Time for a build thread....big turbo

[Sevv]

The cam cover pressure should be pretty much atmospheric,using this sort of cover,and my crazy Romanian friend has one of these on his 700bhp Golf,so I think it should be OK.

i really need to stop listening to that workshop of mine (near the one year mark in 2 months by the way )... though i don't know how good this will be as the oil breather system is being deleted on mine for a 1.8t set up

 

[S3Alex]

i really need to stop listening to that workshop of mine (near the one year mark in 2 months by the way )... though i don't know how good this will be as the oil breather system is being deleted on mine for a 1.8t set up

The 1.8T guys seem to have got the breather delete thing well worked out.

I think the PCV system on the TFSi is a bit of a mess,and designed with only one thing in mind.....emissions.

The Cosworths I ran before had a very neat system,with a cam and crank breather,and an oil separator,returning oil to the sump,and venting only vapour to atmosphere.
The Audi way,venting all the crap into the intake is all very well for burning oil spray and vapour,but as you've seen,a recipe for coked up valves.

 

[Sevv]

The 1.8T guys seem to have got the breather delete thing well worked out.

I think the PCV system on the TFSi is a bit of a mess,and designed with only one thing in mind.....emissions.

The Cosworths I ran before had a very neat system,with a cam and crank breather,and an oil separator,returning oil to the sump,and venting only vapour to atmosphere.
The Audi way,venting all the crap into the intake is all very well for burning oil spray and vapour,but as you've seen,a recipe for coked up valves.

true.. though with your manifold, and when you put the injectors in i think a quick boot should spray enough fuel into the head to clear it no ? thats why i think i might consider buying it over the IE one

 

[S3Alex]

true.. though with your manifold, and when you put the injectors in i think a quick boot should spray enough fuel into the head to clear it no ? thats why i think i might consider buying it over the IE one

Thats true,but still need the time to get it back in,get the injector ECU sorted out and mapped,and then the boost turned up and mapped etc etc.

I think AMDTuning will need some calm pills and plenty of coffee.

What I would say though is the quality of the Boulekos manifold is excellent,and can be bought in standard form without the rail and ports etc for the extra injectors,although it's easy enough to buy the full fat version and simply not use the rail until required.

 

[nothingness]

It's all cleaned up,and the manifold was fitted a couple of weeks ago.

The engine feels a lot stronger,even with slightly lower boost(1.9bar instead of 2bar),so all the crap must have been holding things back quite a bit.

Here's a couple for comparison.


Before.....




After.....





Has to be at least 10% more area if not more,and when you consider that flow is proportional to the 4th power of the radius,it must make a difference.

How much does it generally cost for a decoke?

 

[S3Alex]

How much does it generally cost for a decoke?

I think you'd need to ask AMDTuning for a quote.

That's probably the best way,as it would depend on the car etc,and in any case,mine was already in bits!

 

[S3Alex]

So,here's the feeling after a bit more driving.

The car is definitely stronger and less peaky,on less boost than before,and seems smoother,so as before,clearing all the coal out of the inlet ports has made a difference to the way the thing breathes.

If there's a downside,it's in MPG,as that's dropped from an average of 28.6mpg before all of the work,to around 25mpg overall now,but that has to be weighed against the increased and more usable performance,which I'd definitely trade a few mpg for.

It drives well below 3000 rpm,and will even pull from around 1000 rpm in the lower gears,but the step over 4000rpm is quite something,and it now pulls to the redline a lot better than before,so again,the breathing is clearly better.

Sorting out the compression damping has improved the handling a lot,and removed a lot of the front-end bounce over bumps,so maybe another notch is in order for the next visit to AMD.

The R888s are finally getting reasonably warm every time the car is used,so they're being worked harder,and getting towards where the compound grips better as well.

 

[warren_S5]

Interesting your seeing such a marked drop in mpg, and whilst you'll take it for the extra drivability you don't think it's got anything to do with the ECU going through adaptation to new running conditions. Once I start modding I never know what to believe of the DIS MPG, but I suppose it's relative.

$64000 question for you tonight(!), when will you reach Utopia, and how will you know when to stop? I've seen some folk ruin cars over the years by the pursuit of the next logical progression, but logic and cars aren't always the most comfortable bedfellows!

