Time for a build thread....big turbo

S3Alex said:
No worries at all.

Your posts are always welcome.

Just mod the way I did...a bit at a time.
Makes each step fun.
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thank you, so around when do you think you'll get the rest of the engine work done ? it will be interesting to see how power figures as we are running the same stuff ( minus wmi for me)


btw i ended up going +1mm oversize on the valves (ferrea)
and got the pistons as you recommend with tuff skirting and tuscan rods.. and a fluidampr due to the light flywheel going sintered loba kit
 
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Very nice indeed!

I need time to arrange the car being off the road again and frankly I think that AMDTuning are probably sick of my car at the moment!

Joking aside it would be good to get the feel if what's just been done and maybe look at early next year as the manifold needs sorting as well.
 
S3Alex said:
Very nice indeed!

I need time to arrange the car being off the road again and frankly I think that AMDTuning are probably sick of my car at the moment!

Joking aside it would be good to get the feel if what's just been done and maybe look at early next year as the manifold needs sorting as well.
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definitely see how the car reacts and how quick.. you need to get to know your car again... from how hard you press that throttle to the brakes and gear changes.. and well anticipation
 
Sevv said:
definitely see how the car reacts and how quick.. you need to get to know your car again... from how hard you press that throttle to the brakes and gear changes.. and well anticipation
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Very true.

Should be a damn sight quicker than the DS3 I've been driving for the last couple of months.

Maybe a bit heavier on the fuel though.......
 
S3Alex said:
Very true.

Should be a damn sight quicker than the DS3 I've been driving for the last couple of months.

Maybe a bit heavier on the fuel though.......
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definitely , i should say one thing though at least you had the DS3, i had and still have nothing i use our lousy public transport and it SUCKS! so i cant wait for that pesky audi to come back home
 
Sevv said:
definitely , i should say one thing though at least you had the DS3, i had and still have nothing i use our lousy public transport and it SUCKS! so i cant wait for that pesky audi to come back home
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That really does suck.

DS3 is actually a very good car...well put together,no rattles or squeaks,and looks good into the bargain.
I'd recommend it to anyone looking for a good,reliable economical car.


Now.....the good news.

Got the car back today,after a bit of time thinking I might miss today's chance as the guys found that the brake calipers were not properly set up,and seemed not to have been fitted exactly right,but that's down to the original fitting,and not AMD.

I've only driven it for a few miles,but it's so good to have the thing back.....it sounds really angry compared to before,sort of a sharper,harder edge to the exhaust note.

How does it drive...?

Engine first:
As above,only a few miles on pretty poor roads,but off boost it feels as before,in that it will motor along quite happily at 2000rpm or less,but clearly won't accelerate much.

AMD have added a few presets to the boost controller for me so that I don't slide off the road when it's wet or icy,and also changed the gain to allow the bigger turbo to spool up reasonably quickly.

Below 3000rpm the beast is pretty much asleep,although there is some boost,but once it's above 3500rpm it starts to move,and from 4000rpm up it is way more aggressive than the 3071 was.
I'd expected it to be like that,not only as the turbo is substantially bigger,but also the aspect ratios are optimised for higher up the rpm band,so it behaves as it should.

The way it pulls when it's on boost is way better than before,and feels a lot sharper than the 3071 did,and much more sustained.

I think the surge problems with the 3071 have pretty much gone,but this one has a ported shroud,and better flow characteristics,so again,it should.


I think that Owen Developments have done an excellent job with this turbo,and of course Garrett,and for once,this was a relatively straightforward job in terms of fitting.
 
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^^ I read all that with a big smile on my face... :)

Congratulations Alex, sounds like you've got yourself quite the weapon!
 
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did owens developments supply that turbo with the uprated metal cage bearings??
something i was considering. As standard they have a special plastic bearing housing, and whilst garrett think this is adequate, metal cages are obv going to be more durable.
 
