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Thread: Dane's Hybrid Conversion Thread

  1. #361
    s3dave's Avatar
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    Joys of motoring..... Be interesting to see what cr says ..... No doubt it will be sorted in the end
    Not nice wasted time/ money ....

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  3. #362
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    So the car feels absolutely friggin awesome dispite being in safe running mode. Its so urgent and it makes a suuuweeet noise.

    However it's even fighting me now, its now started missfiring AAARRRGGGHHHH! Not under load like before just all the time. Pretty sure it's cylinder 4 which popped up with a fault code a few times on the dyno.

    So I'll get a coil pack tomorrow and hope it sorts it out.

    And I um... Ran out of water meth already.... In fairness I think I had under half a tank left the medium nozzle must hoof it in! Lol

  4. #363
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    You have had the car for a night and already run out of water meth? lol how long is a tank supposed to last?

  5. #364
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    Yeah Bill must have used it all up...

  6. #365
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    Quote Originally Posted by badger5 View Post
    CARS in danes hands again.. so hoping he's enjoying it and rid of the micra for a while
    too add to the rest of the hassles, the n75 seems to have packed in tonight, giving full on boost no matter whether its connected or not.. joys of vag cars.

    sticking actuator, sticking wastegate, expired n75.......... what else eh?
    One of those jobs mate :-(. Sorry to hear all the aggro that CR have been giving you.

    I feel it might be worth giving them a wide birth here on in, their performance this time around has been sub par to be nice.

    Quote Originally Posted by Dane View Post
    So the car feels absolutely friggin awesome dispite being in safe running mode. Its so urgent and it makes a suuuweeet noise.

    However it's even fighting me now, its now started missfiring AAARRRGGGHHHH! Not under load like before just all the time. Pretty sure it's cylinder 4 which popped up with a fault code a few times on the dyno.

    So I'll get a coil pack tomorrow and hope it sorts it out.

    And I um... Ran out of water meth already.... In fairness I think I had under half a tank left the medium nozzle must hoof it in! Lol
    Oh dear....

    Quote Originally Posted by Dane View Post
    Yeah Bill must have used it all up...
    Bulls**t..... :P
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  7. #366
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    It's not a coilpack so I'm limping it to Bills later, some crazy shiz happening.

    I'll put the kettle on Bill!

  8. #367
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    Quote Originally Posted by Dane View Post
    It's not a coilpack so I'm limping it to Bills later, some crazy shiz happening.

    I'll put the kettle on Bill!
    That will be a hateful drive, but it will sound cool
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  9. #368
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    Hope your luck turns around

  10. #369
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    Yeah don't I know it! It'll still be better than the micra. It sounds amazing already with the milltek etc. and the Forge short shift feels ace too!

    Although it does seem to have a bit of dv chatter...

    Time will tell, although if everything else is anything to go by it wont be simple.

  11. #370
    Dane's Avatar
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    Quote Originally Posted by superkarl View Post
    Hope your luck turns around
    Cheers dude!

  12. #371
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    Quote Originally Posted by Dane View Post
    It's not a coilpack so I'm limping it to Bills later, some crazy shiz happening.

    I'll put the kettle on Bill!
    your wiring problem again I suspect. short to plus on #4 injector is whats poppped up a few times whilst here
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  13. #372
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    Quote Originally Posted by badger5 View Post
    righto....... after several very frustrating days...

    a Conclusion, not the conclusion.

    I have just had the car run uncontrolled boost, on its forge actuator on n75 on and n75 off... Removed it and the things sticking!

    youtube sticking video..
    YouTube - ‪sticking-actuator.3gp‬‏


    Whilst flapping the wastegate penny open and shut repeatedly, it became apparent in a "double take" kind of way... that the thing sometimes did'nt close. The Penny is hanging up on the edge of the wastegate hole. The wastegate hole, bored as it is is causing most of the issues we have been suffering, I am convinced of it. The wastegate penny hanging up on the hole is the final bloody straw!

    Sticking penny (sticking slightly open) combined with a now sticking actuator, this things doomed to never work. days of work completely wasted. It has to come off and start over. not a happy bunny with the turbo one bit! CR will have an irate badger on the phone tomorrow, this is beyond a joke.

    Hi Bill,

    Wow thats some bad run of luck, hope things improve for you.

    I am guessing the actuator rod on the Forge unit is binding on the little blue guide/spring retainer ?

    I have previously had this occur with a brand new Forge K04 unit after the engine/turbo had seen a few heat cycles..

    Is the hotside not Wellys originally ported one, or did CR open it out some more ?

