AH FabricationsMonster Motorsport
Page 9 of 36 FirstFirst ... 234567891011121314151619 ... LastLast
Results 321 to 360 of 1409
Like Tree10Likes

Thread: Another hybrid conversion thread....

  1. #321
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    Quote Originally Posted by Dani_B19 View Post
    Well, will you post up pics and parts of your 3" TIP when you've done it, really want to fit one but im unsure of the 3" alloy joiner as it will need 4 ports adding to it for the dv etc.
    There are people using their diy ones like this.. without issue.

    the one I am mocking up comprises silicon and alloy.. Bend radii on alloy pipe is not tight enough for all alloy. there will be at least one portion which has 76mm silicon bend on it
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  2. # ADS
    ADS
    Join Date
    Always
    Location
    Global
    Posts
    Many
     
  3. #322
    Dani_B19's Avatar
    Audi-sports own special child.

    Status
    Online
    Join Date
    Nov 2008
    Location
    Barnsley
    Posts
    7,171
    I wasn't saying anything against that setup bill, was just saying that's how I've seen people do it.

    So will you be proudcing the tips to sell bill or is it a 1 off for welly?
    Driving the most secretive S3 on ASN

  4. #323
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    its a prototype for ones to sell yes.
    just waiting on my alloy reducing coupler to be finished
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  5. #324
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    OK - so fitting the manifold didn't go so well....

    Access = none. A complete nightmare of a job. 5 hours to remove 7 manifold nuts wasn't the best to be fair.

    Anyway. I've decided now to take the head back off after 800 miles.

    The manifold isn't the only reason for this however. The turbo is suffering from boost creep due to the wastegate channel not being big enough. Basically, at actuator pressure, the boost level will climb up over the rev range. The issue with this being that I have to set the UNOS that is being used to 23 PSI initial, and then it will climb to 25 over the mid range.

    Obviously, in an ideal word, it would hit 25, and then hold 25 for as long as it is able.

    So, the head will be coming off tonight, and I will be fitting the manifold whilst the head is off. Turbo will be off, and then going up to see Bill tomorrow for porting the wastegate, before it all goes back together. Getting it back together tomorrow would be nice, but not really necessary.

    Hopefully expecting it to be back together by early in the week - most likely Tuesday night....

    My advice on K04 manifolds, take the head off to do it. We could have head the head off and half back on in the time it took to remove 7 bloody bolts.
    Last edited by Welly; 16th October 2010 at 18:46.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  6. #325
    Dani_B19's Avatar
    Audi-sports own special child.

    Status
    Online
    Join Date
    Nov 2008
    Location
    Barnsley
    Posts
    7,171
    Ok bill, youll have to keep us posted.

    Sorry to hear that it's not gone so good welly, hopefully youll have the beast up and running tomorrow .
    Driving the most secretive S3 on ASN

  7. #326
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    It's all apart now, belt off, tensioner off ready to be reset.

    Turbo is off and ready for a trip to Bill's tomorrow for some porting action....

    Nice and smooth evening actually, almost relaxing after the stress of last night. Wish I'd just done this in the first place!!

    I've taken some pics of the 034 manifold fitted as well - will post tomorrow.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  8. #327
    Andrew@A.L.D's Avatar
    Cylinder Head Master

    Status
    Offline
    Join Date
    Jun 2009
    Location
    Leeds
    Posts
    3,352
    I bet i'll have to do this then lol
    Was 531bhp 8L S3 thats going to break the 600+ bhp Club then break something else. Lets see what this OD HTAGT3582r can do
    My S3 Twists Drive shafts for fun.

    FOR SALE
    Sparco Torino 2 sport seats
    Adjustable FPR from 1-5 bar, 2 sets of Unused ARP 3/8 2000 rod bolts
    , relentless 200 cell cat pipe, Std AGU Crankshaft. Ported & Reconditioned Cylinder head service.

