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

S3Alex · May 25, 2015

Craig Cull said:
Well, it had to happen didn't it!!

Things were going very well and I was due to pick it up Friday evening to give it a trial.

Rick calls me with a voice that tells you everything.
"Mate, its smoking"
Dropped onto 3 cylinders, cylinder 2 misfire.

Long and short of it, the same valve guide has become loose again.

It arrived on Saturday morning on a recovery truck and yesterday I stripped it in a record time of 1hr 55 mins (done it that many times)
Heads off again ready to go back... But this time we're not using the new head that I bought as we think this could be an Audi test head that's slipped through the net (or out of the back door) which under high temperatures is expanding more than it should and causing the guides to come loose.
So with respect to my head builder...
He is taking my older CDL head and fully porting and polishing it again etc etc and basically making another head for me foc.

**** DO NOT BUY A BRAND NEW HEAD FROM EBAY THAT SHOULD BE £2500 FOR £500 AND EXPECT EVERYTHING TO RUN SMOOTHLY *****

That's my lesson anyway.

On the plus side, 2 maps, one with 25psi of boost and the other with 30psi, pulls hard all the way to 7500 rpm with no issues
(Apart from what developed later)
26psi equates to roughly 450bhp going from maf readings and AFR etc. Just to give you an idea of what its pushing.
Other than that Rick was very impressed with the build and it responded very well to all aspects.

My favourite line of all time was "when it comes back and all is running well with no issues, I think we can really run some man boost in the mid range and open the Rev limiter a little more"
Also the wmi isn't even being used at this stage.

Basically it's looking good for the figures. Holding 30 psi of boost through out the Rev range is just epic anyway so we've already achieved what we set out to achieve.

So a week or 2 and I should have some more Info with a little more positivity

Hi Craig,

Really sorry to hear that.
You've had to work so hard and had so many setbacks that it's about time you had some good luck as opposed to all of this.

I would have thought from what you've said,that 2bar there is going to equate to around 500bhp,so that's an excellent result,and maybe in one way the full power/full throttle run was useful to pick up a potentially catastrophic failure before it happened.

Very best of luck.

Jimmy TDI · May 25, 2015

Bad news mate, but as said at least it's been picked up on in the very early stage so that no major damage has occurred.

Can't beat the customer service from the head builder though, not many would stick at it like he has.

Craig Cull · May 26, 2015

Yeah I guess there's some positives out of it.

To be fair the head has still failed so he does have a reason to stick at it. The Audi test head isn't confirmed but a theory.
I'm grateful he's stuck to it, but that's why I went him in the first place. He's a man of his word and that's what I like.
It's also a lesson to him Aswell as me so we've all gained some experience out of it all.

But on a plus side it will be with him tomorrow and he's hoping to have it back to me by the back end of next week. So hopefully rebuild a week on Friday.

Think it's worse knowing that its running over 450bhp that makes it worse,..... I just want to experience the finished product! Lol!

S3Alex · May 26, 2015

Craig Cull said:
Yeah I guess there's some positives out of it.

To be fair the head has still failed so he does have a reason to stick at it. The Audi test head isn't confirmed but a theory.
I'm grateful he's stuck to it, but that's why I went him in the first place. He's a man of his word and that's what I like.
It's also a lesson to him Aswell as me so we've all gained some experience out of it all.

But on a plus side it will be with him tomorrow and he's hoping to have it back to me by the back end of next week. So hopefully rebuild a week on Friday.

Think it's worse knowing that its running over 450bhp that makes it worse,..... I just want to experience the finished product! Lol!

Hi Craig,

I can understand his need to stick at it,as it reflects his work etc if nothing else.

I'll tell you something from my build.....on Revo software,with the uprated pumps etc,it never made over 500bhp on the GTX3076...just wouldn't do it,and the torque curve had a big hole at around 4500 rpm which wouldn't go away.
Andy at Storm diagnosed the ECU not being able to manage fuelling demands,and with the new ECU and turbo,hey presto,over 600bhp,with no timing or VVT adjustments.

Eventually,everything will fall together,and it will feel amazing...just wait.

Craig Cull · May 26, 2015

S3Alex said:
Hi Craig,

I can understand his need to stick at it,as it reflects his work etc if nothing else.

I'll tell you something from my build.....on Revo software,with the uprated pumps etc,it never made over 500bhp on the GTX3076...just wouldn't do it,and the torque curve had a big hole at around 4500 rpm which wouldn't go away.
Andy at Storm diagnosed the ECU not being able to manage fuelling demands,and with the new ECU and turbo,hey presto,over 600bhp,with no timing or VVT adjustments.

Eventually,everything will fall together,and it will feel amazing...just wait.