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KentKid said:
^^ I read all that with a big smile on my face... :)

Congratulations Alex, sounds like you've got yourself quite the weapon!
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Plenty more where that came from.....if you can put up with reading it all!

The car has had a pretty full overhaul,as so much has been done trying to find the problem with the misfire!

Brakes next:

Again much better all around,as the shims on the fronts were sorted out this morning( as AMD didn't think they had been set up correctly originally),and the rear discs have been replaced,and the pads changed to Mintex 1155s.

The feel and balance are much better,and the car doesn't squirm around as much as before under braking,now that there's a bit better balance between front and rear,and the geometry at the front is improved.
 
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superkarl said:
did owens developments supply that turbo with the uprated metal cage bearings??
something i was considering. As standard they have a special plastic bearing housing, and whilst garrett think this is adequate, metal cages are obv going to be more durable.
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Hi Karl,

Yes....I got the metal cage upgrade.

The previous 3071 had the original plastic cage,and it seems to have survived not only nearly 3 years of use,but also a turbo heat jacket,which tends to retain heat in the core,but I was always careful not to thrash it and switch off immediately.

I think that means the plastic cage is actually pretty decent,but there's no doubt that the metal cage is better.
 
Dean_T said:
Great news Alex, glad to hear the car is back out on patrol! :)
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Yes it is,and about time too,before winter comes along.

It was rapid before,but it feels RABID now.

Once it's on boost,the way it gains speed is a lot better than before.....I don't know how much is down to the turbo,and how much down to the bigger gain settings on the boost controller to allow it to come in quicker and harder(!),but it's very different.

A bit lazier off boost,although even at 2500rpm it's still able to deliver around 0.3-0.4 bar,but it won't spool quickly until around 3500-400rpm when it does go a bit mad.
 
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S3Alex said:
Yes it is,and about time too,before winter comes along.

It was rapid before,but it feels RABID now.

Once it's on boost,the way it gains speed is a lot better than before.....I don't know how much is down to the turbo,and how much down to the bigger gain settings on the boost controller to allow it to come in quicker and harder(!),but it's very different.

A bit lazier off boost,although even at 2500rpm it's still able to deliver around 0.3-0.4 bar,but it won't spool quickly until around 3500-400rpm when it does go a bit mad.
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Thants just unfair......I want my car the now! It's great to see that you'er toy back on the road Al! I'm green with envy right now :yum:

Good news seeing the acceleration has improved when compared with the GT3071 whitch I thought it would not be posible (lower rev range)

Very interesting to see that you'er turbo is on full boost at 3500 and a good figure for a turbo at this size, it looks to me that my turbo will be on a full spool at 3000 with the exhaust porting, head work, & partition delete.

Congrats with the new car m8 & looking forward to meet up with you soon.
 
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Unitronic said:
Thants just unfair......I want my car the now! It's great to see that you'er toy back on the road Al! I'm green with envy right now :yum:

Good news seeing the acceleration has improved when compared with the GT3071 whitch I thought it would not be posible (lower rev range)

Very interesting to see that you'er turbo is on full boost at 3500 and a good figure for a turbo at this size, it looks to me that my turbo will be on a full spool at 3000 with the exhaust porting, head work, & partition delete.

Congrats with the new car m8 & looking forward to meet up with you soon.
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Thanks very much!

I am so pleased to have the beast back.

I'd say it's on full boost by around 4000rpm which is about what I'd expected,but it really is WAY faster when it hits that point,and just pulls hard all the way up the rev range from there.
I didn't expect it to hit the sort of speeds it was reaching anywhere near that fast.

Now....the diff.

Previously,under full load,the car was squirming around as the grip was being lost or gained at the front,even with the Haldex in Race mode,and TC disabled.
With the TC on,all that happened(then and now) is that the car keeps backing off and losing boost and power,and it behaves much better without it.

Now,it really does put the power down better,and with less wriggling about as it was previously struggling for grip,especially around corners and off camber bends.