  9. #328
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by Andrew@A.L.D View Post
    I bet i'll have to do this then lol
    I would mate. Save yourself the stress of doing it in situ. It's simply not worth the hassle. Taking the head of is far easier.

    If it's worth doing, it's worth doing right and all that....
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  10. #329
    Andrew@A.L.D's Avatar
    Cylinder Head Master

    Status
    Offline
    Join Date
    Jun 2009
    Location
    Leeds
    Posts
    3,352
    Its making me think weather its worth doing all this or just going bt now
    Was 531bhp 8L S3 thats going to break the 600+ bhp Club then break something else. Lets see what this OD HTAGT3582r can do
    My S3 Twists Drive shafts for fun.

    FOR SALE
    Sparco Torino 2 sport seats
    Adjustable FPR from 1-5 bar, 2 sets of Unused ARP 3/8 2000 rod bolts
    , relentless 200 cell cat pipe, Std AGU Crankshaft. Ported & Reconditioned Cylinder head service.

  11. #330
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by Andrew@A.L.D View Post
    Its making me think weather its worth doing all this or just going bt now
    Thats a question certainly worth giving some serious thought.

    I'm not all together sure how well the CR Hybrid would deal with the extra displacement of your engine to be honest - not sure it will be man enough.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  12. #331
    Andrew@A.L.D's Avatar
    Cylinder Head Master

    Status
    Offline
    Join Date
    Jun 2009
    Location
    Leeds
    Posts
    3,352
    I was thinking the same now after the trouble your having and you just have a large port head and i have a 2.1 with a ported small port head that flows as well as a large port, the gas speed will be high in mine so i'm sure the turbo will not be man enough.

    Mine passes its MOT yesterday and i'm running it in so when its done i will have to think about this near the time
    Was 531bhp 8L S3 thats going to break the 600+ bhp Club then break something else. Lets see what this OD HTAGT3582r can do
    My S3 Twists Drive shafts for fun.

    FOR SALE
    Sparco Torino 2 sport seats
    Adjustable FPR from 1-5 bar, 2 sets of Unused ARP 3/8 2000 rod bolts
    , relentless 200 cell cat pipe, Std AGU Crankshaft. Ported & Reconditioned Cylinder head service.

  13. #332
    Andrew@A.L.D's Avatar
    Cylinder Head Master

    Status
    Offline
    Join Date
    Jun 2009
    Location
    Leeds
    Posts
    3,352
    Keep me posted welly on whats been done as i'm still working out the BT conversion
    Was 531bhp 8L S3 thats going to break the 600+ bhp Club then break something else. Lets see what this OD HTAGT3582r can do
    My S3 Twists Drive shafts for fun.

    FOR SALE
    Sparco Torino 2 sport seats
    Adjustable FPR from 1-5 bar, 2 sets of Unused ARP 3/8 2000 rod bolts
    , relentless 200 cell cat pipe, Std AGU Crankshaft. Ported & Reconditioned Cylinder head service.

  14. #333
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    okies.. small update.
    Wellys been fitting his 034 mani..
    whilst apart he brought the hybrid k04 along so I could port its wastegate as it was creeping under boost.

    Pictures below of whats been done and required.
    Std k04/Hybrid wastegate port


    Once ported by me


    Quite some difference

    A std K04 throat


    The ported Hybrid of Wellys


    and finally, side by side comparison of a K04 and the ported hybrid
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  15. #334
    Prawn's Avatar
    My other car is a MINI!!!!