I hope so Alex, we're so dam close to the finished product I can almost taste it!!
That's why I'm just taking it in my stride.

I will not be beaten by this build and this will be the fastest Audi A4 quattro B7 in the UK, and I also know rick is the man to make that happen.

Big turbo unicorn A4 quattro coming very soon.

It might be laughing at me now, but I'll be laughing when I'm short/flat shifting through every gear, making sure she feels the pain she's put me through lol!

I'll have the last laugh!

S3Alex · May 27, 2015

Craig...I know exactly how you feel.

I've had a few ups and downs and a few parts that just didn't do what they were supposed to do,and the frustration is huge.

Keep your head down and enjoy it when it's done.

b7chris · May 30, 2015

Love this thread. Would love to do this with mine

Craig Cull · May 31, 2015

b7chris said:
Love this thread. Would love to do this with mine

It's a good platform to start from so it's worth it. If you can deal with the hassle.
But I'm hoping this build illiminates the hassle for others in the future

b7chris · May 31, 2015

It's definitely something im considering, and this thread would certainly help me on my way. I cant wait to see yours finished :racer:

Craig Cull · May 31, 2015

b7chris said:
It's definitely something im considering, and this thread would certainly help me on my way. I cant wait to see yours finished

Me either mate, it's been a long road, but I think it will be worth it.
I should have something positive to say in the next couple of weeks

b7chris · May 31, 2015

Awesome

S3Alex · May 31, 2015

Craig Cull said:
It's a good platform to start from so it's worth it. If you can deal with the hassle.
But I'm hoping this build illiminates the hassle for others in the future

It's good that there are a few like you in the B7 section,me in the 8P,and tufty and Goubo in the 8L section to spread their information around and save others maybe a few pennies along the way.
That sort of thing saved me a lot at the start,and like you I hope it does the same for others now.

b7chris · May 31, 2015

Threads like this are invaluable, even down to the little "how to...." stickies are so good for others looking to do the same. Like i said above, this thread will certainly help me a great deal when it comes to doing my build, without threads like this & stickies, i probably would do half of what i intend to

Craig Cull · May 31, 2015

b7chris said:
Threads like this are invaluable, even down to the little "how to...." stickies are so good for others looking to do the same. Like i said above, this thread will certainly help me a great deal when it comes to doing my build, without threads like this & stickies, i probably would do half of what i intend to

Totally agree mate,
It was hard just going ahead hoping I'd find my way, the obstacles have been a plenty, but because of it I have made a lot of new connections which means I can now supply any parts for the build which are not readily available in the UK.

I'm hoping this build sets the bench mark for B7/B8 tuning for the future, and makes it a very good option for people over the more expensive models.

I also think you have to dare to be different aswell, and I think this build is what will help that happen for people like yourself.

Or so I hope

b7chris · May 31, 2015

Indeed, i would probably be looking for advice from you once i begin my build, although its going to be a very slow build as my b7 is my daily, so it will be a case of a 2nd engine and build that first, im not gonna bother with stage 1 map, then stage 2 blah blah, go big or go home i say, so its straight to a forged lump and big blower for me lol

Craig Cull · May 31, 2015

b7chris said:
Indeed, i would probably be looking for advice from you once i begin my build, although its going to be a very slow build as my b7 is my daily, so it will be a case of a 2nd engine and build that first, im not gonna bother with stage 1 map, then stage 2 blah blah, go big or go home i say, so its straight to a forged lump and big blower for me lol

I do agree on that approach mate, saves a lot of money in the long run. I did the k04 build over a weekend as I used it daily aswell. Started it Saturday, finished Sunday, mapped monday lol!
I've got a few TFSI blocks of your looking for one?

I've had to do this over a few months as I wanted it ready for the show season, but no such luck. Hoping to make it to GTI international though.

Craig Cull · Jun 14, 2015

Well it's been an eventfull couple of weeks people and I was close to selling/torching the ******* at one point, but its now running and goes and sounds like nothing I have ever heard, seen or driven before.

I'll come back with more details but I just thought I'd leave you with the money shot for the time being

b7chris · Jun 14, 2015

Looking good mate. Can't wait for videos

Craig Cull · Jun 16, 2015

Bit of launch control for you aswell. Ignore the paint work, I'm only gonna clean it when it stops giving me grief lol!
http://s1072.photobucket.com/user/C...C-4C28-A59E-1CB62DBC4CC4_zpsdqointyl.mp4.html

Craig Cull · Jun 16, 2015

Ok so it hasn't worked. I'll post it as soon as ive won the war with YouTube lol!

S3Alex · Jun 17, 2015

I see one little pipe needs connecting LOL.

It looks great Craig and after so much work.

Just to cheer you up......
Mine is undriveable right now as the front calipers have worn and are unsafe.
Now waiting for AP to get around to making up a new kit for me.

