EM TuningAH Fabrications
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  1. #1
    www.badger5.co.uk

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    another S3 hybrid with Frankenturbo exhaust manifold/CRB5 hybrid

    Another S3 with a hybrid K04 completed. (finally)

    Car needs a better fuel pump as fuel pressure is dropping after 6krpm and going leaner than 'ok'
    MAF is bog stock narrow band S3 one.. screens etc all original

    Complete kok to map and restrain it from surging which it so wants to do with too much boost too soon in the rev range. Finally cracked it and skirting up the edge of its surge line but not crossing it.

    Needs WMI in its life! With WMI and additional cooling/timing possible, this can get towards wellys figures.. where it is short overall of them as is.. Good airflow, but clearly some inefficiencies in combustion process (heat) holding power back, and top end fueling is just not being supported by the cars tired fuel pump.

    Headline figures 302bhp/293lbft

    Code:
    Group A:	'003				Group B:	'020				Group C:	'118			
    	RPM	Mass Flow	Load	Ign. Timing		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization		RPM	Temperature	Load	Absolute Pres.
    TIME					TIME					TIME				
    STAMP	 /min	 g/s	 %	 °BTDC	STAMP	°KW	°KW	°KW	°KW	STAMP	 /min	°C	 %	 mbar
    
    
    99.32	1600	13.22	9.4	27.8	98.62	0	0	0	0	99.01	1600	30	0	1020
    100.54	1640	23.67	42.7	21.8	99.73	0	0	0	0	100.13	1600	30	0	1020
    101.61	1640	27.67	76.5	19.5	100.9	0	0	0	0	101.22	1640	29	95.3	1090
    102.83	2000	37.92	87.8	21.8	102.05	0	0	0	0	102.42	1840	27	95.3	1180
    104.03	2600	60.47	97.6	24	103.23	0	0	0	0	103.63	2440	26	95.3	1360
    105.23	3160	117.58	100	15.8	104.44	0	0	0	0	104.84	2960	26	95.3	1810
    106.42	3720	140.47	100	18.8	105.63	0	0	0	0	106.03	3520	26	71.8	2320
    107.63	4200	157.83	100	19.5	106.84	0	0	0	0	107.24	4040	26	71.8	2420
    108.74	4640	200.47	100	17.3	108.02	0	0	0	3	108.41	4520	26	74.9	2470
    109.94	5160	232.81	100	13.5	109.14	0	0	0	3	109.54	5000	28	78.4	2540
    111.13	5600	247.36	100	16.5	110.34	0	0	0	2.3	110.72	5480	30	80.4	2540
    112.33	6040	252.81	100	16.5	111.53	0	0	0	2.3	111.91	5880	32	83.9	2540
    113.54	6400	263.69	100	15	112.73	0	3	0	2.3	113.13	6280	33	86.3	2540
    114.74	6880	267.53	100	15.8	113.95	0	4.5	0	4.5	114.36	6720	36	87.5	2540
    115.93	7200	261.92	100	13.5	115.14	0	4.5	0	4.5	115.53	7080	39	88.6	2540
    117.13	7480	271.5	100	13.5	116.33	0	4.5	0	3.8	116.74	7400	41	89.8	2540


    The dyno compared to the revo which was on there before.. (highest K04 car ever here btw! tough act to follow - hehe)
    the wobbly drop off >6krpm is aligned with the fueling going lean with dropping fuel pressure after then. New pump will fix this



    I have also come to the conclusion that wellys car is a Mutant - nothing gets quite as much as his did.. Freakish.. lol
    Last edited by badger5; 22nd September 2011 at 14:02.
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  3. #2
    1st Gear

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    Good results Bill, i guess hasn't got large port head is it?
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  4. #3
    www.badger5.co.uk

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    it has.. but no wmi..
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  5. #4
    s3dave's Avatar
    TFSI Hybrid

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    has that got the rs6 comp wheel bill?

  6. #5
    S3 Paul's Avatar
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    Is this the Spec CR will be offering their hybrid in or a special job for you?
    Noggy Blue 2001 S3

    I ask questions because i change my mind so much. If i ask questions you have already covered... just leave it be?

  7. #6
    Prawn's Avatar
    My other car is a MINI!!!!

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    Looking good Bill, amazingly high airflow figures considering the bhp output.....

    As for Wellys being a mutant, could i suggest that the only remaining difference between it, and all the others you've done, is surely the XS manifold?

    Every other conversion has either been with a stock manifold, or a short runner type in a similar layout to stock? Like Dougs Franken manifold, and your custom built one, compared to the XS manifold, being all equal length with an awesome 4-1 collector.

    Also, the fact that fitting the XS manifold alone took it from 302 on the ported stock mani, 330 on the 034, then straight up to 344 on the XS, surely that's suggesting that it's flow capability is WAY above and beyond the others?
    -------------------------------------------------------------------------------------------------

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  8. #7
    www.badger5.co.uk

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    Quote Originally Posted by s3dave View Post
    has that got the rs6 comp wheel bill?
    no this is the 2283

    Quote Originally Posted by S3 Paul View Post
    Is this the Spec CR will be offering their hybrid in or a special job for you?
    Its built to a very specific spec I have drawn up base don my experiences thus far

    Quote Originally Posted by Prawn View Post
    Looking good Bill, amazingly high airflow figures considering the bhp output.....

    As for Wellys being a mutant, could i suggest that the only remaining difference between it, and all the others you've done, is surely the XS manifold?

    Every other conversion has either been with a stock manifold, or a short runner type in a similar layout to stock? Like Dougs Franken manifold, and your custom built one, compared to the XS manifold, being all equal length with an awesome 4-1 collector.

    Also, the fact that fitting the XS manifold alone took it from 302 on the ported stock mani, 330 on the 034, then straight up to 344 on the XS, surely that's suggesting that it's flow capability is WAY above and beyond the others?
    you cant ignore the WMI contribution to timing/cooling - wellys had it, this does'nt (yet) - his could run 21 degree timing this one is 13-17deg under same conditions with a failing fuel pressure over 6krpm..

    XS merge collector is a nicer flow path to me. The FT mani runs smaller bore pipe than mine did.
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  9. #8
    www.badger5.co.uk

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    Quote Originally Posted by S3 Paul View Post
    Is this the Spec CR will be offering their hybrid in or a special job for you?
    I cant speak for CR.. sorry, I dont know.
    Its a specific unit I asked to be made to exacting spec - we know how well (not!) Danes Cr went, so I was not going to allow that to occur again from sloppy spec/quality this one was built by their top guy to the agreed spec.
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  10. #9
    S3 Paul's Avatar
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    Ah, Ok, i need to decide what to do with my spare hybrid CR currently have.
    Noggy Blue 2001 S3

    I ask questions because i change my mind so much. If i ask questions you have already covered... just leave it be?

  11. #10
    2nd Gear

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    Just to let people know the car drives very nicely, 3/4/5 gear pull really well and nice and smooth on cruise

    Had a little problem as the MAF gave up the ghost <1 g/s at 3000 rpm, probally a shock to the system with all the extra airflow, replaced and all is well.

    A additional DA31 fuel pump is on the way, then I will give it the full beans,

    Then I will start thinking about WMI, with or without the additional tank??

  12. #11
    www.badger5.co.uk

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    cool... wmi for the win.. fo sho
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