S3 PE1820 big turbo build

Welly said:
I think, with a little time and thought you could probably get comparable gains for a lot less money spent.

On GT30 upwards, yes, I can see the point.
Click to expand...

Soon see mate... should be getting my new FMIC this week so curing the pressure drop issue I currently have leaving the last restriction as the std inlet mani... see how it goes I guess...

<tuffty/>
 
tufftybloke said:
Soon see mate... should be getting my new FMIC this week so curing the pressure drop issue I currently have leaving the last restriction as the std inlet mani... see how it goes I guess...

<tuffty/>
Click to expand...

Oh yes! its all go in our neck of the woods!
 
Just give me a month...
 
Maybe, although having the k04 hybrid inside sticker could almost be like having a tdi badge on the back if it ends up like Bills Ibiza back in the day...
 
Dane said:
Maybe, although having the k04 hybrid inside sticker could almost be like having a tdi badge on the back if it ends up like Bills Ibiza back in the day...
Click to expand...

I'm not convinced that is going to be true mate to be honest. That hybrid will be hard to beat in the respect of power delivery.
 
yeah it was pretty awesome, but fingers crossed that the IHI does it for you.
 
Welly said:
Tempted with a good inlet manifold I must admit, however the cost of them is horrendous, and for this build it's simply money I haven't got.

The missus would out right cut my nuts off if I spent £700+ on an inlet manifold.
Click to expand...

Ye I do agree it is a very expensive mani but it does work but weather the gain is worth the price, probably not. I would have thought a SEM mani on yours or Pauls setup would give very good gains.

Welly said:
LOL, should I get one of these to replace the one I have now?

IHI inside stickers. For IHI turbo,vw golf, bora 1.8T on eBay (end time 03-May-11 20:47:04 BST)
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Ye defo get that sticker. I have never seen that on a S3, seen loads of hybrids and 1.8T etc sticker but not a IHI.
 
audi upgrades
So... I won't having that AJH manifold then. Turns out the bloke is **** knocker and has decided he wants more money for it.

To be fair, it looks like a bit of an **** to fit. The runners, being slightly curved, means that the entire manifold sits a little to the left of the OEM one. I'm concerned that on fitting, there will be space issues with the charge pipe.

Also, all the attached sensors to the manifold will have to have the wiring extended to make them fit into their new holes - the IAT being the main one.

Not worth the hassle, I will just port mine....:ninja:
 
finesse said:
So what options do you have?
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Assuming you mean with regard to the inlet manifold? Two realistic ones. Port my own out as much as possible, mainly the inlet port to try and produce less of a step on the way into the head. Also, I could look at buying an after market inlet manifold - however this is going to be VERY costly, and it's money I don't have.
 
aragorn said:
could you use an AGU one but cut/weld the throttle body onto the right end?
Click to expand...

I did think about this, however the problem would be that you would have to weld it directly onto the plenum to achieve the best effect, and that would be a bit of a pain TBH.
 
audi upgrades
Yep that one is, but they do mention in the description that they do a design for large port heads and/or the runners do look 'large'
 
Your poor dremel.:nyah:
 
Last edited:
Another great thread from you mate. Hope it all goes well. You certainly put plenty of thought into your projects, esp with the little paintshop pics lol.

Keep it coming!
 
Welly said:
Very tempting...
Click to expand...

I did consider this one too mate... looks a better finish than the OBX but too cheap to be an RMR unless the seller has no idea what they are selling...

Short runners on this one but not sure it will make too much difference all things considered... I think I will hold out for a SEM myself...

<tuffty/>
 
Good progress yesterday - a day off (with a few errands to run as well) an the lovely weather made me crack on.

Did my most hated of jobs - removed the engine mount, reset the tensioner and installed the new cam belt. Thank god that's out of the way!

Started off by taking some comparison shots of the turbos as the hybrid is going today:

23.jpg


I also took my 'mocked' (or bodged) oil lines up to the hydraulics company who will be making them. Was hoping for them to be back Friday -however that wasn't to be - Monday they should be sorted.

24.jpg


Then moved on to created the correct shape and size charge pipe....

25.jpg


Then carried on my manifold porting work.... The first picture shows the difference between the porting of one side and not the other, and then the completed port.

26.jpg


27.jpg


Then prepped my new TIP with the parts bought for it. I have decided the have the 007P welded directly to the 3" alloy on the TIP rather than mess about with hoses connecting it. Not sure how this will work out, however time will tell....

28.jpg


Then finished a few other housekeeping bits and bobs.

Finished up the night with this:

29.jpg


Well deserved - I was knackered.
 
What its not finished and running yet Welly? Your slacking lmao. Looking good mate so when do you want to come up and work on mine?

Do you think I could fit the XS manifold with out taking the head off or will it just be to much of a nightmare?
 
Speedy Steve said:
What its not finished and running yet Welly? Your slacking lmao. Looking good mate so when do you want to come up and work on mine?

Do you think I could fit the XS manifold with out taking the head off or will it just be to much of a nightmare?
Click to expand...

I would say it is next to impossible mate to be fair. The need for studding the turbo requires the head to be off really...
 
A few bits ordered arrived through the post today - turbo hoses and a few other odds and ends.

The inlet manifold is finished, rocker cover repainted, turbo hoses trimmed and fitted, throttle body ported.

Awaiting a few bits now and I can start putting it all back together...

Some photos:

30.jpg


31.jpg


32.jpg


33.jpg


34.jpg
 
What you used to port the manifold mate? That the standard TB?
 
Your certainly moving fast on this build bud. Mines dead in the water until i get the exhaust made this week then i can crack on with boost pipes etc as you have

enlighten me on your turbo choice buddy, i know its an ihi but whats the spec and comparable performance expectations?
 
Dani_B19 said:
What you used to port the manifold mate? That the standard TB?
Click to expand...

My Dremel mate, with sanding bits to give a nice smooth taper. Seems to have worked really well and hoping that it will help the transition from small port to large port.

It is the standard TB yes, I've deliberately left it with the rough finish - I think it will help the water meth atomise on the way through the TB.
 
MUSH said:
Your certainly moving fast on this build bud. Mines dead in the water until i get the exhaust made this week then i can crack on with boost pipes etc as you have

enlighten me on your turbo choice buddy, i know its an ihi but whats the spec and comparable performance expectations?
Click to expand...

I like having something in hand to get on with - I get bored easily... lol

Turbo choice was down to several factors. Availability, price and the need to do something different. With respect there are a few GT30 builds these days, however you don't see as many IHI builds.

Also, If the turbo goes south it's very easy to get another, and very easy to fit in top mount form.
 
Yep top mount is the way forward, you may have even pulled your last head off..!! Lol
 
Very nice, you just use normal flap wheels? Looking into starting mine next, should be fun :) lol.
 
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