Craig Cull · Jun 17, 2015

S3Alex said:
I see one little pipe needs connecting LOL.

It looks great Craig and after so much work.

Just to cheer you up......
Mine is undriveable right now as the front calipers have worn and are unsafe.
Now waiting for AP to get around to making up a new kit for me.

Which pipes that mate? The extra injectors? Haha! Not yet, cba at the moment. Sort this build first I think.

No way! That's not something you want to find out when you've got just shy of 600 pony's is it?
Hope you sort it!

S3Alex · Jun 17, 2015

Craig Cull said:
Which pipes that mate? The extra injectors? Haha! Not yet, cba at the moment. Sort this build first I think.

No way! That's not something you want to find out when you've got just shy of 600 pony's is it?
Hope you sort it!

I knew you had that extra rail waiting!

Like yours I know how it goes from one thing to another and I knew there was a problem from a couple of weeks back when it started squealing if it was wet.

Yours looks so much better than the cramped S3 bay.....a real treat.

You can actually see the results of the work.

Jon13s · Jun 17, 2015

What a great read and a credit to you.

Attention to detail and methodical approach is really good to see.

It makes me all the more tempted to play with my DTM albeit not to the extremes of this project.

F4B UP · Jul 6, 2015

Can you point me to a link regarding the balancer shaft delete please. Looks great, Ive just bought a b7 tfsi but it won't be going this daft!

Stanningtonglen · Jul 11, 2015

Craig, a great thread and a great build and a credit to you mate
soon be up and running keep up the good work cant wait to see it finished

Craig Cull · Jul 13, 2015

Stanningtonglen said:
Craig, a great thread and a great build and a credit to you mate
soon be up and running keep up the good work cant wait to see it finished

Thanks mate

Craig Cull · Jul 13, 2015

F4B UP said:
Can you point me to a link regarding the balancer shaft delete please. Looks great, Ive just bought a b7 tfsi but it won't be going this daft!

I can supply you a full pump with the balance shaft delete, but that's he best I can do.

Craig Cull · Aug 16, 2015

Well its been a while since my last confession and im afraid my luck has definitely hit its worst possible point.

The head dropped a valve and smashed the engine to bits. Damaging all 4 pistons, all 4 bores and destroying the head. It damaged all 4 injectors and the turbo.... £5k down the swanny.

Long and short of it in this situation, i couldnt prove the cause of the failure as i stripped the head off and because of this i had to make as much money back from the working parts as possible and buy another engine.

So!!! I was close to walking away but i just wont be beaten. I havent come this far to fall at the final hurdle. This car has amazing potential and is so dam tidy that i couldnt break it. It would break me if i had to do that.

I now have an engine that was built by TSR Performance and wqs running 580bhp in a leon cupra.
I had the turbo rebuilt by turbo clinic and bought 4 brand new rs4 injectors. Had to replace the intercooler, intake and upgraded to ngk race plugs. Nice way to spend £4500...
I forgot to mention that i had to do a 650 mile round trip to get the engine which took me 12 hours.
We then re installed the engine after fitting the new pick up pipe and changed the chain and tensioner while it was out.

This was last week and my intentions was to attend vw festival this weekend.....

Well lets finish on a positive note!!

Here she was yesterday making me a very happy man.

It entered the show and shine, didnt win but made a massive impression and got some serious attention. This is the only top mount garrett gtx3076r in the country and it was very appreciated by all the enthusiasts and i made alot of new friends and contacts out of it.

Its been a very bad ride and i can remove and refit the full engine from a bare block to a driving car in 6 hours. I can also tell you every singe tool you would need to finish the job.
Ive learned alot about my car....well everything really. But this isnt going unnoticed and im hoping to secure something very special for all you tfsi owners before the year is out.... not to mentiom our very own turbo intake pipes and intake set ups designed by yours truely.

Thank you everyone for supporting me and veing positive about this build, i promise to pass on my knowledge to everyone where possible and hopefully help make these cars even more of a joy to own.

Power figures will be known very soon.although steady driving to to ensure this is build is long lasting is a must. I give it some pasty earlier and its is god dam fast. But i dearnt really brake its back just yet.

Loads of videos will be here first. Make sure you join audi a4 club uk on facebook to see more updates.

Charlie Farley · Aug 16, 2015

Looking great craig, sad to read about the failure though ,but as they say , these things are sent to test us.
love the car chap, keep up the great work and pics.
rob

Craig Cull · Aug 16, 2015

A4Rob said:
Looking great craig, sad to read about the failure though ,but as they say , these things are sent to test us.
love the car chap, keep up the great work and pics.
rob

Cheers rob, they certainly are, im positive now though

S3Alex · Aug 16, 2015

Craig,I am so sorry you've had such a hard time,and I hope the new engine matches up to expectations.