I think Quaife have done what they do best and produced a really worthwhile addition.
 
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Here is a really naughty picture.


This thing was very bad indeed and needs to be punished severealy.









This is the final cause of all the problems.
 
Last edited:
And one more to prove that it does get cleaned occasionally.





Allright,I admit it......AMD had it cleaned.

Thanks again!
 
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Congrats mate, now i join Unitronic as to being envious hehe but congrats glad you're happy with it .. now as a good lesson tell everyone how much you've spent on the car since buying it ;) hehe for any that is thinking to do what we are doing (sighh)
 
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audi upgrades
Sevv said:
Congrats mate, now i join Unitronic as to being envious hehe but congrats glad you're happy with it .. now as a good lesson tell everyone how much you've spent on the car since buying it ;) hehe for any that is thinking to do what we are doing (sighh)
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I'm not sure I even want to think of the costs.

But.....it goes like hell,and I do like that.
 
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Unitronic said:
Throttle body sensor?
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I've seen a pic of one that had the throttle body pot track all corroded,but Ben promised to open this one up and see what's inside.
 
S3Alex said:
I'm not sure I even want to think of the costs.

But.....it goes like hell,and I do like that.
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hell i divulge on that its cost me close to £13,000 thats the turbo suspension engine gearbox clutch and fuel system.. i still have to get my brakes sorted haha im laughing before i start crying my estimated time to get that audi back is 31 January or 10 of February 2014 now thats hard to swallow...

on the bright side though not many people got 500-600 odd HP going through the wheels :p and its worth it esp when you get arrogant homers in vauxhalls fords and some supercars thinking oh.. wait he only has 250hp :p ( then it would be appropriate ask them to take a picture of your tail lights
 
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Sevv said:
hell i divulge on that its cost me close to £13,000 thats the turbo suspension engine gearbox clutch and fuel system.. i still have to get my brakes sorted haha im laughing before i start crying my estimated time to get that audi back is 31 January or 10 of February 2014 now thats hard to swallow...

on the bright side though not many people got 500-600 odd HP going through the wheels :p and its worth it esp when you get arrogant homers in vauxhalls fords and some supercars thinking oh.. wait he only has 250hp :p ( then it would be appropriate ask them to take a picture of your tail lights
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If I say how much it cost I get the usual...."why didn't you buy and R8/Porsche etc etc".

The answer of course is that to get one of those to this level would be even more money.

And yes.....surprises the hell out of drivers of rather more expensive cars.
 
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S3Alex said:
If I say how much it cost I get the usual...."why didn't you buy and R8/Porsche etc etc".

The answer of course is that to get one of those to this level would be even more money.

And yes.....surprises the hell out of drivers of rather more expensive cars.
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totally agree with you funny you mention that my sister tells me you couldve bought a porsche cayman for that price and turboed it if you wanted gave your same response its just silly money for them porsches. besides the point S3/RS3 i think are the most beautifully production cars around the world.. not many can rival them in their class not even the new mercedes A series AMG
 
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Sevv said:
totally agree with you funny you mention that my sister tells me you couldve bought a porsche cayman for that price and turboed it if you wanted gave your same response its just silly money for them porsches. besides the point S3/RS3 i think are the most beautifully production cars around the world.. not many can rival them in their class not even the new mercedes A series AMG
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Beauty is in the eye of the beholder for sure,but it's a well made,quality car,that demands more power and torque.

I simply don't tell my wife how much it costs,and as I've said before,when it gets to the point where your partner finds the car scary,then you're near the right sort of power levels!

Maybe I'd have a 911 someday(but it would have to be a Turbo or GT3/2 etc) but right now,I'm more than happy with the S3.
 
