BuuBBa's S3 project

[BuuBBa]

Hello AS people, and greets from Finland!

After 7 months I have decided to get some more power, but cause VAG cars are new to me, I would like to have some advices.

My current setup (as I bought it) is:
GT2871R .63
FMIC
680cc injectors
3" DP + Rays (same as Simons) cat-back
Some stiffer clutch

I bought another engine (AGU) which had hole in sump, but I have not had time to open it, and check the possible damages.

The setup that I have been thinking:

2,0l stroker crank (bought)
Woessner 82,5 mm, CR 9,2 pistons
H-profile con rods with rifle drilling
Big port head (bought)
Big port manifold (will polish a bit) (bought)
Bosch 044 fuel pump + new lines
1400-2000cc injectors
ARP-bolts (main, head, cam, crank)
Calico rod bearings & OEM main bearings
TFSI coils
R32 TB
S4 MAF
Fluidampr

And much much more to come.. At least oil pump, cam chain (how about tensioner?), timing kit + water pump (which pump?).

First I will be using the GT2871R and stock valves & valve springs.
Hoping to see near 400hp with E85.

Suspension will be B8 (bought) + eibach, supersport top mounts, adjustable rear arms (parts for manufacturing bought) and some poly bushes.
Brakes will be upgraded with decent pads at first.

If You see some great offers or used parts (which I could need) on USA www-sites, please let me know..
My uncle will bring me the parts end of the July when hi moves from USA back to Finland..

Hoping to get the engine done this summer, but that depends on wallet and how sympathetic my GF will be concerning the build...

As I said I have very little experience with my S, so hopefully people can stand my silly guestions

All ideas, praises, disses and guestions are welcome!

 

[s3dave]

Maybe go for a GT30 turbo?

 

[Dani_B19]

Any pics of the car?

 

[BuuBBa]

Maybe go for a GT30 turbo?

Bigger would be better, but at first I will be using the 2871.
Mayby after a year or two I`ll upgrade the clutch, make full head work and then go for bigger turbo. Was thinking about holset HX35 super or BW EFR-serie (if the prices will drop considerably).

Any pics of the car?

Will post some pics after I get my camera back from service (forgot the memory card inside of it)..

 

[BuuBBa]

Lets start with guestion concerning the bearings.

I was going to get Calico rod bearings, but now found some ACL Race bearings, which looked good (many good reviews on internet).
The kit would contain main, rod and thrust bearings, but it has one note that I would like to know.
"Note: Rod bearing has tab at the end" Is that the right set to go with IE or SCAT con rods (which I was thinking)?

 

[BuuBBa]

Few pics with winter tires:

Summer wheels (OZ Ultraleggera 8x18) are waiting center rings, which should arrive friday.

Also something that I have bought:

I-beams
044 pump
Injector dynamics 1000cc (I thought that 2000cc would be too big for stock ecu, and becaus found "cheap" set of id1000).
Gearbox bushings from verdict motorsport
ACL race bearings

Now trying to choose which pistons I should get.. Found some honda guy who offers CP pistons pretty cheap, so asked if he could get me a set for Audi.. With those CR would be 9.5:1, but I would like to have skirt coated and some upgraded pins also..

Still waiting Eibach springs (got wrong set last thursday, and now waiting for right one).

Damn school takes all my time now, cause all the exams are piled up for next two weeks...

What are the cheapest H-beams from UK (or abroad to UK)? I had a conversation with my local part dealer, and thought that the prices of their rods were pretty ok.. Just thinking if I could offer rods for You, AS-guys, a bit cheaper than Your dealers..

 

[Sam_]

2000cc injectors?! Wouldn't that be like 4 of these?

 

[BuuBBa]

Sam_, something like that

But I`m going to run with ethanol (E85) which needs to be injected about 30% more than petrol.
With that big injectors, the quality will matter a lot, and thats why I choosed Injector dynamics 1000cc which SHOULD be best on market. To get 400 crank hp I should see duty cycle around 85% with 3bar fuel pressure.

 

[BuuBBa]

Just little update..

Yesterday I changed oils for rear diff, gearbox and engine. Also gave the motor flush with Forte.
I used Redline 75W90 to rear (about .8l), Redline MT90 and Shockproof to gearbox (1.9+0.4l) and Castrol Magnatec 5W40 to engine. The gearbox quieted a lot especially while engine breaking and the valvetrain came quieter also. Also replaced the rear wiper with glas plug.

The pistons (Wossner 82.5, CR 9.5:1), ID1000cc injectors, I-beam (Brute), 330lph delphi inline fuel pump (044 will be on sale), and all the bearings has arrived.

I was going to order the S4 MAF (078906461B) but found out that IF, I will change the turbo, I will max out the maf readings. So is the RS4 maf next step or is there some size between S4 and RS4 mafs? The max reading should be 380-400g/s.
This was very usefull site concerning mafs (especialy S4 and RS4): Mass air flow - S4wiki
What is the part number for RS4 maf? Or is there some other maf with same diameter which would work?

EDIT: I assume 077 133 471 would be the right one?

Now the heater blower is making something funny.. Usually when it blows max it works well, but when it tries to get the temperature stable it blows hard 1sec then few seconds less, so it fluctuates a lot. What could cause? Interior temp sensor?

 

[BuuBBa]

Fast driving while the parts are coming from USA (in container).. Well rear wiper deleted and glass plug installed, wow..

Few questions concerning the rear bushings.
I'm going to make adjustable rear control arms and same time the bushings. Should I go with polyurethane or does those squeek?
Same time the rear ARB is going to be changed to 16mm (21F and 19R when the engine is swapped) and once again, should I go with oem rubber or PU? How about the clips, cause I found two different part numbers for those: 8L9511411 and 8A0511439. What is the difference?