It should,as it's from a well respected source,and it's already tried and tested,but I know how uncertain these things are.

You know I wish you the very best of luck,as you certainly deserve some!

SDHA4SLine · Aug 16, 2015

Gutted for you about the original power plant, hope this one behaves for you. Chin up keep going old chap, you're doing yourself proud with the can do attitude :salute:

Craig Cull · Aug 17, 2015

S3Alex said:
Craig,I am so sorry you've had such a hard time,and I hope the new engine matches up to expectations.

It should,as it's from a well respected source,and it's already tried and tested,but I know how uncertain these things are.

You know I wish you the very best of luck,as you certainly deserve some!

Thanks mate, it has filled me with uncertainty tbh but im trying to get past it and move on. Ive been bringing it on boost gently this morning and its great. Just keep getting out and checking things like oil return pipes arent touching the headers etc.

Had a beauty of an incident..... smoke from the bonnet, thought it was just the heat wrap burnibg off a little. Went for fuel, popped the bonnet... full blown engine fire!!! Managed to sort ut with the fire extinguisher very quickly.... but in a petrol station of all places!!!

So needless to say i keep a powder extinguisher in the boot. But then i put my engine in, hit 25 psi of boost and this happens....

You honestly couldnt write this ****

Craig Cull · Aug 17, 2015

SDHA4SLine said:
Gutted for you about the original power plant, hope this one behaves for you. Chin up keep going old chap, you're doing yourself proud with the can do attitude

Thanks mate. I need to keep going just to say its been done. Id be devastated if i walked away and someone else finished it for £10 lol

S3Alex · Aug 17, 2015

You're right...you couldn't make it up if you tried!

What caused the fire?

That mess in the boot is going to take some cleaning up as well.

I showed you what a bit of smoke from mine came down to,didn't I....thought the car seemed a bit flat one day,and it wouldn't hit full boost,so opened the bonnet when I got home and saw some smoke,and followed it to the melted MAF wiring...

I sometimes think(and my guys at AMD would agree) that these cars fight you all the way when you start doing things to them.
It's like they just don't want to be modified.....

Craig Cull · Aug 17, 2015

S3Alex said:
You're right...you couldn't make it up if you tried!

What caused the fire?

That mess in the boot is going to take some cleaning up as well.

I showed you what a bit of smoke from mine came down to,didn't I....thought the car seemed a bit flat one day,and it wouldn't hit full boost,so opened the bonnet when I got home and saw some smoke,and followed it to the melted MAF wiring...

I sometimes think(and my guys at AMD would agree) that these cars fight you all the way when you start doing things to them.
It's like they just don't want to be modified.....

The turbo cartridge turned slightly under boost, meaning the oil return was on the headers which burned straight through the pipe, which in turned soaked the heat wrap. Then intense heat caused ignition.
Totally agree, they fight all the way, but once your there its great. The fire extinguisher happened last week. Its all clean now thank god.

S3Alex · Aug 17, 2015

Craig Cull said:
The turbo cartridge turned slightly under boost, meaning the oil return was on the headers which burned straight through the pipe, which in turned soaked the heat wrap. Then intense heat caused ignition.
Totally agree, they fight all the way, but once your there its great. The fire extinguisher happened last week. Its all clean now thank god.

Agreed.....it's a battle all of the way,finding out things you never wanted to,or even thought of.

The headers radiate a huge amount of heat even when wrapped or coated,and that was what ****** the MAF wires on mine.....the hot air was getting directed around the sides of the heat shield,staright onto the wiring.

This is the thing when no-one else has done what you're doing,as you find all of the problems.

Craig Cull · Aug 17, 2015

S3Alex said:
Agreed.....it's a battle all of the way,finding out things you never wanted to,or even thought of.

The headers radiate a huge amount of heat even when wrapped or coated,and that was what ****** the MAF wires on mine.....the hot air was getting directed around the sides of the heat shield,staright onto the wiring.

This is the thing when no-one else has done what you're doing,as you find all of the problems.

Do you ever have issues with your IE vent to atmosphere catch can spitting oil out of the filter? Or do they just fill up very quickly when the pcv is removed?

S3Alex · Aug 17, 2015

Craig Cull said:
Do you ever have issues with your IE vent to atmosphere catch can spitting oil out of the filter? Or do they just fill up very quickly when the pcv is removed?

Hi Craig....no problems with oil spitting out unless it's really brimmed.

Another thing....since swapping to Motul 300V,and changing the ECU the amount of muck has really gone down by about 75%.

Before all that,it did fill quickly,and was spraying stuff around the engine bay.....also swapped to a Pipercross soft foam filter for the top of the can.

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

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