    Status
    Offline
    Join Date
    Dec 2006
    Location
    Basingstoke
    Posts
    9,067
    wellys turbo has 2 cracks in the exhaust housing!
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  16. #335
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    one is a line, one is a hairline crack yes,
    exchange turbos, rebuilt.
    non invasive crack mostly in the thick section I removed material away from. See bottom picture its no longer there.

    dissimilar sections in castings will be the areas where higher stress's will occur, so to me, thinning this as part of the porting for flow process, will hopefully make things more reliable, as will the higher flowing manifold & lower egt's.
    We will see how it pans out.
    Last edited by badger5; 17th October 2010 at 22:24.
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  17. #336
    Andrew@A.L.D's Avatar
    Cylinder Head Master

    Status
    Offline
    Join Date
    Jun 2009
    Location
    Leeds
    Posts
    3,352
    I'm still thinking weather its worth me doing this and the 034 manifold or spending more money now and getting a GT3076r?
    Was 531bhp 8L S3 thats going to break the 600+ bhp Club then break something else. Lets see what this OD HTAGT3582r can do
    My S3 Twists Drive shafts for fun.

    FOR SALE
    Sparco Torino 2 sport seats
    Adjustable FPR from 1-5 bar, 2 sets of Unused ARP 3/8 2000 rod bolts
    , relentless 200 cell cat pipe, Std AGU Crankshaft. Ported & Reconditioned Cylinder head service.

  18. #337
    Prawn's Avatar
    My other car is a MINI!!!!

    Status
    Offline
    Join Date
    Dec 2006
    Location
    Basingstoke
    Posts
    9,067
    Quote Originally Posted by badger5 View Post
    one is a line, one is a hairline crack yes,
    exchange turbos, rebuilt.
    non invasive crack mostly in the thick section I removed material away from. See bottom picture its no longer there.

    dissimilar sections in castings will be the areas where higher stress's will occur, so to me, thinning this as part of the porting for flow process, will hopefully make things more reliable, as will the higher flowing manifold & lower egt's.
    We will see how it pans out.
    Clever stuff Bill, excuse my half cut one line reply last night, looks like top notch work.

    I'm surprised that CR havn't ported the wastegate in some ways, having built so many of these turbo's now surely they've encountered the boost creep issue before? where do you stand now with any form of guarantee from CR turbo's for the rest of the unit? Obviously you've greatly improved it, but could they perhaps use it as an excuse to void a warranty?
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  19. #338
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    Quote Originally Posted by Prawn View Post
    Clever stuff Bill, excuse my half cut one line reply last night, looks like top notch work.

    I'm surprised that CR havn't ported the wastegate in some ways, having built so many of these turbo's now surely they've encountered the boost creep issue before? where do you stand now with any form of guarantee from CR turbo's for the rest of the unit? Obviously you've greatly improved it, but could they perhaps use it as an excuse to void a warranty?
    they have been told by me on first running wellys to port the wastegate... they build the turbos, they dont map them or see how they run ever... so my feedback to them on as we go is continued development and evolution of the things.

    I fancy seeing what a hybrid with the larger turbine, + clipped would run... next one might have this spec to see.. (only when used on a hi flow manifold tho)

    The porting I have done, is something they themselves will do on future ones anyhow.
    turbo remanufacturers can always come up with a reason to void warranties.. sux, but thats how they are all too often
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  20. #339
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    Quote Originally Posted by Andrew@A.L.D View Post
    I'm still thinking weather its worth me doing this and the 034 manifold or spending more money now and getting a GT3076r?
    you need to match your displacement and flow to a suitably sized unit..
    GT30R may go very well on yours.. did you do full valvetrain upgrade?
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  21. #340
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Good morning peoples....

    Let me open with bugger bugger plop plop arse.

    So, moving on.

    Engine is all back together now, worked my nads off to get it put back together last night so I could use it for work this morning.

    And all was going so well. Until I fired the engine up at about half 8. The gasketless manifold-turbo flange was blowing like a trooper. Bummer.

    Not sure currently of the cause of this - however there are 2 possibilities:

    1) It needs a gasket.

    2) The downpipe flange is contacting on the manifold and preventing the turbo and manifold from mating up properly.

    1 is easy. Fit a gasket, so I will be trying this first. There is a possibility that the flange simply isn't all that straight, and is allowing gas out.