 

[S3Alex]

Interesting your seeing such a marked drop in mpg, and whilst you'll take it for the extra drivability you don't think it's got anything to do with the ECU going through adaptation to new running conditions. Once I start modding I never know what to believe of the DIS MPG, but I suppose it's relative.

$64000 question for you tonight(!), when will you reach Utopia, and how will you know when to stop? I've seen some folk ruin cars over the years by the pursuit of the next logical progression, but logic and cars aren't always the most comfortable bedfellows!

Good points!

I'm not sure if you ever reach that sweet spot where you couldn't do a little bit more,or at least feel that you could.
Maybe when the bodywork is a pile of rust!

I don't think it's adaptation,so much as just a lot more grunt available and right to the top end,where it was definitely getting a bit rolled off before.

I'm considering ruining the back seats by removing them,as I essentially haul 50+kgs around every day and never,ever use them,and then maybe losing a bit more from at least one of the front seats when I can make up my mind.
That lot alone would amount to around 70kgs,or 5%,which would make a difference.

 

[warren_S5]

Good shout. Weight is the killer with this generation of cars, and you get effectively 'free' handling and power improvements for no outlay. It's the weight reduction that makes the handling so much sweeter than any suspension set up can compensate for.

 

[S3Alex]

Good shout. Weight is the killer with this generation of cars, and you get effectively 'free' handling and power improvements for no outlay. It's the weight reduction that makes the handling so much sweeter than any suspension set up can compensate for.

They just get heavier and heavier.

I know some of the newer models have cut weight a bit,but at the expense of a lot of aluminium and CF,where older cars were simply a bit lighter to begin with.

If I can lose about 75kgs,I'd be happy.....and that would be equivalent to my weight out of the car.

 

[warren_S5]

Do you have a racing battery or is the associated risks that carries a step to far to offset the benefit? 75kg's is a significant weight saving, if you had to add the equivalent BHP to overcome it you'd need a fair few £ to make up the equivalent!

 

[S3Alex]

Do you have a racing battery or is the associated risks that carries a step to far to offset the benefit? 75kg's is a significant weight saving, if you had to add the equivalent BHP to overcome it you'd need a fair few £ to make up the equivalent!

I considered a Braille carbon or similar,and the only downside is capacity and the need to keep it fully charged......maybe.

 

[warren_S5]

I so hope to see this car at a show / event one day!

 

[grchmason]

I so hope to see this car at a show / event one day!

That makes two of us Warren

 

[S3Alex]

Have to see when the next AMD day is.

 

[stetheo]

Good to hear it's now easier to drive below 3000rpm. I imagine this has really helped the every day drivability/usability of the car.

Interesting about the mpg, is that down to you just enjoying it more now though? Still pretty impressive considering the power outputs. I only get an average of 24.5 (current average for this year tank to tank) and I have significantly less power than you.

That's a significant amount of weight that can be shredded just through removing the rear seats. What about the big heavy front seats, any thoughts on them?

 

[S3Alex]

Good to hear it's now easier to drive below 3000rpm. I imagine this has really helped the every day drivability/usability of the car.

Interesting about the mpg, is that down to you just enjoying it more now though? Still pretty impressive considering the power outputs. I only get an average of 24.5 (current average for this year tank to tank) and I have significantly less power than you.

That's a significant amount of weight that can be shredded just through removing the rear seats. What about the big heavy front seats, any thoughts on them?

To be fair to Revo,the car always has been very driveable at low rpm,with no coughing or hesitation,but it's just smoother now,and has less of an obvious step onto the power.

I think the mpg is no doubt down to me being able to drive it harder,and the car not rolling off at the top end,which has to be down to all the crap in the inlet.
Don't forget also that I can't drive it hard much of the time anyway,as the roads etc just wouldn't allow that,but the great thing is that off boost,driving into work,it will easily top 30mpg.

I do have some ideas for those big heavy,leather electrically heated seats.....

This beauty weighs 3kgs...

 

[stetheo]

To be fair to Revo,the car always has been very driveable at low rpm,with no coughing or hesitation,but it's just smoother now,and has less of an obvious step onto the power.

