Stacey's Belated Yo Yo Build Thread

[StaceyS3]

Yep by design I might add.

suffering with muchos hay fever today which has'nt helped.
Tial project tomorrow.. and it looks pretty fiddly.. then oil drain, and coolant lines...

Did you have a minimum boost level in mind? Not checked the tials opening pressure as yet.. will do that tomoz.

Yeah remember you saying was deliberate placement of boxes to get it to sit tight to thw floor pan.....so I can now slam it on some air bags :undewech:

Not sure about the wastegate as suppose its a balancing act between something being capable to keep it shut for response and having a low boost setting?

What would you reconmend? 1 bar?

 

[badger5]

I will aim for a bar yea.. same as tufftys

 

[badger5]

WG springs adjusted from 25psi opening!!!! down to 15-18psi now.. 3 springs in there, now 2.

Just ordered 2" vband clamp kit to make the joiner for external gate off flexi to the rest of the system.. will chase supplier see if they can do a next day delivery.. fingers crossed. Will weld up top piece to gate finish welded this afternoon.. Everything is uber tight, but we do have some clearance. Definate sequence of assembly required. Lost count of how many times on and off the wg and turbos been this morning, and ramp up ramp down... Very time consuming job.

 

[badger5]

 

[StaceyS3]

Looks brilliant and is all very snug

Cant remember where I read the info for spring combos but know I aimed for around 1 bar but obviously no where near that lol

 

[badger5]

I think Tial make their figures up from fairy dust... They are always miles off. I am mean Miles off! lol Used to it by now but its a pia to need to change springs from what you ordered because they get it so wrong.

anyhows.. tial gate pipe as far as I can do until 2" vbands arrive tomorrow (hopefully)

 

[badger5]

PIA job this is.... hot, sticky day... Boo

 

[badger5]

 

[badger5]

 

[Andrew@A.L.D]

Top work bill

when will you be mapping her? I bet she beats mine on power

 

[StaceyS3]

Looks wicked Bill :thumbup:

So I suppose thats the exhaust finished now

I hope it beats you previous results Andrew but will wait and see.....500 would be an absolute result

 

[Scullies]

Did you start it up. Huh....huh... Did you?

 

[badger5]

oil and water lines next.. oil drains going to be a proper cnut to fit in... kinda busy all around the turbo. lol

weekends mission..
wish us luck

 

[Andrew@A.L.D]

Looks wicked Bill :thumbup:

So I suppose thats the exhaust finished now

I hope it beats you previous results Andrew but will wait and see.....500 would be an absolute result

It should do

I really need to get round to getting my new down pipe and system done also i'm going to step up to a 44mm wategate as the 38mm one is on its limits with mine i think?, funny as i have never seen any boost creep with my set up but i don't want to risk it anyway

 

[Jason.s]

Pics of rear with oval tip needed lol

 

[StaceyS3]

oil and water lines next.. oil drains going to be a proper cnut to fit in... kinda busy all around the turbo. lol

weekends mission..
wish us luck

Good luck

It looked challanging without the DP and wastegate pipework so can only imagine what its like now

 

[StaceyS3]

It should do

I really need to get round to getting my new down pipe and system done also i'm going to step up to a 44mm wategate as the 38mm one is on its limits with mine i think?, funny as i have never seen any boost creep with my set up but i don't want to risk it anyway

Cant wait to see what yours will do when pushed

Would have thought you would be alright as from what I have read the higher the target boost the smaller the wastegate can be used and that people generally have problems with creep when trying to run lower boost?

The bigger gate on mine was purely down to james lcr having creep on his 38mm gate, but I think a lot of it could be down to mani design

 

[Andrew@A.L.D]

True i just want to get mine running 35/38psi

 

[badger5]

It should do

I really need to get round to getting my new down pipe and system done also i'm going to step up to a 44mm wategate as the 38mm one is on its limits with mine i think?, funny as i have never seen any boost creep with my set up but i don't want to risk it anyway

I believe yours is choked by CTS's 2.5" downpipe outlet section. When you get the larger one done I think you will be surprised quite the difference it makes to everything.

 

[Andrew@A.L.D]

The 2.5 downpipe has done well so far but it has to go now

I do hope it makes a massive differents with the 3 inch plus downpipe

 

[Broken Byzan]

True i just want to get mine running 35/38psi

Why so high? That's race/Quatermile type boost and they don't care about drive ability or longevity

I don't even blow my tyres up that much...

 

[Andrew@A.L.D]

The gtx3076 is more efficient at them pressures. The rest of the engine has now been built to cope with it now

 

[badger5]

The gtx3076 is more efficient at them pressures. The rest of the engine has now been built to cope with it now

 

[badger5]

The 2.5 downpipe has done well so far but it has to go now

I do hope it makes a massive differents with the 3 inch plus downpipe

If any of what I have shared with you on your post links has sunk in, you will realise the difference back pressure on the turbine vs its effect on the efficiency of the setup, you 'know' the 2.5" would have been like blowing thru a straw... and would have been significantly more power for 'same' boost levels you ran.

total flow.. you know this

New revision should be mental... look fwd to seeing it

 

[StaceyS3]

Would have thought a downpipe should definately make a nice difference on yours mate as im sure if a k04 gains from a bigger bore dp then that would be magnified with a turbo of your size.....theres definatley more ponies to be seen out of yours yet

Had a look at my comp map with that conversion table and that suggests that mine will peak around 28 psi which is lower than I thought really but supoose won't really know where the peak will be until Bill plays on the dyno

