Dane's Hybrid Conversion Thread

Lol it's not that hard to spot ;)

Nice one Bill, this is why I don't take my car anywhere else, you the man!
 
audi upgrades
yea, but..........
Ordered a smoke tester which should arrive today...
Power is not what it should be currently, and although injested airflow is 240g/s region, the corresponding power/torque is reading low. Its behaving as if its got a boost leak, but thus far we've been unable to find where on earth it is.. Hence ordering several hundred quids worth of Smoke Tester, with UV leak equipment to go searching.
We have done boost leak checks where we can access the pipework and 2bar held ok, and one small leak found in my welding of the outlet alloy, via pin hole I had'nt noticed *(shame)* and remedied and another from a failed silicon charge pipe off the turbo, which has been mysteriously getting "oiley" on its outside since first seeing the car.. checked with 10psi under water and it blows bubbles. New one here to fit when Dane's back for leak checking with the smoke tester

There's a 'hiss' kind of noise going on, but its source is elusive as hell. Hoping smoke tester reveals where the hell its coming from.
Also some actuator adjustment to do to squeaze it a little more and hold boost @ high rpm a little more.

Upside, clutch works fine, it takes loads of timing now like wellys/tufftys, zero leaks from anything, inc gbox, so for once in its life its *touches wood* leak free fluids wise.

One things fo sho, hybrids aint plug and play.
 
been investigating with smoke tester on Danes this afternoon/early evening..
found a leak on the TIP on the billet part to turbo.. small but evident. Also top hose on TIP leaked onto branch piece. fixed them.

PCV is leaking on its elbow off the breather block.. With the UV dye in the smoke, you can see where it is in the dark. Very cool to see evidence which is'nt as evident when smoke wafts by gently.. It lights up green under the uv torch. I am liking my new kit a lot.

We did a charge pipe forwards test, bunged up exhaust tail pipes also and saw nothing. Then did a TIP forwards and found the couple mentioned. Then after fixing them (not PCV, need a part to fix that one) did exhaust backwards. Smoke peeing out of the rear box exhaust clamps and also from the decat to miltek join. We ran out of time for tonight but will resume tomorrow pm.

Whilst here, new replacement under warranty turbo silicon pipe fitted also. Another known leak gone. Actuator was also tweaked up again to 14psi open pressure.. Started at 9 as supplied, then adjusted to 12psi, and now max'd at 14psi.. We will see whats occuring in due course.

Refilled wmi again :p and off he goes.
 
Never heard of that UV smoke test kit. Sounds ace though! Nice one
 
It works well for sure! It was good to be of help for once :)

It doesn't feel like we've found the extra horses at the moment though so well see what happens tomorrow
 
Meh its the other side, we need to seal it up to eliminate it from getting into engine bay, it sounds sweet though :)

Get one!
 
I had mine tested with a uv smoke kit, they are fantastic, definitely a worthwhile investment for you and could save a lot of time in the future.
 
glad to hear it's running again dude, shame it's not making the power. I'm sure Bill will get it though!

Then you can delivery my turbo ;)
 
It's running ok, so I was thinking of doing a delivery run this weekend if youre around :)
 
I wont' be touching the engine before the Ring westy!

As sad as it sounds, I've got a goal in mind for what I want to achieve with just a ko3S, then I'll smash that lap time next year with the hybrid!

Dane, I'm about all day sunday. in portsmouth Saturday doing my roll cage :)

You're welcome any time sunday though dude, got tea and biscuits and everything!
 
badger5 said:
been investigating with smoke tester .... Very cool to see evidence which is'nt as evident when smoke wafts by gently.. It lights up green under the uv torch. Then after .... did exhaust backwards. Smoke peeing out of the rear box exhaust clamps and also from the decat to miltek join. We ran out of time for tonight but will resume tomorrow pm.
Click to expand...

Bill -- does the exhaust forward test reveal any possible leaks at the manifold or turbo flanges? Is this how you found the "pinhole" leak on the tubular steel?
 
slappy_dunbar said:
Bill -- does the exhaust forward test reveal any possible leaks at the manifold or turbo flanges? Is this how you found the "pinhole" leak on the tubular steel?
Click to expand...