I think the mpg is no doubt down to me being able to drive it harder,and the car not rolling off at the top end,which has to be down to all the crap in the inlet.
Don't forget also that I can't drive it hard much of the time anyway,as the roads etc just wouldn't allow that,but the great thing is that off boost,driving into work,it will easily top 30mpg.

I do have some ideas for those big heavy,leather electrically heated seats.....

This beauty weighs 3kgs...

Yeah i guess when going down this route with a car, you always want to maintain the every day driveability as much as possible. I know you saying the inlet clean has helped top end, do you think this will have had an impact on the lower end of the range so will have helped the earlier pick up from the turbo? The reason I ask is I'm getting mine cleaned when it get's serviced and was told to expect a better throttle response low down.

Always amazes me you are able to get such good economy on the daily commute. Really got the best of both world, unreal power combined with relatively 'good' economy.

Nice, that's a significant weight reduction! Can't imagine they are too comfortable for long journeys though...

 

[snowy]

Can't imagine they are too comfortable for long journeys though...

maybe gel cycling shorts would help with that ...

 

[S3Alex]

maybe gel cycling shorts would help with that ...

View attachment 32537

Now that reaaalllllyyy would NOT suit my lardy ***.

Yeah i guess when going down this route with a car, you always want to maintain the every day driveability as much as possible. I know you saying the inlet clean has helped top end, do you think this will have had an impact on the lower end of the range so will have helped the earlier pick up from the turbo? The reason I ask is I'm getting mine cleaned when it get's serviced and was told to expect a better throttle response low down.

Always amazes me you are able to get such good economy on the daily commute. Really got the best of both world, unreal power combined with relatively 'good' economy.

Nice, that's a significant weight reduction! Can't imagine they are too comfortable for long journeys though...

Compared to a 440bhp old school Cosworth,or even worse,the GpN Escort,these things are so far ahead on fuel management it's unreal.

The seats.......also come with nice comfy suede panels.

 

[S3Alex]

Bit the next upgrade bullet today,having seen the state of the inlet valves,and bought this little lot from Integrated Engineering.

IE 2.0T FSI Billet Valve Cover




IE Vent-To-Atmosphere Billet Catch Can V2



IE Rear Breather Blockoff Plate for Transverse 2.0T FSI/TSI Engines

IE Boost Cap For FSI, TSI, and 2.5L 5CYL Engines

IE Billet Block Breather Adapter for 2.0T FSI and 2.5L 5 Cyl Engines

AN Male TO NPT Male Fittings Black

Size
-10AN To 1/2"NPT

Braided Nylon Black Hose by the Foot


AN TO AN 90 Degree Jam Nut Male Fittings Black














And with a little luck,that lot should remove my car's appetite for coke.

 

[Sevv]

should be interesting let me know how that goes; as i might follow that setup myself too...

as for the seats just follow what they do in F1 roughly... mold some foam to your *** haha.. and maybe cover it with suede or leather im sure it would look great with some white stitching on the side

 

[S3Alex]

should be interesting let me know how that goes; as i might follow that setup myself too...

as for the seats just follow what they do in F1 roughly... mold some foam to your *** haha.. and maybe cover it with suede or leather im sure it would look great with some white stitching on the side

I contacted IE a few days ago,and as with a lot of US based companies,the replies were immediate,and helpful,including a fitting guide for the cam cover and breather.

I can only think that this little lot should completely bypass the awful PCV thing and all the problems that go with it,but of course it means a breather system and catch can that vents to atmosphere,but then I'm used to oily smells from my previous cars so it's really a small price to pay.

Seats.....I still need to get down to Tillett,and actually try one of those seats,and I just need time for that...which I haven't got.

 

[S3Alex]

Unbelievable.....


Place the order on the 13th....

Arrived this morning from the States.

Top marks to Integrated Engineering.

 

[warren_S5]

Looks a lovely piece of kit Alex. The PCV is a menace, and blighted my last car with running issues. I then fitted various catch cans from a range of manufacturers and it was better but not 100% right.

Glad to see you got the kit so soon, just ordered a CD of eBay from a woman in Nottingham and that's taken a week and a half to arrive (that said its taken Stobarts a week and a half not to deliver my new S5 from Sheerness in Kent to the dealers so that could set an even longer wait record by the time they sort their S**T out!).