    Regards
    Morgan

  14. #373
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    Bill seems to have cured the misfire, the positive supply wire's insulation had perished and cracked, taped it up with a bit of relooming and it hasn't done it since

  15. #374
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    Quote Originally Posted by badger5 View Post
    Sticking penny (sticking slightly open) combined with a now sticking actuator, this things doomed to never work. days of work completely wasted.
    Diabolical might not be the right word after all.

  16. #375
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    Quote Originally Posted by Morgan-VAGCHECK View Post
    Hi Bill,

    Wow thats some bad run of luck, hope things improve for you.

    I am guessing the actuator rod on the Forge unit is binding on the little blue guide/spring retainer ?

    I have previously had this occur with a brand new Forge K04 unit after the engine/turbo had seen a few heat cycles..

    Is the hotside not Wellys originally ported one, or did CR open it out some more ?

    Regards
    Morgan
    sadly not.. CR replaced it as they reported it was cracked.. (stupidly I had'nt checked before I sent it, it was always cracked slightly from 1st refurbished and wellys)
    CR's bored out chinese housing! is shyte.

    From what I now believe, I must have lucked on the magic size and porting on wellys as it ran mint. Boring a sodding great 29mm hole right into the hotside however is just crap!

    CR's *cough* porting - bore it out right thru


    Std k04 hotside


    Wellys original one I ported


    Hmmm - spot the difference

    turbines:
    Std turbine


    clipped CR turbine
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  17. #376
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    Bill -- what trim is that clipped turbine wheel? Is it a stock K04 unit at 50/42 or possibly a 50/45 from an RS6?

  18. #377
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    Quote Originally Posted by slappy_dunbar View Post
    Bill -- what trim is that clipped turbine wheel? Is it a stock K04 unit at 50/42 or possibly a 50/45 from an RS6?
    its supposed to be a 7 degree clip, on an RS6 turbine wheel
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  19. #378
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    You realize of course that this ham-fisted "clipping" procedure is motivated by a surging issue seen on a small, different turbine rotor, right? Clipping an RS6 wheel? Why do that?

  20. #379
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    Quote Originally Posted by slappy_dunbar View Post
    You realize of course that this ham-fisted "clipping" procedure is motivated by a surging issue seen on a small, different turbine rotor, right? Clipping an RS6 wheel? Why do that?
    hiya, not quite right doug.

    roberts (rsmith on scn) LCR was smallport, 2283/k04 with unclipped RS6 turbine, and his was the one which had issues and surging..

    Wellys was "just" on the edge of surging, when it ran initial boost spike of 24psi, and almost none when it ran 22psi

    It was on the basis of this that the clipped turbine was thought to be a cure for surge. robert had the v2 unit which ran rs6 turbine with 13 degree clip and 2474 comp wheel, but this neither surged nor made power & would'nt hold boost, being quite flat in comparison to the V1. Roberts fmic did however have a higher pressure drop across it, which would of hindered flow (hampered surge) imho. fixed now however by a big fmic he now has.

    V1.2 (this one) is 2283 and 7 degree clip on RS6 turbine, AND, massive wastegate porting (aka bored out to hell)
    no hint of surge, and on spool and airflow plots it did seem to compare well to wellys original one. no dips in airflow like seen with surging units.

    the lupo's k03/2283 also has 7 degree clip and has no surge.. my two gauge cars I can relate to. wellys original, danes current, and lupos hybrid

    would i want a clip again? I dont think so.. and would manage its tendancy to want to surge by suitable boost mapping.
    Last edited by badger5; 31st May 2011 at 21:32.
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  21. #380
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    Man I love this thing and it isn't finished



    I found a tunnel - just for the sound

  22. #381
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    Great sound :D

  23. #382
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    Cheers man,

    Right you lot are goin to be so proud of me, I actually fixed something!

    So my exhaust starts blowing, it's done this in then past and it's been the egt sensor jumping out of the turbo, a quick call to bill ( sorry for interrupting your evening dude) and I think I can do it.

    So off comes the tip and low and behold the egt sensor is sitting on top of the gearbox. But I can't see where it goes in and everything is chuffing boiling. After a quick call to Welly (cheers dude) I put on a pair of gloves remove the charge pipe, strut brace and heat sheild so I can kind if see what's happening and try and find holes to put the sensor in - I only bloody did it!

    Proper proud of myself I start putting everything back together, get to tightening up the jubilee clip for the red charge pipe and.... Click! F-ing bullsheet motherfecker found another one after half an hour and now every things groovy!