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Phew I don't even want to go there thinking what it has cost me to date! :blownose: Its very depressing but it does have its up's! :rock: I get constant folk who don't really understand our adiction who like to point out that I could of driven the GT3 for the same price but in fact its not the same really!,,,,,,To be honest GT3 is awesome and its got the power and speed & X factor to it but its not a personal build that you cary with it it has that XX factor to it for 1/4 the price and probably alot faster picking up the other halfs messages at ASDA! :superman:
 
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Unitronic said:
Phew I don't even want to go there thinking what it has cost me to date! :blownose: Its very depressing but it does have its up's! :rock: I get constant folk who don't really understand our adiction who like to point out that I could of driven the GT3 for the same price but in fact its not the same really!,,,,,,To be honest GT3 is awesome and its got the power and speed & X factor to it but its not a personal build that you cary with it it has that XX factor to it for 1/4 the price and probably alot faster picking up the other halfs messages at ASDA! :superman:
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I think it's like all aspects of modifying cars,from cosmetic to performance,a lot of people don't understand the reasons why you'd do it.

I wanted a hatchback again,liked the S3 but quickly found it was sloppy and just not quick enough,and so the madness began.

If I hadn't owned two severely modified cars before,I'd probably not have embarked on this,but one thing I did learn from those cars was that pretty much anything CAN be done,if you chuck enough time and money at it.

The questions are do you want to,and at what point does it become daft.
 
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S3Alex said:
I think it's like all aspects of modifying cars,from cosmetic to performance,a lot of people don't understand the reasons why you'd do it.

I wanted a hatchback again,liked the S3 but quickly found it was sloppy and just not quick enough,and so the madness began.

If I hadn't owned two severely modified cars before,I'd probably not have embarked on this,but one thing I did learn from those cars was that pretty much anything CAN be done,if you chuck enough time and money at it.

The questions are do you want to,and at what point does it become daft.
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I think theres a fine line between feeding our adiction & to how far we are willing to go! so this's the line we like to draw but we both know its hard to draw that line when the bug has bitten.....Its people like us, adrenaline junkies who created this world we live in so there will never be a limit to our darftness! :jester:
 
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Unitronic said:
I think theres a fine line between feeding our adiction & to how far we are willing to go! so this's the line we like to draw but we both know its hard to draw that line when the bug has bitten.....Its people like us, adrenaline junkies who created this world we live in so there will never be a limit to our darftness! :jester:
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That's true.....and without people like us,where would the tuning companies be?

So in fact,we're just doing our bit for the economy.
 
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sliced said:
any vids of this beast in action?!
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Just got it back after 2 1/2 months....and it's raining!

Seriously though it might mean revealing my identity as an old git who needs some exercise,but I will see what can be done.
 
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S3Alex said:
Just got it back after 2 1/2 months....and it's raining!

Seriously though it might mean revealing my identity as an old git who needs some exercise,but I will see what can be done.
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haha perfect weather to test Quaife diff to its limits:wub:
 
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sliced said:
haha perfect weather to test Quaife diff to its limits:wub:
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It worked really well last night.

Switched off the TC,and left the diff to do it's thing and it finds grip really well.
 
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A few piccies from Ben...


Firstly the rather nicely machined runner flap delete kit from APR.


755c30af54a38286e1fe7d6365a9cb58_zps6fcecfdd.jpg


Nice packing....

And nice parts....

ac0b21657bafb723fddf8acc19ad9fa0_zpscae88bb8.jpg



Considering the issues regarding rough starting and cold idling with this kit,and mapping that's not specific for it,I've really not noticed any problems at all.
 
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S3Alex said:
A few piccies from Ben...


Firstly the rather nicely machined runner flap delete kit from APR.


755c30af54a38286e1fe7d6365a9cb58_zps6fcecfdd.jpg


Nice packing....

And nice parts....

ac0b21657bafb723fddf8acc19ad9fa0_zpscae88bb8.jpg



Considering the issues regarding rough starting and cold idling with this kit,and mapping that's not specific for it,I've really not noticed any problems at all.
Click to expand...


lol. mmmmm I like I like! You going :jester: the now Al! The increase in power on just this little upgrade will give you around 50hp depending on you'er setup! Are you going to lift the heads too?