    2, not so easy. Two options if this is the case. Use a thicker gasket to try and put some space in between the turbo and mani. Take the downpipe off and shave some metal off the flange itself.

    Neither of the two particularly hard to do, both just a pain in the chuff if we're being honest, and hassle I could have done without. After all the extra hassle this has been!! lol. Still, I shall take it on the chin and get on with it as usual....

    I was considering just driving it, but I have decided against it to be fair.

    Anyway, some photos of the manifold fitted to my head:

    New Exhaust Mani Gasket:


    1 Fitted Manifold (And the ******* flange):


    OEM and 034 together.


    Bye bye OEM mani.....
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  22. #341
    Broken Byzan's Avatar
    Photographic Moderator

    Status
    Offline
    Join Date
    Apr 2004
    Location
    Cardiff, United Kingdom
    Posts
    12,357

    My Social Networking

    Follow Broken Byzan On Twitter Add Broken Byzan on Facebook Add Broken Byzan on Google+ Visit Broken Byzan's Youtube Channel
    Welly, have you used Velcro instead of a Head gasket this time, just in case, LOL

  23. #342
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    OK, adding to this, here is my gasket dilemma....

    The 034 Motorsport maifold's collector is substantially larger than both the turbo's neck and the T-M gasket. Photo below to illustrate (Cheers Bill... )



    As you can see from this, the mani is substantially larger than the T-M Gasket. So, realistically, the gasket needs to be ported.

    The next issue being that the manifold has now been fitted,and making a gasket to fit something you can't see won't be so easy... so I have to guesstimate via photographs.

    Here is my best guess!



    I think it's somewhere close, and I will have to grind it out and see what's what.

    Also going to invest today in a bendy inspection mirror so I can have a good look at what's going on down there...
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  24. #343
    JD09's Avatar
    I'm not modding, I'm improving

    Status
    Offline
    Join Date
    Dec 2009
    Location
    Cheshire, Alderley Edge
    Posts
    3,078
    Lovely lovely lovely! Looking good chap

    Just out of interest (I know, not exactly a tuning/how much BHP can we get question), these are all mods to the turbo system on a 1.8T engine are they not? . . . so could this mean that, regardless of mods to the turbo, you could still stay off boost and simply achieve the same MPG as you did before/as any standard 1.8T S3 achieves?

  25. #344
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by Byzan A4 View Post
    Welly, have you used Velcro instead of a Head gasket this time, just in case, LOL
    Now that was just mean..... . But a good point, I didn't think of that..... lol.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  26. #345
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by JD09 View Post
    Lovely lovely lovely! Looking good chap

    Just out of interest (I know, not exactly a tuning/how much BHP can we get question), these are all mods to the turbo system on a 1.8T engine are they not? . . . so could this mean that, regardless of mods to the turbo, you could still stay off boost and simply achieve the same MPG as you did before/as any standard 1.8T S3 achieves?
    Yep. I've been pottering it around lately as the fuelling isn't quite right and been getting 26.8 mpg average....
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  27. #346
    S3 Nattie's Avatar
    Quattro ist fĂĽr sissies

    Status
    Offline
    Join Date
    May 2009
    Location
    Cardiff
    Posts
    1,600
    Quote Originally Posted by badger5 View Post
    they have been told by me on first running wellys to port the wastegate... they build the turbos, they dont map them or see how they run ever... so my feedback to them on as we go is continued development and evolution of the things.
    Thats really suprising CR do not have any turbo maps for the turbos they do. What sort of maximum airflow can a Hybrid K04 produce.


    Quote Originally Posted by Andrew@A.L.D View Post
    I'm still thinking weather its worth me doing this and the 034 manifold or spending more money now and getting a GT3076r?
    From looking at your setup a GT30 does sound more suitable. You should try and flow your valvetrain first to see what airflow can be achieved through it.

    Quote Originally Posted by Welly View Post
    Yep. I've been pottering it around lately as the fuelling isn't quite right and been getting 26.8 mpg average....
    Lol how often do you stay off boost for welly.

