Time for a build thread....big turbo

[S3Alex]

So...tumble flaps and cold starts....


Anyone remember these...?




During it's last holiday,I had these fitted,and the tumble flaps removed.

Once the car is warm,the flaps make no difference to the way the car runs,and it may gain a few bhp and lbs with them removed,but those flaps DO make a difference in cold weather from a cold start.
It will start just fine,and idle without any coughing,but as soon as you put any load on,it hesitates and coughs and farts until the engine temp is above 80C.

I do know that APR have a software revision for cars running their software,and with flap deletes,but clearly mine runs Revo,and whilst it won't do any harm at all,it's fascinating to see what a small metal intake flap can do for a cold start.

Anyway....need the flaps removed for the next step.

 

[S.]

hey alex couldn't revo adjust your map to run rfd kit?

 

[S3Alex]

hey alex couldn't revo adjust your map to run rfd kit?

It's kind of on their back burner to be honest,and would require a bit of work to the cold start mapping,to open up the fuelling a bit,and then pull it back when it's warm,so I think it's work they don't really have as a priority right now.

 

[sliced]

Things are quite on this thread, everything going well i take it?

 

[S3Alex]

Things are quite on this thread, everything going well i take it?

All well thanks.

Car going well,very quick and no problems.

It's just the owner needs a bit of a rest!

 

[S3Alex]

With the New Year approaching,it's time to think of what's coming.....

1.Got to get those wastegate springs installed,but maybe after the cold weather goes!

2.Head needs porting.
I've decided to send the head off to Loba and have their Stg 2 head work done.

LOBA 2.0 TFSI CNC Stage 2 cylinder head machining | 2.0 TFSI 195 kW (265 PS) | S3 | Audi | LOBA Motorsport GmbH




3.Supertech valve train....inlet and exhaust valves.


4.Intake manifold.

I have a couple of things on the go here,but this one has kind of hit the top of the list right now....





5.Still need the carbon wings,and Backdraft Motorsport have some very nice ones that will be on the list,and AMD have some trusted fitters to arrange that,and the spraying.

6.Splitter.....think I've got that one covered.

 

[Granta]

I like you New Years plans!

 

[S3Alex]

I like you New Years plans!

I have a lot of incentive,to get the work done,and maybe coax a bit more out of the car......a very good friend on another forum has set the bar way higher than I can reasonably get to,but maybe somewhere in the mid-upper 500s would be nice,as well as achievable.

I wouldn't push it that far without getting the head done,as that's the limiting factor now,and so far,all of the settings such as timing,fuelling and boost have been pretty conservative,so getting the top end done in one big hit seems like the right thing.

Forgot the exhaust manifold.....found a nice tubular one.

 

[Sevv]

was gonna say changing the exhaust from the ATP you would get allot of extra flow . what mani you thinking of Alex ? FFE ?

 

[15Degrees]

Alex loving your new mod ideas I really need to update my thread as i have made tons of changes now. Alex my wastegate springs were for a 600 hp turbo think I need to lower them now im running smaller?

 

[Dean_T]

That stage 2 head sounds very tasty indeed!

 

[S3Alex]

was gonna say changing the exhaust from the ATP you would get allot of extra flow . what mani you thinking of Alex ? FFE ?

Just a few ideas at present,but some I need to pull together quickly when I arrange all this.

The supplier of one system is in Greece.

 

[S3Alex]

Alex loving your new mod ideas I really need to update my thread as i have made tons of changes now. Alex my wastegate springs were for a 600 hp turbo think I need to lower them now im running smaller?

As long as the wastegate blow off pressure is set a little above the maximum boost you're going to run then you'll be fine.

The actual flow/bhp capability of the turbo don't come into that as much,unless you use the full potential,in which case you'd be looking at around 3 bar.

Mine currently is only running 2 bar,and the wastegate springs won't hold more until i get a couple of them swapped over to allow a bit more.

 

[S3Alex]

That stage 2 head sounds very tasty indeed!

Thank you!.....should be more than enough.

 

[S3Alex]

And found another piece to add to the collection....

And got the injector specs for the inlet manifold......

Can either use Audi TT 180 or S3 8L inectors depending on flow rate and intended power.

Then I need one of these....

 

[S3Alex]

034Motorsports supplementary injector controller for running up to 10 extra injectors(don't think I'll need all of those!).

Runs according to boost pressure and RPM with full mapping and would allow us to run the 4 extra injectors above the level at which the RS4 injectors max out,which should be around 550bhp.

That lot,plus the head work should allow a good bit more to be had from the engine.

 

[NHN]

New year & he's of, lol.

Ooooooh look at those welding joins, nice work it would seem.

 

[S3Alex]

New year & he's of, lol.

Ooooooh look at those welding joins, nice work it would seem.

Well....got to have a project and some goals for each year.

The gear I've chosen comes highly recommended from a very good friend and I know he uses only the best gear in his car.

I've had a good look at the other manifold available and this looks amazing.