    All that time spent at bills must have rubbed off on me!

  24. #383
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    Are the threads gone on EGT? why does it blow out?

  25. #384
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    It tightened up well enough so there must be some thread there, but it's done it on 2 turbos now.

    If it weren't so expensive or didn't work I'd replace it.

  26. #385
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    the probe threads are there and look undamaged, and tightens up ok every time.. but it also works its way out every time.
    this is now on 2 different turbo hotsides its wound back out from.. Weird.

    Well done on the fix Dane.. my heart sunk when you called last night (1st night I have taken off for weeks) as I though "oh no manifold I made has croaked" - Phew it was'nt, and I hoped it was the egt probe.

    with whats on the way to me turbo wise, I will need to do something re the egt fitment, so will "fix" it so it cannot unwind when we revisit it.

    T-boy and now actual spanner monkey :D

    (only need to remove TIP tho dude, as you can reach round to get the egt probe)
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  27. #386
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    Quote Originally Posted by badger5 View Post
    the probe threads are there and look undamaged, and tightens up ok every time.. but it also works its way out every time.
    this is now on 2 different turbo hotsides its wound back out from.. Weird.

    Well done on the fix Dane.. my heart sunk when you called last night (1st night I have taken off for weeks) as I though "oh no manifold I made has croaked" - Phew it was'nt, and I hoped it was the egt probe.

    with whats on the way to me turbo wise, I will need to do something re the egt fitment, so will "fix" it so it cannot unwind when we revisit it.

    T-boy and now actual spanner monkey :D



    (only need to remove TIP tho dude, as you can reach round to get the egt probe)
    Getting there hey! I had no idea where the hole was when the turbo's in situ so I took it all off so I could sort of see what hot bits I was nearly touching lol

  28. #387
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    Next youll be changing the oil every 5000 miles Dane. I know what you mean though having all the work done makes you happier to work on it yourself
    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...

  29. #388
    Dane's Avatar
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    Happy doesn't even begin to describe it, I did a little ' I actually fixed it' dance

  30. #389
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    How much "slack" does the lead have for that EGT probe? You mentioned it resting on the transmission when it fell off. Is there enough wire to make it possible to re-locate that probe to the manifold perhaps?

  31. #390
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    It wouldnt be far off I dont think

  32. #391
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    the issue with the factory egt probe is it sits into a counterbore and is clamped into the counterbore by the m12x1 nut. not like usual 1/8" npt type fittings. to fit this probe into a.n.other location an adaptor would need to be made to replicate the factory fitment (like I have done on tufftys)
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  33. #392
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    Bill -- a photo was posted earlier in the thread. Here it is again.

    The hole here is M12 x 1.00 thread, yes? The probe casing carries this thread as well, with a locknut that then spins down to the machined surface, securing it. Am I right?


    Last edited by slappy_dunbar; 2nd June 2011 at 18:42.

  34. #393
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    Quote Originally Posted by slappy_dunbar View Post
    Bill -- a photo was posted earlier in the thread. Here it is again.

    The hole here is M12 x 1.00 thread, yes? The probe casing carries this thread as well, with a locknut that then spins down to the machined surface, securing it. Am I right?
    Yeah that's him, the probe bit itself bottoms out to create "the seal" and the nut secures it in place.

  35. #394
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    Here's a good look at it. Like you said elsewhere, it has a sort of ferrule which is shaped to seat into the countersunk hole.


  36. #395
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    thats it doug.. the nut clamps it to the counterbore which has the slight chamfer lead angle on it.. It cant be too deep else the nut bottoms out on the thread on the turbo housing and the ferrule is not pushed into its seal face (like the CR/chinese housing on Danes currently is..) - I have 3 x M5 plain stainless washers packed under the ferrules head to make up the machining error gap..
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  37. #396
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    Quote Originally Posted by badger5 View Post
    I have 3 x M5 plain stainless washers packed under the ferrules head to make up the machining error gap..
    Hmmmm, not ideal. One of the issues with those housings, that and the threads for the manifold bolts....
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  38. #397
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    A sample turbine housing w/ EGT bung is coming to me now. If you can get me a depth dimension for that countersink I'll check to see how it compares.

  39. #398
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    will do.
    FedEx delivered today also - thanks for the t-shirts.. nice touch.
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  40. #399
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    Hello Dane,

    Glad to hear you are enjoying the car, did you have a finished figures or is there still work to be done??

  41. #400
    Dane's Avatar
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    What? Reporting that, only I'm allowed to spam my thread, take that, bam!

 

 

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