The heater blower still makes that funny fluctuating..

The turbo is going to be changed to Holset HX35 Super (54/55mm) or something else with similar wheel sizes..

 

[Dani_B19]

Pu bushes for both the tie arms and arb will be fine, just grease them up properly before fitting them.

 

[Prawn]

Sounds like an interesting project mate! I hear lots about E85 on US and other forums in Europe, never hear anyhting about it in the UK at all

 

[Dani_B19]

Guys on vortex seem to love e85. Can you even get it over here?

 

[BuuBBa]

Thanks Dani_B19 and Prawn for the comments!

I should get around +30hp and +50Nm with e85 over 98oct. Also the price of e85 (1€/l vs 1.63€/l) is still so much cheaper in Finland, so even it takes ~30% more it will be cheaper to drive with it. But the fuel economy is not the reason for going with e85

Has anyone heard or tried Strong-flex bushings: Strong-Flex.eu - Elastomery w motoryzacji i przemyśle ?

The car is now in my friends hands, who cleans and polishes it. I'll post pics after sunday when I get it back!

 

[BuuBBa]

Some updating..

Most of the (bottom) engine parts has arrived.

The suspension have been updated to Bilstein B8, eibach springs, adjustable rear tie arms (+ Strongflex PU bushings on those) and PSI top mounts. The top mounts unfortunatelly creaks too much, and now looking for FK lowering spring plates but cant find those anywhere local.
Could someone act as a middleman to help me get the plates? Venom motorsport has those but they dont offer international shipping..


What do You guys think that, what valvetrain parts I should change or updgrade? I was thinking about inconel exhaust valves, stiffer springs, guides, and lighter retainers, but how about the std inlet valves and lifters? Can I use the old ones (just clean those) or are the lifters done after 200k km (~125k miles)? First I will use NA cams and maybe later upgrade to some cat cams or IE ones.. The rev limiter will be around 7100-7500rpm.

Just few pics of the new suspension parts

Old vs New

Adjustable rear tie arms and PU bushes

 

[BuuBBa]

Bought genuine Ross tech cable and now have been logging few times.

First looked block 032 which shows 2,8% so there might be tiny boost leak somewhere. Next scanned the fault codes and VCDS gave "system too rich bank 1" and "pressure drop between xxxx". I cleared the codes and went for a logging drive.


RPM MAF N75 % Boost specified Boost (actual)

2120,00	35.14	84.3	1710.0	1100.0
2320,00	45.28	84.3	1090.0	1190.0
2600,00	53.00	84.3	2430.0	1250.0
2920,00	71.97	84.3	2540.0	1320.0
3320,00	102.64	84.3	2540.0	1480.0
3840,00	156.31	84.3	2550.0	1800.0
4480,00	194.94	71.0	2550.0	2370.0
5120,00	210.42	72.5	2550.0	2500.0
5720,00	241.00	67.8	2550.0	2450.0
6280,00	251.97	67.5	2550.0	2350.0
6760,00	265.61	63.5	2480.0	2340.0

Engine load was 191.7 between 3840-6760rpm
After the quick drive and logging I scanned again and found just "system too rich" code, but not cleared it. Once again the 032 was 2.8%.

Then I went for another drive and found something interesting. Max engine load was this time 165-180 at around same rpm, maf max was 234g/s and the N75% 1.5 through the RPM lane. Also the actual boost was just 0.9bar.

So is the N75 faulty or does the map suck and make some safe mode for boost?

 

[Andrew@A.L.D]

Nice project

As said above 2000cc injectors are massive for that turbo

Go GT/GTX30 and some 830/870cc injectors also it might be worth swapping the S4 maf to a RS4 maf? That depends on what power you are going for

 

[BuuBBa]

Thanks Andrew!

Well the new setup will be actually a bit different than the original post says. Shame that its not allowed to edit old postes..

Bottom: 92.8mm crank, I-beam brute (rifle drilled), 9.25:1 82,5mm Wossner pistons, ACL race bearings (has some coating), ARP bolts, new oil pump. All those are waiting in the garage.

Fuel system: Injector dynamics 1000cc injectors, 4bar FP regulator, all new fuel lines, Walbro 416lph fuel pump in-tank which feeds the engine and Deatschwerks 200 pump for pumping from side to side of the tank (acts as a second output of original fuel pump). I will run the engine with ethanol (E85) so thats why so big things.. The pumps are still in the "to buy list".

Misc: Xcessive manufacturing plenum with AEB runners (just like Tuffty), Holset HX35 "super" turbo (54/60mm wheels) and home made divided manifold for it. Any of these I haven't bought yet. The price of holset is less than half of the GTX30, and the holset turbos are still very good quality and those can be rebuilded if necessary.

All the gaskets, chains etc. are bougth but still need the fluidampr, RS4 maf and bigger TB. Propably missed something..

Two weeks ago I bought a complete head from VWvortex. The head was ported and fully built with ferrea valvetrain. Unfortunatelly the head has not arrived and the seller haven't replied any my messages. Paid with paypal so I'm not too worried about money but would be nice to know if I have to look the valvetrain parts and let some local pro make the head. That just means that it will be stock large port as I dont have money fort porting atm.. I think I'll start with the NA intake cam.

As the injectors are so small (for E85) the power will be limited aroun 450hp. I calculated that with 4bar FP the injectors duty cycle is around 88-90% with those power levels. Unfortunatelly next size that Injector dynamics offers are 2000cc and I dont think I want those with stock ECU.

I still have about a year before I graduate so thats why everything progresses so slow. And its my only vehicle.. I will (or hope to) make better diary with pics since the project with the engine beguns..


But still confused about the current situation (see my previous post) and would like to hear some advices.