2.0T FSI Forged Engine Build Has Started, Big Turbo Build.

So as mentioned earlier, I'll show you a little of how things went down when the new parts arrived.

First of all, the quality is outstanding, not to mention the size of the downpipe. Also the beauty of the v band on both the mani and the downpipe means you have a lot more maneuverability when it comes to setting everything else up around it.

Here's the parts anyway..


And here's the difference between a good manifold, and a **** manifold...







As you can see the previous exhaust builder didn't use any lube.

The next issue we came across was my choice of wastegate. The current mani is designed for a Tial mvs wastegate which is considerably cheaper than the Tial mvr wastegate, which typically doesn't fit the flange. (This kit will be supplied in future for the Tial mvs only, or any other 38mm wg)

So I managed to get a collector extension made (which will need to be controlled by the tuner) which now fits my mvr, and will also allow me to run the screamer to the boot of the NSF bumper corner, which hopefully should create some interesting footage when we get on the strip.





The added advantage of the mrv is it now fills the blank space on the offside, which I originally tried to fill, at my expense.

Also the down pipe was a squeeze but does in fact fit with abit of adjustment.
Needless to say the milltek doesn't fit the new down pipe, so I had a 3" to 2.5" x 24" centre section which connects everything nicely. So now we are only really running the milltek rear silencers from the split. The rest is now custom.

The intake has proved the biggest challenge of them all as no matter what we have done it has always been an issue.
So we ordered an 034 Motorport cobra pipe. It's originally meant to go above the chassis leg, we have used it on the underside, this meaning we can have the full cone of the filter in sight as you look through the offside grill. All I'm going to do now is modify the old Intercooler duct to direct the cold air straight to the filter. Fortunately it's far enough back to hopefully avoid any water being consumed from the front.



As you can also see the charge pipe from the turbo also goes down behind the filter along with the screamer, so somehow we've managed to fit it slightly behind the filter which I'll be finishing tomorrow.

Long and short of it, I think I may be posting a running video of it by tomorrow or Tuesday.

It's been a ****** long road with lots of swear words but I think we're back on track!!
Watch out rick!! She's coming next weekend
 
Cheers chaps, thanks for the positivity, looks like we're nearly out of the woods.
I'm going to post a few more pics this afternoon, as it hasn't really been as straight forward as it looks. Once again due to my choice of wastegate etc, intake pipe and what not. I'll explain more this afternoon.

Think we've got around 3 more parts to source and we're finished.

But!! Anyone thinking of this conversion on their B7, im pleased to say you can come directly to me for a full kit that will be available very soon. Exciting times on the R&D side :)

Craig....that's a really excellent gift to the forum.

It's great to be able to feed something back,but a full kit is superb news for a lot of people,as going it on your own,or being the first,isn't easy.

Which wastegate did you choose?
 
Craig....that's a really excellent gift to the forum.

It's great to be able to feed something back,but a full kit is superb news for a lot of people,as going it on your own,or being the first,isn't easy.

Which wastegate did you choose?
Alex, I'm glad you said that, because the blood sweat and tears is all worth it if it makes this build easier in future for other enthusiasts. It's what its all about and as much as its nearly killed me, the reward at the end is worth every penny.

I've used a Tial MVR
 
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You must have been posting as I was typing!

OK..Tial wastegate......you have so much more room on the A4 than we all have on the S3,and that makes a LOT of difference.

I was advised by Nortech to go for a Turbosmart Hypergate45,as they'd found some of the Tial gates creeping a bit,but I have to say that my previous Tial never seemed to give any problems.

Just to give you and idea of the "luxuries" of space.....



How's that for cramped....LOL
 
Alex, I'm glad you said that, because the blood sweat and tears is all worth it if it makes this build easier in future for other enthusiasts. It's what its all about and as much as its nearly killed me, the reward at the end is worth every penny.

I've used a Tial MVR

That was a lot of what I felt as well....

Of course I enjoy making the car doing something that Audi never intended for it,but if I can make it easier for others who might want to do the same,then it's an added bonus.
 
You must have been posting as I was typing!

OK..Tial wastegate......you have so much more room on the A4 than we all have on the S3,and that makes a LOT of difference.

I was advised by Nortech to go for a Turbosmart Hypergate45,as they'd found some of the Tial gates creeping a bit,but I have to say that my previous Tial never seemed to give any problems.

Just to give you and idea of the "luxuries" of space.....



How's that for cramped....LOL
Someone has spent a lot of time making things to fit your platform then, coz that is tight as a ducks ***! And as we know, they don't let water in so that's tight

I wanted turbo smart but they didn't do a black one in that size (as rediculous as it sounds) it just totally killed my colour scheme lol!
I've heard the same about creeping but I'm hoping rick can isolate this for me. (Ricks got a lot to do lol!) I almost feel for him but then again he also enjoys it so I'm sure the car will be a weapon when he's finished.