    Nathan
    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. #347
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    Quote Originally Posted by S3 Nattie View Post
    Thats really suprising CR do not have any turbo maps for the turbos they do. What sort of maximum airflow can a Hybrid K04 produce.




    From looking at your setup a GT30 does sound more suitable. You should try and flow your valvetrain first to see what airflow can be achieved through it.



    Lol how often do you stay off boost for welly.

    Nathan
    No nattie thats not what I said..
    "They dont map" any of the turbo's.... not that they dont have spec information on their compressor maps etc....
    "map" as in remap
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  29. #348
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Result!!

    I took my mock up gasket seen above down to Longlife in Berkeley and they are going to make me one out of their exhaust mani gasket material this afternoon... Bargain!

    Also, the three turbo bolts wound out this time without bringing the heli coils with them... Looking forward to getting my gasket and fitting...
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  30. #349
    S3 Nattie's Avatar
    Quattro ist fĂĽr sissies

    Status
    Offline
    Join Date
    May 2009
    Location
    Cardiff
    Posts
    1,600
    Quote Originally Posted by badger5 View Post
    No nattie thats not what I said..
    "They dont map" any of the turbo's.... not that they dont have spec information on their compressor maps etc....
    "map" as in remap
    My bad, didnt read it properly. Im doing my final year project on my S3 and looking at turbo mapping now and I need to get a standard K04 and possibly a BT compressor map at some point in the near future.

    Do you have any compressor maps for the hybrid K04 to upload by any chance Bill.

    Nathan
    Last edited by S3 Nattie; 18th October 2010 at 14:40.
    For sale

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

    PM for info.

  31. #350
    S3 Nattie's Avatar
    Quattro ist fĂĽr sissies

    Status
    Offline
    Join Date
    May 2009
    Location
    Cardiff
    Posts
    1,600
    Quote Originally Posted by Welly View Post
    Also, the three turbo bolts wound out this time without bringing the heli coils with them... Looking forward to getting my gasket and fitting...
    Them 3 bolts are a right pain in the ass. Audi have revised them though as the new ones I bought had longer heads on them so the socket doesnt slip as easy.

    Nathan
    For sale

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

    PM for info.

  32. #351
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by S3 Nattie View Post
    Them 3 bolts are a right pain in the ass. Audi have revised them though as the new ones I bought had longer heads on them so the socket doesnt slip as easy.

    Nathan
    Not so much that that's the issue. I have been using the revised ones.

    What happened when I unbolted the turbo last time was that rather than the bolt unwinding from the helicoil that's in the K04 Turbos, it was in there so tight it actually unwound the bolt AND the helicoil from the turbo. This leaves you with the bolt stuck in the manifold.

    And that sucks, quite frankly. It is a royal pain.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  33. #352
    Speedy Steve's Avatar
    5th Gear

    Status
    Offline
    Join Date
    Nov 2008
    Location
    Leicester
    Posts
    1,246
    Quote Originally Posted by badger5 View Post
    they have been told by me on first running wellys to port the wastegate... they build the turbos, they dont map them or see how they run ever... so my feedback to them on as we go is continued development and evolution of the things.

    I fancy seeing what a hybrid with the larger turbine, + clipped would run... next one might have this spec to see.. (only when used on a hi flow manifold tho)

    The porting I have done, is something they themselves will do on future ones anyhow.
    turbo remanufacturers can always come up with a reason to void warranties.. sux, but thats how they are all too often
    Favoritism how come i didnt get that?
    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...

  34. #353
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by Speedy Steve View Post
    Favoritism how come i didnt get that?
    Your's didn't suffer from it mate for some reason. We were talking about this the other day.

    Your maps reflect that there is no boost creep with your turbo, as the 26 PSI the MBC is set to, holds until the turbo starts to run out of puff towards the later revs. Yours was set at 26, then dropped down to the 22-21 psi region. which is fine.