Sourcing the injector controller wasn't as easy but once again USP Motorsports have come through with a straightforward solution and I already have their fuel pump system on the car which should be good for 600bhp.

 

[S3Alex]

And one other thing while my short term memory loss permits....




My friend above works amazingly well,finding grip where previously there wasn't any,but a few times recently the car understeered really badly,and I couldn't see why that was happening.

It almost felt like there was little or no front end grip on cornering and trying to accelerate out of the corner,with the car just trying to push straight on,or slide wide,so I thought it was worth a few goes with the TC off.

Problem solved.

Feels as if under those conditions the TC and diff fight each other for directing torque,and the end result is collosal understeer,which if you think of the way that Audi's TC works,by applying braking to a wheel it senses as having less grip,and the Quaife directing torque to wherever there is some,ties the car in knots.

With the TC off,the overall feel is much better and the diff just gets on with it's job.

 

[olethalb]

have you bought the above inlet or are you tempted to wait for IE's inlet due to be released shortly - looks very nice.

plans sound great as ever

 

[S3Alex]

have you bought the above inlet or are you tempted to wait for IE's inlet due to be released shortly - looks very nice.

plans sound great as ever

Thank you!

I took a look at the IE intake in draft form and given the transverse inlet to it,fitting the throttle body and DV will be interesting at best.
The other inlet however,is tried and tested,and working on a 600bhp+ TFSi that a very good friend has built up,plus it has the additional fuel rail and injector ports which would be the major reason for buying such a manifold.

The IE system has none of that.

As soon as all of the times etc have been put together,that little beauty is on it's way over here.

 

[olethalb]

the ie inlet does have the port injection option and will fit the same as other manifolds but looks real nice and they say will be aiming to market at under $1000

 

[olethalb]

I can't comment on fitting but apparently is 'stock' just looks nicer than any others i have seen so far, i'll stop spamming your thread now

 

[S3Alex]

I can't comment on fitting but apparently is 'stock' just looks nicer than any others i have seen so far, i'll stop spamming your thread now

Not at all...spam away!

Whilst it may not suit my requirements,it may suit someone else,and having the information here always helps,so feel free to post.

The help I've had from others here and elsewhere has always been great,and I'm happy to have anything useful on here,but on the manifold subject,the input I've had from my mate with the huge power TFSi,plus the manufacturer of the exhuats and inlet have been excellent.

 

[Sevv]

cant find that inlet mani on IE's site, as im after a manifold with better flow rates

 

[S3Alex]

cant find that inlet mani on IE's site, as im after a manifold with better flow rates

Try the one I'm getting.

I'll drop you the address.

 

[S3Alex]

Couple of updates....

Very helpful supplier for the manifold and exhaust,more of which when the parts are ordered.

Also,may need to revise the head work and change the provider for that....awaiting APR calling me back.

 

[Sevv]

how come you're not going with loba Stg II, i know IE do a great job but its not cheap at all.. they actually get a whole alloy block and CNC machine it weld it and then port it but at 5K its a steep price to pay for bare head work

 

[S3Alex]

how come you're not going with loba Stg II, i know IE do a great job but its not cheap at all.. they actually get a whole alloy block and CNC machine it weld it and then port it but at 5K its a steep price to pay for bare head work

I've been looking at times,availability and a few other things,and in retrospect I may be better placed to have it done in the UK.

Having said that,APR don't do anything for the TFSi head,only the K03 head,which isn't any help,but they did point me to Race Developments UK,who have been more than helpful.
Loads of advice,lots of help,and I do know others(inc APR) who've been to them,so that may be the best place to go.

SO......I need to start ordering parts shortly,I think.

 

[KevZA]

All i can say is DAAAAMMMHHHH.

Alex i have been following this thread since around April 2012. Have never really been fit enough to comment with all the technical jargen that is in this post.

What you have right there is my dream car mate.

What i would give to take it down the road or even spend those few seconds on the quatermile .

I currently have a 2008 2.0TFSI and have started saving over the past few months to start my entourage. Only thing is there is no AMD tuning anywhere near me here in South Africa

My biggest concern is spending a large amount of money at a place i don't know.

Maybe i should ship my second wife to you.

Anyways sexy sexy sexy car bud.

Keep up the awesome work

 

[S3Alex]

Kev,

Thank you very much indeed for the compliments.

I replied to your thread,just to say weigh up the pros and cons before deciding what to do.

There are a couple of other South Africans on here,and VAGOC,who may be of some help in finding a decent tuner over there for you.

I'm very fortunate in having people I can trust over here,and they've done a fantastic job in giving me a properly quick and reliable car.

Very best of luck,and if I can be of any help,please let me know.

 

[KevZA]

Thanks for the assistance bud.

I will definitely get in contact with the guys from VAGOC.

It's one thing to get all the external plug a play gadgets and do the installations yourself but once you take the block out and start playing around with internals that is a totally different ball game and personally i would need to trust that guy more than my wife

Keep the updates coming looking forward to seeing that beast of yours in action.