I'll be glad to be the first in the UK to go this far with the B7 as it just makes things more interesting in the future. Especially when there isn't that many b7's pushing big power. The capabilitys of this chassis are very under rated. But I like to be different so I hope it makes people want to get involved
 
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Mapping cannot work around creep sadly. It's more to do with manifold design than the the wg itself. A properly designed wg port on the manifold will eliminate creep
 
Mapping cannot work around creep sadly. It's more to do with manifold design than the the wg itself. A properly designed wg port on the manifold will eliminate creep
I think the manifold design is on our side this time, so if it does creep I think it will be down to my extension pipe so I know where the issue is, which is a good position to be in, for a change lol.
Can I not just put a stronger spring in?
 
Someone has spent a lot of time making things to fit your platform then, coz that is tight as a ducks ***! And as we know, they don't let water in so that's tight

I wanted turbo smart but they didn't do a black one in that size (as rediculous as it sounds) it just totally killed my colour scheme lol!
I've heard the same about creeping but I'm hoping rick can isolate this for me. (Ricks got a lot to do lol!) I almost feel for him but then again he also enjoys it so I'm sure the car will be a weapon when he's finished.

I'll be glad to be the first in the UK to go this far with the B7 as it just makes things more interesting in the future. Especially when there isn't that many b7's pushing big power. The capabilitys of this chassis are very under rated. But I like to be different so I hope it makes people want to get involved

LOL re the duck's ***.

There is absolutely NO space left down there on mine.


This was after Nortech had made everything fit,but before replacing all the transmission bits,and you can see how it just clears everything....

 
LOL re the duck's ***.

There is absolutely NO space left down there on mine.


This was after Nortech had made everything fit,but before replacing all the transmission bits,and you can see how it just clears everything....

That's dam tight! The oil and water kit was supplied by Nortech, I can now see why they designed it that way. I
 
That's dam tight! The oil and water kit was supplied by Nortech, I can now see why they designed it that way. I


There is just no room.

I admit it's my own fault for putting that turbo in,but Nortech were the only ones who could guarantee it would fit,out of the very few people who do make this sort of kit for the S3.

One of the other things I like from your build is that you can actually see where your hard earned cash has ended up.
 
There is just no room.

I admit it's my own fault for putting that turbo in,but Nortech were the only ones who could guarantee it would fit,out of the very few people who do make this sort of kit for the S3.

One of the other things I like from your build is that you can actually see where your hard earned cash has ended up.
I've got to be honest, that's the thing that's made it all worth it, the turbo is just smack bang in your face from the minute you open the bonnet. I love that!
It also makes it a lot easier to work on.
 
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I've got to be honest, that's the thing that's made it all worth it, the turbo is just smack bang in your face from the minute you open the bonnet. I love that!
It also makes it a lot easier to work on.

I like that....and I expect all the people who've ever lost skin on mine would appreciate that as well!
 
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Once again great work Craig. I look forward to seeing the B7 conversion package you plan on offering.
 
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Really coming together nicely this one.

Sorry Craig but there are others out there already....
Image


Image
 
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Really coming together nicely this one.

Sorry Craig but there are others out there already....
View attachment 55007

Apologies...last post edited as I realise it might have seemed a bit off,and I do apologise for that,so..... if it turns out the power,who cares what it looks like......has it run yet,or is it like mine,waiting for the day it hits the RR?
 
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Aha....just read your parts list.....you've gone down the Syvecs route as well...
 
Really coming together nicely this one.

Sorry Craig but there are others out there already....
View attachment 55007

View attachment 55009
Cheers, I've not seen any proving any figures though mate. I'm sure there's plenty in the making. But I've searched everywhere to find one on YouTube etc. I've found nothing.
Not sure about the location of the turbo either, its dam close to the chassis leg down there. That's why I went top mount.
Looks nice though.
 
As above.....edited last post of mine as it may have come across as being a bit rude,and I didn't intend that.

What I was trying to say was although it doesn't look as neat as Craig's,if it turns out the figures,and does the job,that's good.

I noted the Syvecs ECU,and I see you've kept the S3 injectors.....let me tell you,that was a GOOD move.
 
Cheers, I've not seen any proving any figures though mate. I'm sure there's plenty in the making. But I've searched everywhere to find one on YouTube etc. I've found nothing.
Not sure about the location of the turbo either, its dam close to the chassis leg down there. That's why I went top mount.
Looks nice though.
Shame you didn't pipe up when I said I was having problems....
 
You have to image the chassis legs going through the pipe work so it does look a bit odd.

Yes it's been running for a while now.
 
You have to image the chassis legs going through the pipe work so it does look a bit odd.