Al what's you'er setttings you have set on the car with the SPS switch and do you play around with the settings? WMI, could you explain what you using & doing on that side of things if you don't mind me asking?
 
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Unitronic said:
lol. mmmmm I like I like! You going :jester: the now Al! The increase in power on just this little upgrade will give you around 50hp depending on you'er setup! Are you going to lift the heads too?

Al what's you'er setttings you have set on the car with the SPS switch and do you play around with the settings? WMI, could you explain what you using & doing on that side of things if you don't mind me asking?
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Hi there.

I'm not sure how much the delete kit adds to this sort of setup in term of power and torque,but for sure there'll be some.

The biggest bit by far though is the GTX3076......it's totally different to the previous turbo,and despite it coming in a bit further up the rev range,the way it pulls to the red line is just night and day by comparison.
This thing is still well on it by the time the limiter is coming up,and not getting anywhere close to running out of puff.

Settings.....I honestly don't know,and I do tend to leave it alone now once it's set up and running.

WMI....I've got an AEM kit,which I think is one of the most reliable and easy to set up.
The Aquamist is better in some ways,but more expensive,and requires a lot of ECU feeds and mapping.

The AEM kit is boost triggered,and you set a value to start at,and a value to max out at,and it progressively feeds in the WMI over that range.
Mine starts at around 0.5bar,and maxes out at 2.2 bar.

There are a range of injectors to use depending on desired flow rate,engine capacity and boost....we're using the largest currently.

Mix is 50:50 demin water to methanol,and that's as high as you should go,although anything less is also fine,and will reduce temps,but not increase octane rating in the way that methanol added will.
 
And some piccies of the root of all the troubles.

8b75653da8b43da970793f5c3b59b1bf_zps8a9ff473.jpg




ceb239121e56238f7b3306e434e81ddd_zpscd5815e2.jpg



Looks innocent enough there.


The actuator motor in it's casing.....


d171bd4c1f2929a931c4a746a958065d_zpsf7cab0bb.jpg



Armature etc out of the casing......


66dc77b79282c78340df64f8ef0e07ae_zps98e108a1.jpg




And lastly,what came out of it when it was opened.....


ea5b9506fe77b6799567ece08cab07b5_zpsdff632b4.jpg
 
Doesn't look to bad tbh, strange it caused such an issue, I expected it to be in pieces.
 
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NHN said:
Doesn't look to bad tbh, strange it caused such an issue, I expected it to be in pieces.
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I think all the gritty bits may be one thing,but we also need to see the potentiometer track,which is behind those gears as far as I can remember.
 
This is true, but my dsg box liquid change showed more bits than that lol, but as you say more parts to cause issues than what's seen by the naked eye, I'm just glad you found the issue.

Bit like me finding the root cause to banks not processing emails from a client was down to a single missed "." in a non authenticating address, lmao, simple things are usually the cause, but feck me takes time to track it down.
 
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NHN said:
This is true, but my dsg box liquid change showed more bits than that lol, but as you say more parts to cause issues than what's seen by the naked eye, I'm just glad you found the issue.

Bit like me finding the root cause to banks not processing emails from a client was down to a single missed "." in a non authenticating address, lmao, simple things are usually the cause, but feck me takes time to track it down.
Click to expand...

Damn right.

Tracking this down was a real job for AMD,but they got there by working it until the thing was found.

Half the problem was that a couple of things seemed to have sorted the problem until the big map went back on,and then it popped up again,and I guess that something like load correction becomes magnified every time you increase values with a bigger power mapping.

Certainly it seemed OK after changing the Lambda probe and cleaning the MAF,but recurred when Stg4 went back on,and then they logged mine Vs another car simultaneously and just went through ALL of the data channels until they found which was radically different.
 
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