1.8T 20V Con Rod Failures

After our chat the other evening this is my next job. :thumbsup:
 
have there been instances of rod failure on stage 1 maps or even just standard engines?
 
ah, yeah i remember you had that failure, didnt realise you were stage 1. Do you think its too conservative to have new rods beofre going stage 1?
 
I don't think it's conservative to have new rods at any time. IMO 1.8T rods are gash.
 
Welly said:
I don't think it's conservative to have new rods at any time. IMO 1.8T rods are gash.
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ahh man! i hate reading stuff like this it makes me think theyre gonna go now everytime i drive my car :(
 
DaveA3 said:
ahh man! i hate reading stuff like this it makes me think theyre gonna go now everytime i drive my car :(
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You should be OK dude to be fair, what the output on your A3? Bear in mind that the S3s have the same rods as you (presuming you're an AGUer) and run more power standard....
 
You also have to put it on the choice of stage1 map also, all this 'low down grunt' with 'push in the back' torque is bad for the rods.
 
Welly said:
You should be OK dude to be fair, what the output on your A3? Bear in mind that the S3s have the same rods as you (presuming you're an AGUer) and run more power standard....
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185bhp with boost leaks lol should be about 190bhp think it was something like 214 lb/ft torques need to double check that. yeh im on an AGU.

cheers man thats good to hear :D
 
DaveA3 said:
185bhp with boost leaks lol should be about 190bhp think it was something like 214 lb/ft torques need to double check that. yeh im on an AGU.

cheers man thats good to hear :D
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You should be A OK mate, I wouldn't lose sleep.
 
superkarl said:
is a revo map a dangerous one then on standard internals?
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No, not dangerous. However, REVO maps are known for their aggressive delivery by all. Much less progressive than other maps, and that's due to the torque production. As Jo said, early and harsh torque isn't the best for the rods.

Many people are using, and have used, REVO maps for a long time with no issues. But out of the generic maps available, I would say they are the most likely to cause issues. That's not to say will.
 
i see what you mean. id want a more progressive map anyway. my car is off the road soon and after the wear and tear stuff i've got to do, rods are my number 1 before i get a map. better safe than sorry
 
People need to stop thinking there engines are going to fall apart any minute lol. Ye rods fall but its a very small minority that do and they tend to be running quite a bit more torque and power than the standard engine spec.

Im doing a con rod FEA assignment in uni now and wanted to do it on a S3 rod but havent got the dimensions on one to measure accurately.

Nathan
 
well perhaps if i change my rods because im too scared to go without doing it you could have my OEM rod to do your FEM :moa:
 
Lol thats sounds like a good idea to me.

Nathan
 
S3 Nattie said:
People need to stop thinking there engines are going to fall apart any minute lol. Ye rods fall but its a very small minority that do and they tend to be running quite a bit more torque and power than the standard engine spec.

Im doing a con rod FEA assignment in uni now and wanted to do it on a S3 rod but havent got the dimensions on one to measure accurately.

Nathan
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I have some in my garage - what measurements do you want? (or are you meaning you want to test to destruction?)

Also have some IE and Brute ones if you need a comparison.
 
I would need the following;

Length from top to bottom
Width of the rod
Diameter of the gudgeon pin and bearing but I think I have just found them on the net.
Distance from the gudgeon pin to the outer side of the rod.
The radius of the rod stem where it meets the gudgeon pin and the bear
Diameter of the stem just after the radius's top and bottom
The radius's, diameters and lengths of the intersect in the rod and how far into the rod it is to get a section view of the rod.
Would also need the measurement around the bearing but unsure how to describe them.

Its pretty easy to measure the rod but its then working out what happening within the engine such as cylinder pressure at certain rpm's, air/fuel mass within the cylinders, the acceleration and resistant forces acting on the rod, tension and compression forces, vertical and horizontal force acting on the rod and bending monents/loads etc to get a full understanding of what the rod if being exerted too.

Im actually doing my final year project on My S3 and might start a thread as it should contain very useful info.

Does anyone know what the factor of safety is on a S3 rod.

If I had one I would measure one up myself. I might be able to get one in the from a vag garage I know by me. Mainly have jags and Ford rods in uni.

Nathan
 
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Nathan, what package are you using for analysis? Ansys, Abacus, Catia, Solidworks?

I would guess a safety factor of 1.5
 
We have got solidworks but I dont use it, heard its quite user friendly. Were using NX now and I think NX7 is being installed over the weekend, think thats the latest NX verison you can get. NX is very good but like most software, it likes to freeze and run very slowly sometimes.

Nathan
 
If I listened to every horror story I'd heard about S3's etc, I'd never have got a remap and would of sold it a long time ago... Lol
 
well you hear the horror stories, and then the cost and pain in the *** of sorting it out. so if you can prevent it, you may aswell. i know i dont want to be buyin new engines. especially when your car has done as many miles as mine. Im over modding for power, i want to increase the longetivity of my car now, because i dont wana sell, so il keep till it proper dies. Rods just come into the equation when prolonging the life of it. its just a bonus that i won't ever need to worry about bending one. unless one day i have a spike of 500lbsft of torque or somethin crazy like that, which will never happen.
 
leggy said:
If I listened to every horror story I'd heard about S3's etc, I'd never have got a remap and would of sold it a long time ago... Lol
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Lol Im with you there. Everyone on this forum will try there best to give everyone else the best advise as possible and 99% of the time its very good advise. But theres got to come a point where you say its not realistic or cost efficient to do so for YOUR situation.

Nathan
 
NX makes me sick, but it is powerful.

I have a conrod I modelled here if you want......
 
Lol ye NX is very powerful software and it nearly literally made me sick last year when I was doing some work and it decided it wanted to just randomly freeze and shut off and I never saved any of my work. Good job I have a very understand lecturer.

You have got a actually working model of a S3 con rod. That would be interesting to have a look at.

Nathan
 
Not S3, just a generic one I used for analysis and mold and manufacturing in NX

NX:Flush::Flush:
 
Look, bottom line, I thought it was useful info for people.

It doesn't happen to everyone, but it DID happen to me.

If I can help people avoid the drama and cost that I went through, then I will ****** well try! lol.
 
Totally agree, it is a job which should be on every enthusiasts list.

It's not appealing because it doesn't provide epic 5bhp gain like an air filter or stop better like 8 pot brakes
 
I dont think you will have a lot of change out of a grand with new shells, oil, belt ,gaskets etc.

I agree with welly, he is not scaremongering, just giving good info that may or may-not be heeded, depending on your application......
 
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thanks guys, im not gonna rush out and do it, but food for thought, cheers Welly!
 
Welly said:
Look, bottom line, I thought it was useful info for people.

It doesn't happen to everyone, but it DID happen to me.

If I can help people avoid the drama and cost that I went through, then I will ****** well try! lol.
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I agree with you, thats what forums are for, giving members advise to benefit them or fill them in with info.

Just wondering, what are the torques for the shell.

Nathan
 
This is the reason why i wont do anything to the engine.
 
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