Yes it's been running for a while now.

Now I understand.

My apologies for not getting that.....different cars and different solutions,even if the engine is basically the same.

How are you getting on with the Syvecs if Craig doesn't mind the OT question....
 
No don't mind at all, might aswell find out now seens I'm at the end of the build. It's good to see people are or should I say aren't willing to help/trade info when they've already done the same build. But then pipe up at the end. Maybe I just like to help people, or others just like to watch people struggle.

Confuses me....
 
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351gs@6k and 22lbs with only the S3 injectors.

Turbo fits fine without any modification, but it will never have the potential of yours Craig.

You will love the Syvecs and the Toucan set up on yours Alex.
 
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Craig if you want my advice I am here for you, but please remember we are in direct competition.

Don't forget that your struggle has lead you to find a first class solution for the A4.
 
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351gs@6k and 22lbs with only the S3 injectors.

Turbo fits fine without any modification, but it will never have the potential of yours Craig.

You will love the Syvecs and the Toucan set up on yours Alex.

On S3 injectors I can work that out roughly to bhp,but I think the Syvecs will maximise the potential of even the S3 injectors.
On mine there was a serious lambda issue with the RS4's so they're out,and the S3's back in with the port injectors above that.
 
I just need to get mine running properly!
 
Craig if you want my advice I am here for you, but please remember we are in direct competition.

Don't forget that your struggle has lead you to find a first class solution for the A4.
I guess when you put it like that, I see your reason for not stepping in.
At the same time, I'm not really trying to compete with anyone, I'm trying to build a very fast A4 that gets me noticed for all the right reasons. But mainly for my own enjoyment.

I suppose in reality your right that I have found a partial solution for the A4 but all of that will only become reality if it all works together as you know.

The k04 hybrid was a walk in the park in comparison to this build.

Well I hope we meet at a few events then so we can share our problems with the finished product. Apologies for biting your head off....
 
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Centre section connected...



Intake and dv return sorted, just waiting on a clamp do the screamer and a flexible dv return pipe and were ready to drive!!


We had the engine running last night and all I can say is it run sweet. That's why the Intercooler is connected without the front panel.

I will be going for the first drive since July on Friday :)
 
Centre section connected...



Intake and dv return sorted, just waiting on a clamp do the screamer and a flexible dv return pipe and were ready to drive!!


We had the engine running last night and all I can say is it run sweet. That's why the Intercooler is connected without the front panel.

I will be going for the first drive since July on Friday :)

Nice indeed!

Re the test drive.....with or without the bumper?....LOL
 
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Nice indeed!

Re the test drive.....with or without the bumper?....LOL
I'm gonna rebuild the front end completely minus the under tray, so I can drop the oil after the first 30-40 miles, also then I can plug in VCDS and see what it is or isn't liking before most of it is mapped out.

Then I've got a 300 mile drive to do over the next week before I drop the oil again and put the nano drive in.

It's booked in with rick a week on Saturday :)
 
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I'm gonna rebuild the front end completely minus the under tray, so I can drop the oil after the first 30-40 miles, also then I can plug in VCDS and see what it is or isn't liking before most of it is mapped out.

Then I've got a 300 mile drive to do over the next week before I drop the oil again and put the nano drive in.

It's booked in with rick a week on Saturday :)

That all sounds good.

More work for you there.....Storm have recommended Motul 300V 5/40 oil for mine,which I'm assured is very good stuff,but means even more frequent oil changes.
 
That all sounds good.

More work for you there.....Storm have recommended Motul 300V 5/40 oil for mine,which I'm assured is very good stuff,but means even more frequent oil changes.
Yeah I think I'll drop mine every 5k after the initial running in period. Everybody raves about the 5w40 nanodrive and you get 1 ltr free when you buy 5 litres for £59.
Not bad for the amount of protection it offers
 
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That should have been a video, but it's not happening lol! I'll post it later when YouTube stops messing around.

Road test today!!
 
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That should have been a video, but it's not happening lol! I'll post it later when YouTube stops messing around.

Road test today!!


Brilliant.

Really looking forwards to what you think of it after all that work.
 
Brilliant.

Really looking forwards to what you think of it after all that work.
Went for a drive today and it's not boosting properly, removed the tip and the turbo is spooling in every way.
Disconnected the vac pipe to the wastegate and hit 7psi lol!
I'm confused so instead of creating a stressful situation, I've come home and cracked a beer to reflect on the situation....
 
Went for a drive today and it's not boosting properly, removed the tip and the turbo is spooling in every way.
Disconnected the vac pipe to the wastegate and hit 7psi lol!
I'm confused so instead of creating a stressful situation, I've come home and cracked a beer to reflect on the situation....


Good idea.

What are you using to control boost etc?