Need a full engine bay shot once all this is fitted. Intrigued to see what it all looks like together. Bit of oil smell is how motorsport used to be pre-1990s! Nothing wrong with the smell of oil on a man, better than Brut ;-)

 

[stetheo]

Unbelievable.....


Place the order on the 13th....

Arrived this morning from the States.

Top marks to Integrated Engineering.

Wow! That's quicker than most companies in the UK can manage to deliver.

 

[S3Alex]

Looks a lovely piece of kit Alex. The PCV is a menace, and blighted my last car with running issues. I then fitted various catch cans from a range of manufacturers and it was better but not 100% right.

Glad to see you got the kit so soon, just ordered a CD of eBay from a woman in Nottingham and that's taken a week and a half to arrive (that said its taken Stobarts a week and a half not to deliver my new S5 from Sheerness in Kent to the dealers so that could set an even longer wait record by the time they sort their S**T out!).

Need a full engine bay shot once all this is fitted. Intrigued to see what it all looks like together. Bit of oil smell is how motorsport used to be pre-1990s! Nothing wrong with the smell of oil on a man, better than Brut ;-)

Thanks Warren.

I think this is the only thing that will remove the problem(i.e. the PCV system in its entirety!),and it's nice gear as well.

 

[S3Alex]

Wow! That's quicker than most companies in the UK can manage to deliver.

The delivery times from US companies I've used have been amazing.

I've had things from USP,and another company called Boltz,that make great CD racks etc,and now IE have beaten even those,with a total time of around 40 hours.

I thought the USP tracking note this morning was a joke until I checked.

 

[S3Alex]

And,I think to round off the work,maybe some new valves....

 

[warren_S5]

Oooooh nice Alex. Any exotic materials going on there (they look darker at one end than the other unless they've just been 'treated'. What make are they?

 

[S3Alex]

Oooooh nice Alex. Any exotic materials going on there (they look darker at one end than the other unless they've just been 'treated'. What make are they?

Just a good mix of heat resistant metals.

Ferrea and Supertech both make valve kits for the S3 and a number of other VAG models and I've chosen a Ferrea kit.

Advantages are a bit more bhp possibly as the stems are slimmer and a higher(8000) rpm limit.

 

[S3_Mat]

Makes sense to raise the rev limit i'm sure the turbo is still boosting hard at 8k. I see your forward planning getting rid of the PCV now!

 

[wuta3]

See, this thread is quickly approaching tear-inducing levels of modding. That's a problem *logs out*

 

[wuta3]

Oh dear oh dear. Found some absolute filthy porn browsing the IE website:

 

[Sevv]

Wow! That's quicker than most companies in the UK can manage to deliver.

I order of awesomegti and I get it it in australia 3 days later that says it all

 

[Sevv]

Just a good mix of heat resistant metals.

Ferrea and Supertech both make valve kits for the S3 and a number of other VAG models and I've chosen a Ferrea kit.

Advantages are a bit more bhp possibly as the stems are slimmer and a higher(8000) rpm limit.

Welcome to the club alex finally doing head work.. I used the oversize ferrea valvetrain kit with titanium springs and retainer its a must with the turbo we run or I shall be running... next for me would be the pcv delet as you did with yours I think its best

 

[S3Alex]

Well thank you all!

The IE cam cover and breather kit is ready to go.

The valve kit will be sourced shortly,and I think it will be the stock sizes for that as opposed to a 1mm oversize,unless AMD recommend differently,as I've had conflicting views on oversizing,so i'm not sure right now about that.

Wuta's found my current stash of car-porn,and IE are turning out some very nice things at the moment,so the time is right.

 

[Sevv]

Well thank you all!

The IE cam cover and breather kit is ready to go.

The valve kit will be sourced shortly,and I think it will be the stock sizes for that as opposed to a 1mm oversize,unless AMD recommend differently,as I've had conflicting views on oversizing,so i'm not sure right now about that.

Wuta's found my current stash of car-porn,and IE are turning out some very nice things at the moment,so the time is right.

lol.... WHEN WILL IT END!!! i wonder...

 

[S3Alex]

lol.... WHEN WILL IT END!!! i wonder...

You're one to talk!

Anyway,with the likes of our Romanian friends regularly topping 600bhp and a lot more,where is there to go but up.