Not completed the exhaust fwd test.. there was wafting smoke at the engine side, but pretty sure it was the big leaks in the exhaust clamps further back blowing fwd. Restesting tonight, fixing those leaks so anything else can be visible.

I did'nt have the smoke tester @ the time to see the pinhole in the tubular, it was visual blemish.. May not have been a thru hole, but I capped it anyhows just in case.

Preload has been added, it wont do more than 14psi (pump test, not run on dyno yet) without running out of travel. I am not expecting to see much difference up top, but we will see. Smoke test next to see exhaust back fwd and confirm whats occuring around the manifold. Boost side its 100% leak proof. PCV leaking, but is'nt connected to the manifold in any way.
 
W3STY said:
Ok ;)

It's interesting about the small leaks in the TIP. As there are a lot of bits involved in the tip there is probably quite a high chance of a leak compared to a full silicone TIP.
Click to expand...

The issue on the TIP was the billet part had'nt been smeared with silicon sealant like I say it should be. the top hose was the hose clip had slid off the hose (which was trimmed previously for std airbox, and short). Quick undo, slid down further, do up, all is good. Remember this cars intake has been on and off over a dozen times whilst doing this hybrid, with turbo swaps, actuator adjustments, actuator swaps etc etc..

The smoke test is cool tho.. liking it a lot.
£65 for the service for folks. (blatent plug)
 
Sooo, we hit a bit of a brick wall with this.

We double checked for boost leaks and triple checked checked the timing, there was a small leak around the actuator but nothing theres nothing that can be done and is kind of normal and there was nowt wrong the timing.

So we put it on the dyno and blue and white smoke started coming from the exhaust, I'm sure Bill will confirm the exact cause of the leak, I don't want to give out any miss information.

But I'm pretty much fed up hybrids now, and maybe the car, it's fought us every step of the way thus far! But the plan is to put my standard ko4 back on for now whilst I decide about a plan for the future, but I've put so much into it so far it would be a big waste to get rid of it.

My first thoughts are gt30 or rs4... But I don't want to give up lol
 
oh this is an anticlimax....!! Please crack on lol

Whats the idea then, engine or turbo gave up...?
 
audi upgrades
Sorry to hear you're having problems Dane. Persevere mate, it will be so much better for it when it comes right and you're in safe hands.
 
To support what Danes feelings must be after this traumatic hybrid experience.. We all feel extremely dissapointed in how this particular prolonged hybrid exercise has turned out. there is some ring blow by yes, and rings are not at their best but leakdown test shows a 25% so not terrible either. Compression is 210-220psi across all the cylinders, so its issues are not looking engine related. to confirm the oil smoke cause, we disconnected and blanked the oil feed to the turbo yesterday morning, after getting it warm before hand and it smoking, held the turbo stationary, and ran the same tests, no smoke. QED, source is the turbo. this is the second hybrid turbo on the car and we still get issues. A lot of wasted time (and I mean a lot) in this with defective parts ultimately ruining the outcome. :(

None of us are happy about this.. Least of all Dane and myself.

Positives... It has a very good flowing and cooling FMIC now, it runs a largeport head, water meth, already has rods in there for future.

Refitting the original k04, mani, and injectors and reverting to the previous map is to not check anything but to walk away from hybrids on this. Its too costly for everyone involved. We have all had enough in this instance.

GT30R becons.. :) lol

With RS4 ownership comes RS4 running costs... Remember engine out for most jobs on these.. ker-ching ££ labour times.
beware of out of the frying pan into the fire syndrome.

Let the dust settle, reverted to stock, and see whats best to do thereafter.

I will have my tubular exhaust manifold available tho barks if you want to run it. Proven beyond doubt to be functional, leak free etc etc .

In terms of comparison of F23 to Ver1 CR (my ported version), the 2283 wheel unit does seem to have more grunt & airflow.. If only you can trust a company to build it to the right and consistent spec, it has merit.
 
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