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  1. #121
    Westy's Avatar
    Double Dark Side! Diesel & 8P

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    Both Alex's behave
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
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  3. #122
    superkarl's Avatar
    MAN OF STEEL

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    its fair to say we are very bored idiots

  4. #123
    Welly's Avatar
    Testing dodgy Chinese gear...

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    Quote Originally Posted by Westle View Post
    Both Alex's behave


    No more from me.
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  5. #124
    Welly's Avatar
    Testing dodgy Chinese gear...

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    Quote Originally Posted by superkarl View Post
    its fair to say we are very bored idiots
    Work sucks. It gets in the way of all the other things I want to do - yet pays for them.

    Catch 22.
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  6. #125
    Alex C's Avatar
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    Quote Originally Posted by Welly View Post
    Dude, I think we better pack it in.... lol.

    Point made...
    Alex S3 AMK
    Bilstein B8s, H&R Springs, Neuspeed ARBs, Genuine 18" BBS LMs & LCR Brembos

  7. #126
    Dane's Avatar
    Faster than a V12 Q7

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    I've got one
    DaneS3-rod install

    Oh wait...

  8. #127
    finesse's Avatar
    6th Gear

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    Ok I concede

  9. #128
    Welly's Avatar
    Testing dodgy Chinese gear...

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    Quote Originally Posted by finesse View Post
    Ok I concede
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  10. #129
    Sam_'s Avatar
    Down under

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    I imagine it's a head off job to do the rods?
    Handling mods++. GTX30 soon-ish. Hiding parts from the mrs since 2011. Build thread

  11. #130
    Welly's Avatar
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    Quote Originally Posted by Sam S3 View Post
    I imagine it's a head off job to do the rods?
    Yep, otherwise impossible basically.
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    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Prawn View Post
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  12. #131
    Dane's Avatar
    Faster than a V12 Q7

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    I think Bill removed my head and sump to do mine.

  13. #132
    Welly's Avatar
    Testing dodgy Chinese gear...

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    Quote Originally Posted by Dane View Post
    I think Bill removed my head and sump to do mine.
    You have to AFAIK, as I can't imagine getting the ring compressor in from underneath would be easy, if actually possible at all.

    Also to do it from below you would have to remove all 4 oil squirters.
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  14. #133
    s3dave's Avatar
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    Yep head off for this engine...

  15. #134
    Dane's Avatar
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    I know... I'll check the thread from when Bill changed my rods and check

  16. #135
    www.badger5.co.uk

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    my personal theory why Audi's do indeed seem to fare worse than their other k04 cousins...

    4wd.. all of the cars power is tractable power, so loads are higher, both from traction and the extra 4wd weight.. Engines working harder.
    Combine with Audi's insane AVS servicing, and the milage the S3's are at now....

    my 2p on why anyhows
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  17. #136
    S3 Nattie's Avatar
    Quattro ist für sissies

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    Just a little info for you guys on fatigue and material properties in relation to fatigue on con rods.

    Con rods experience cyclic loading ie stresses exerted on a con rod goes from tension to compression, tension to compression .... and so on for a number of cycles, like a sin wave.

    Steel is a ferrous metal and the material properties of the ferrous metal in terms of fatigue typically follow this type of S/N curve. S/N curve is the relationship between the "stress amplitude" exerted on a material and the "number of cycles" it will last for before it begins to fatigue under cyclic loadings.





    As you can see from the S/N curve above, for a steel, if the stress amplitude exerted on the material is less than the "fatigue limit" of the material then the material/part will last for an infinite amount of cycles. There is also a S/N curve for aluminium and it shows why con rods and not made out of aluminium for mass productions engines as the fatigue limit constantly decreases as the number of cycles increase until the time it actually breaks.

    When looking at con rod design there will be a safety factor which basically means, if you have a factor of safety of 2 then the part has been designed to withstand twice the amount of stress which will be exerted on it. As you increases the performance of the engine, the stress amplitude exerted on the rods increase until the worse happens and you exceed the fatigue limit of the material which the con rod is made out of and the material begins to fatigue and then eventually break/bend a rod.

    This is just some info on fatigue in relation to con rods for anyone who wanted to know.
    Last edited by S3 Nattie; 24th May 2011 at 22:07.
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  18. #137
    superkarl's Avatar
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    So ideally youd want a certain grade steel which fatigue limit decreases very very slowly, alowing more cycles at any given stress amplitude. It would also vary with rod design, something only tcesting would show

  19. #138
    S3 Nattie's Avatar
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    Well different types of steel have different UTS (Ultimate Tensile Strength) points so the stresses they can withstand will vary with different types of steel, different yield strengths. But steels or any ferrous metal will follow that type of S/N curve. The material will never fatigue if the stress amplitude is kept under the fatigue limit (300MN/m^2 in the graph).

    However in terms of rod design, other areas can cause materials to fatigue such as the surface finish of the material and the shape of the part. Sharp edges and angles can cause stress concentrations which could cause cracks and if the crack is perpendicular to the stress then if will get bigger and eventually cause it to fail.

    The graph only goes up to 10^10 cycles (10,000,000,000 revolutions) but the curve would stay near enough flat for 10^20 cycles.

    If you want know how fatigue tests on parts take place, search "Wohler machine" on the net. It basically rotates a material which is fixed at one end and a load on one end to replicate cyclic loadings but gives you a mean stress of zero.
    Last edited by S3 Nattie; 25th May 2011 at 00:31.
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  20. #139
    Alex C's Avatar
    6th Gear

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    one more
    Quote Originally Posted by pompeysteve View Post
    Well I think I've got you beat!
    Picked up my new S3 last thursday at 17:30, after hunting high and low for 6 months to find the spec I wanted with low miles.
    Absolutely loved it, loads of horses and handles beautifully, everything my last S3 lacked.
    5 hours later it dropped a con rod down the motorway at 4000 revs!
    Quote Originally Posted by pompeysteve View Post
    It had a Backdraft motorsport 330hp conversion carried out about 11000 miles ago, without the con rod upgrade, so that would be my guess.
    Dropped the car back to them this morning, and will know more once they've got it apart.
    Alex S3 AMK
    Bilstein B8s, H&R Springs, Neuspeed ARBs, Genuine 18" BBS LMs & LCR Brembos

  21. #140
    Westy's Avatar
    Double Dark Side! Diesel & 8P

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    A 330 conversion without uprating the rods...... madness
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  22. #141
    Welly's Avatar
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    Quote Originally Posted by Westle View Post
    A 330 conversion without uprating the rods...... madness
    Yeah, that is a bit dumb IMHO - why would you spend all the money and not do the rods?

    They do say that they bigger blowers tend to level out the torque, however there will still be a LOT of torque there.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  23. #142
    finesse's Avatar
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    Lol I think everyones rods are going to break or bend

  24. #143
    superkarl's Avatar
    MAN OF STEEL

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    same conversion Don is running on here, he doesnt have rods either, think he's had his conversion done quite a while.
    rod lottery

 

 
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