sandip View Post
    Is the new target 400bhp? lol
    I wish.... sadly impossible with a 35 lb comp wheel...
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  39. #1318
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    Quote Originally Posted by Welly View Post
    I wish.... sadly impossible with a 35 lb comp wheel...
    Not to worry, 370bhp?

    I think we should all guess where it'll be after water/meth lol
    3.2 V6 with Custom Code VVT Attack Software


  40. #1319
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    359hp

  41. #1320
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    The grand plan is this.

    I plan to see what can be achieved with the hybrid power wise, and with water meth. It's probably worth mentioning that the MAF element which was in the S3 when it was dyno'd was underreading by around 5 g/s but I suspect that the affect on the output will be small to none. My MAF element is back in now, and am seeing what I would expect from the air flow readings.

    Once we have a figure, I plan to see what can be achieved by dropping the boost from 24 PSI down to 20, and adding timing to replace it. My engine runs a lot of timing advance as it is, but with less boost, the timing can be advanced more.

    Less boost means less heat, which ultimately means more chance of the manifold lasting. I would rather have a reliable car at 340 ish BHP running water meth, than a car which is running on a wing and a prayer, on a 'not if but when' basis.

    Ideally, I would like to see over 350 BHP, and if i can find a way to run that reliably, then fantastic. If not, I need to stop figure chasing...
    Last edited by Welly; 8th February 2011 at 23:48.
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