    With mine, the boost creep was quite bad. In contrast to your turbo, we would have to set the MBC at 23 PSI, it would creep up to 25 PSI towards the mid range, and then drop to the 22-21 region towards the later revs.

    Obviously, with a ported wastegate, I will be able to run 25 on the MBC and it will hold, like yours does until it starts to give up.

    Don't feel left out dude...
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  35. #354
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    Quote Originally Posted by Speedy Steve View Post
    Favoritism how come i didnt get that?
    not favouritism, just locality.. and wellys motor aspires to your power levels..
    I did'nt see creep on yours for some reason.. (possibly intercooler and head differences)

    anyhows... what about that wmi it desperately needs !
    :D

    ran a.n.other hybrid'd car sunday.. with wmi.. 305-309bhp/280lbft consistently with WMI working on 50/50 mix
    Last edited by badger5; 18th October 2010 at 15:41.
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  36. #355
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by badger5 View Post
    not favouritism, just locality.. and wellys motor aspires to your power levels..
    I did'nt see creep on yours for some reason.. (possibly intercooler and head differences)
    And plus I took the thing back off myself to have it done, after fitting it once.....
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  37. #356
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,941
    yep, that makes a huge difference, as I just dnt have time with a workshop full of cars for BT conversions currently.
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  38. #357
    Lemon S3's Avatar
    Alex

    Status
    Offline
    Join Date
    Sep 2009
    Location
    Bicknacre, Essex
    Posts
    1,314
    Quote Originally Posted by Welly View Post



    The next issue being that the manifold has now been fitted,and making a gasket to fit something you can't see won't be so easy... so I have to guesstimate via photographs.

    Here is my best guess!



    I think it's somewhere close, and I will have to grind it out and see what's what.

    Also going to invest today in a bendy inspection mirror so I can have a good look at what's going on down there...
    I know you're getting one made....but to get the right size hole on your gasket, get a piece of paper and place it over the manifold hole and press on the edges with your finger to crease the paper then just cut round the creases...voila, a template
    1999 APY S3 Imola Yellow

    PS3: Broady_11

  39. #358
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by Lemon S3 View Post
    I know you're getting one made....but to get the right size hole on your gasket, get a piece of paper and place it over the manifold hole and press on the edges with your finger to crease the paper then just cut round the creases...voila, a template
    And this is what I would normally do..... However.... The manifold is currently fitted to the head, on the car, upside down, with a turbocharger covering the hole.

    Thus making any sort of template is impossible.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  40. #359
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    OK - results are in.

    The gasket Longlife did for me was just the job. 3mm thick (wow!), and made of a composite of pure carbon and stainless steel. Not too shabby.

    The thing looked a bit rough around the outside edges, but the lad who did it was saying what a pain in the arse they are to make. Only cost me a tenner in the end.

    Photos:

    OEM and Custom gaskets


    3mm thickness.


    OEM and custom gasket overlay - hole they made inside is spot on.


    Is now running with no blowing manifold..... So far so good anyway,

    Still awaiting my injectors though....
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  41. #360
    Welly's Avatar
    Testing dodgy Chinese gear...

    Status
    Offline
    Join Date
    Aug 2009
    Location
    Gloucestershire
    Posts
    10,680
    Quote Originally Posted by Welly View Post
    Not so much that that's the issue. I have been using the revised ones.

    What happened when I unbolted the turbo last time was that rather than the bolt unwinding from the helicoil that's in the K04 Turbos, it was in there so tight it actually unwound the bolt AND the helicoil from the turbo. This leaves you with the bolt stuck in the manifold.

    And that sucks, quite frankly. It is a royal pain.
    Since I had a photo to illustrate what I was talking about here ^^, I thought I'd add it in....

    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




 

 

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Single Sign On provided by vBSSO

Garage Plus, Vendor Tools vBulletin Plugins by Drive Thru Online, Inc.

Content Relevant URLs by vBSEO