 

[badger5]

Back Pressure difference on Garys MK2 I recently made its 3" full system.. from its previous 2.5" system.
For no other change in mapping, it rose from 400bhp to 450bhp... 50bhp gains not to be sniffed at... All fixed duty cycle by its Greddy EBC.
and that "just" runs a 3" downpipe we made when we first built it a few years ago... 3" rest of system and reduced back pressure and noise reduction just helped it run more efficiently.. and made more power. Go figure

 

[badger5]

Would have thought a downpipe should definately make a nice difference on yours mate as im sure if a k04 gains from a bigger bore dp then that would be magnified with a turbo of your size.....theres definatley more ponies to be seen out of yours yet

Had a look at my comp map with that conversion table and that suggests that mine will peak around 28 psi which is lower than I thought really but supoose won't really know where the peak will be until Bill plays on the dyno

More boost more heat to contend with.
More boost would kick up the mid range torque, but I think the convergance of the peak torque falling away quicker @ the same kind of level of bhp.. If pushing it to hard too soon, the cyl temps will rise and when up in the revs we will see if tolerating less timing, which it will pull, increasing egt's further.. Thats my predction based on having been doing this for a while.. Balance of how hard to push vs sustained top end without it getting too upset about the temps. wmi of course will be helping stabilise the temps and combustion, so a very good addition.

Oil drain is a proper PIA, although think we have made something which could work. Need some braided hose tho to complete and a fitting to weld onto the lower part of the oe pipe. Water pipe I have run out of it seems (metal 3/8") and have ordered some which hopefully with get there tuesday. Will try and get the oil drain pipe bought and collected somehow tomorrow. All yesterday making iterations on how the hell to route it at all.. lol.. oh joys of custom BT's eh

 

[StaceyS3]

Back Pressure difference on Garys MK2 I recently made its 3" full system.. from its previous 2.5" system.
For no other change in mapping, it rose from 400bhp to 450bhp... 50bhp gains not to be sniffed at... All fixed duty cycle by its Greddy EBC.
and that "just" runs a 3" downpipe we made when we first built it a few years ago... 3" rest of system and reduced back pressure and noise reduction just helped it run more efficiently.. and made more power. Go figure

Sounds like a right result

The S3 should certainly flow...... as its all about the flow

 

[StaceyS3]

More boost more heat to contend with.
More boost would kick up the mid range torque, but I think the convergance of the peak torque falling away quicker @ the same kind of level of bhp.. If pushing it to hard too soon, the cyl temps will rise and when up in the revs we will see if tolerating less timing, which it will pull, increasing egt's further.. Thats my predction based on having been doing this for a while.. Balance of how hard to push vs sustained top end without it getting too upset about the temps. wmi of course will be helping stabilise the temps and combustion, so a very good addition.

Oil drain is a proper PIA, although think we have made something which could work. Need some braided hose tho to complete and a fitting to weld onto the lower part of the oe pipe. Water pipe I have run out of it seems (metal 3/8") and have ordered some which hopefully with get there tuesday. Will try and get the oil drain pipe bought and collected somehow tomorrow. All yesterday making iterations on how the hell to route it at all.. lol.. oh joys of custom BT's eh

Understand what your saying bill....more boost doesnt always equal more power and if you can get simular power for less boost and heat with more timing then thats got to be a win, will be very happy if not hitting a wall always with egts like the old setup (heat pump) when driving "spiritedly" lol

Just caught the pics on FB and its looking good, have you decided on routing on the upper part of the drain yet as that looked rather crowded up there?

 

[badger5]

Upper part was already done, lower part was the more challenging bit. Transfer box, drive shaft, manifold runners etc all in the way.. yay!

you can see in this bit the top section which drops behind the manifold runners, and then curves back in and under them just above the transfer box, with a -10an fitting on the end, onto which the short flexi hose section sits. The new lower section was then fabricated to coincide with this hose, so no stress is on any of the pipes. I will cover the flexi hose in some heat wrap also given its sat under and around some very hot things inevitably.

Mid section which joins upper

Lower section which joines mid flexi

 

[Sam_]

I've got all this to come

Going to use the TSR downpipe though I think just for ease (don't know of any decent fabricators like Bill, etc over here).

 

[badger5]

drains upper section and complete assembled off car

and complete thing ready to leak test before I finish assemble it onto he turbo and sump etc..

 

[badger5]

Also the locking rings I added to it to keep hotside bolts from backing out (which they seem prone to do on Tial hotsides)
From Owen Developments... same as badgerwagens turbo has

 

[Sam_]

Ah yeah, I just got my Pag Parts .72 vband housing and he uses those little locking tabs. Inconnel bolts too apparently.

A shame you don't sell the oil/coolant lines as a kit

 

[badger5]

 

[StaceyS3]

Looks wicked and very professional

Them locking tabs should definately help....its all the little things like that make a huge difference to the reliability and something so small could be so costly if they fail

 

[badger5]

water lines now invented and created.. funky shape on the one.. I think I should name this build fiddly as ****.. lol

 

[Jason.s]

Fill her up and get her fired up! Video of first start up needed too!

 

[badger5]

will see how many leaks it has once fluided up...

 

[Scullies]

will see how many leaks it has once fluided up...

0 leaks, because this baby needs to start prowling the streets. That turbo is begging to suck up half the atmosphere and throw flames out the exhaust, while its eating exotic cars for breakfast.