Maybe post some youtube vids. :thumbsup:

Regards,

 

[S3Alex]

Thanks for the assistance bud.

I will definitely get in contact with the guys from VAGOC.

It's one thing to get all the external plug a play gadgets and do the installations yourself but once you take the block out and start playing around with internals that is a totally different ball game and personally i would need to trust that guy more than my wife

Keep the updates coming looking forward to seeing that beast of yours in action.

Maybe post some youtube vids. :thumbsup:

Regards,

Anything I can do to help part another member from his hard earned cash!

As before,I was very fortunate with AMDTuning having good recommendations when I went there first,followed by progressive work on my car until they got going on the engine build.

I've found that tuners who also have an active interest in racing are the best I've ever had......before AMD and the S3,I had a couple of Cosworths,and had one seriously poor experience before meeting a guy who worked on RS200s,and rallycross cars,as well as having raced in several series inc BTCC,and Historic GpC.

These people have an attention to detail that some others don't,and they want cars to be reliable.

It's worked for me,and if you can find the same,you'll be fine.

 

[dandav1985]

Very impressive build mate, I thought mine was fast I bet this is a rocket....lol.

Cheers Dan

 

[S3Alex]

Very impressive build mate, I thought mine was fast I bet this is a rocket....lol.

Cheers Dan

Thank you very much,Dan.

It's thanks to ASN and VAGOC plus my long suffering mates at AMD that the car has got this far to be honest.

Great fun and works well.

More to come soon.

 

[KevZA]

Hey Alex,

Any progression?

Please will you post some vids for us when you get a chance. :thumbsup:

I would love to hear the sound when you flat foot a pulloff

 

[S3Alex]

Hey Alex,

Any progression?

Please will you post some vids for us when you get a chance. :thumbsup:

I would love to hear the sound when you flat foot a pulloff

Funnily enough I was trying to sort the list out.

I think after talking to several people what will happen is the new inlet manifold,plus associated injectors and controller,and a few other odds and sods,and the valve gear,and then sit back and see how it runs before any more.

And need to get the uprated wastegate springs in as well.

Just waiting now for AMDTuning to get back to me.

 

[Sevv]

Funnily enough I was trying to sort the list out.

I think after talking to several people what will happen is the new inlet manifold,plus associated injectors and controller,and a few other odds and sods,and the valve gear,and then sit back and see how it runs before any more.

And need to get the uprated wastegate springs in as well.

Just waiting now for AMDTuning to get back to me.

it will run like a dream mate.. at least you have progress unlike myself.. my indy Seb @ EuroAutomotive in Sydney thinks 8-9 months wait isnt too much and i have to wait 3 more months since the box and engine specialist cant pull there hand out of their *** haha

another thing worth looking at Alex is PBC Pro Boost Controller - Plex Tuning

quite good.. thats what ill be using myself.. controls everything literally its like another ECU communicating with the OEM one.

 

[S3Alex]

it will run like a dream mate.. at least you have progress unlike myself.. my indy Seb @ EuroAutomotive in Sydney thinks 8-9 months wait isnt too much and i have to wait 3 more months since the box and engine specialist cant pull there hand out of their *** haha

another thing worth looking at Alex is PBC Pro Boost Controller - Plex Tuning

quite good.. thats what ill be using myself.. controls everything literally its like another ECU communicating with the OEM one.

Hi Sevv,

Sorry to hear you're being held back again.

It's seriously frustrating not being able to get the car going,and we've had a few times,but nowhere near as long as you've suffered.

I do need to get on and order the parts,and arrange a time to get it all going,but fitting it in with work is the major problem.

That controller looks very interesting,and I'll pass it on to the guys.

 

[<tuffty/>]

I love the idea of a reasonably stock looking car that goes like hell ....I've tried to keep near that with mine but I'm running out of ways to do that.

Spent the afternoon having a proper read through this... and this post is very much up my street lol... don't know if you have ever ventured into the 8L section and had a look at my S3 faffing at all but I am very much all over the OE sleeper look (some say I am a little OCD about it lol)

Nice to see a TFSI being pushed beyond the norm... not many people prepared to do it to this level and they just don't seem as modding friendly as ye olde 20v... that said there is still plenty of life in the 20v of course... especially as we can nab the cranks from the TFSI and use them in our blocks... gotta love VAG's laziness/design ethics that allows this to happen

Will make sure I keep tabs on the progress...

What did you set your Tial pressure at in the end? I have found from builds I have done that the spring charts are a little off (as the ratings are based on a 1:1 back pressure ratio)... on my MVS I had 0.9bar spring setup but actuator pressure was more 1.1bar

Going to try 0.8 bar in the 44mm Tial I am using now and see what happens... would prefer to have a lower base pressure to try and make the car a little more civilised as stiffer setups can make everyday driving a bit of a chore..

<tuffty/>