Audi S3 - Stroker Big Turbo build.

i wonder howlong this engine can last??? i mean its full of dust everywhere, on every side (as we see on picture up even from under the sky ) doesnt this sand make any damage on engine or atleast on some parts of engine and how it looks air filter after thatkinda dusty ride and some bearings of pulleys like altenator for example ???????
 
For a country that is mostly desert, they have a lot of car wash stations and they always busy. Thats a lot of wasted water!
My S3 mostly collects dust as my daily is more suited for abuse
View attachment 55700

They will fail your car for having "open air filters" - so I fit the stock airbox and engine cover to make it look as stock as possible.
Then the turbo gets wrapped in about 3 oem K04 heat shield blankets and an Audi TT plastic under try gets fitted. The inspectors are not that smart, they know its a 4 cylinder turbo car and I am a bit lucky as there are only 4 Audi S3's in the country. So they not to sure what the engine is meant to look like, even though its the same as a TT engine and there's a lot of TT's here.
Anything bling looking will attract attention then they start to look deeper.
So far black paint and lots of dust seems to be working :)


Ahhh fair enough mate that's mental
 
A midnight/early morning club drive, still 30deg C at 2am in the morning but a lot cooler than the daytime.
Was impressed with Bumble Bitch, only running 23psi and manages to slowly pull away from my mates stage 2 TTRS

Angry exhaust and some NLS


and some original selfie stick action - mk7 Gti wanted to play.


luckily I was in the far lane and was on the brakes about a second before the flash.
Obviously Gti owner lost the "race" but he at least won the prize from the police :busted cop:

Snapshot
 
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And a video of the drive up the mountain road.

dash cam = RS6 V10 :wub:
front bumper cam = S3
boot cam = TTRS
and DJI drone

 
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I finally got round to testing my buttons.....
IMG 6900 Medium


I have hooked up the copper momentary button to the brake switch signal wires. Took me a bit of time to work out how the feck the brake pedal switch worked. It has 4 wires, 2 are 12volt and 2 are earth, but the trick is when you install the pedal switch, you have to turn it to click it into the locked position. Now when its in the lock position there is a small tab on the pedal switch that engages the brake switch signal circuit.
So what happens when you push the brake pedal, the brake light circuit closes and the brake signal circuit opens - I think that's right, it might be the other way round.

So all I did was wire each terminal from the push button to the brake pedal signal wires, one to the 12v and one to the earth.
Now when I push the button and the throttle is past the required % = safe map switching on the fly.
No more dodgy left foot "braking" :)

Now to the FUN button...... as you can see in the above picture it says BOOST
and when its on, it LIGHTS UP :rockwoot:

IMG 6901 Medium


Now the fun button does 2 things.
No1 - It turns on the WMI
No2 - It turns "on" the N75

The fun button is a push on/off NO/NC button.
I have hooked it up to 2 relays. One relay is connected the 12v feed to the n75, so when the fun button is on the relay engages and completes the N75 circuit, giving the ECU control over the N75. When the fun button is off, n75 circuit is open and it runs wastegate pressure.
Its the same setup for the WMI system, but with different wiring for the relay

I used 5 pin relays as they are NO/NC and can be used to turn circuits off or on. So when the fun button is on, one circuit becomes closed and the other becomes closed. So I used the closed circuit to "activate" the relay and turn the WMI on. Again this took me awhile to work out and the hamster in my head was tired from keeping the wheel spinning for so long :tonguewink:

and here's 40seconds of your life you will never get back ....
 
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lol... beat me too it... been meaning to wire in the button I fitted adjacent to the ESP switch for ages... guessing yours still flashes the brake lights or have you sorted that?

<tuffty/>
 
Also installed a dual WMI tank setup.
I first had the tank outlets connected in series to the pump inlet. This was a FAIL, as the pump drained the first tank and then battled to suck from the second tank as it was sucking in a fair bit of air from the first tank. So I changed the tanks to be in parallel and both lines feed into to a Y connecter, then into the pump. I used 8mm tubing from the tanks to the Y connector and then the Y connector has a 6mm feed to the pump.
Tested this setup and both tanks drain at the same speed. WINNING!!!

Y connector

Y


Tank setup

IMG 6801


and since its my birthday this weekend, I bought these.....
Pro Race 1.2 18x8 ET35
It has probably been one of the worst ebay transactions in my life, so much admin from the seller. Like they didn't want to sell the wheels.
Anyways its done now and a big thank you to Leigh for offering to help, but delivery to him was extra admin for the seller. So Andrew has been kind enough to help me out - both of you are legendary people :respekt:

Pro race 12
 
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lol... beat me too it... been meaning to wire in the button I fitted adjacent to the ESP switch for ages... guessing yours still flashes the brake lights or have you sorted that?

<tuffty/>

Your post inspired me but all that esp switch stuff looked way to oem for me :)
Brake lights do flash but that's none of my concern, I'm moving forward. Forgot those fools I leave behind :racer:
 
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Is it really that hard to dab the peddle? Lol
Not at all, its pretty easy once you get the hang of it, but its sure not the safest thing to do on the freeway doing 120kph. I have to use a lot of brain power to touch the brake pedal with my left foot.
The button is SOOOOOOO much easier, NO LIFT MAP SWITCHING FTW :rockwoot:
 
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I feel I need to sort mine out now... lol

<tuffty/>
 
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they finally arrived !!!
IMG 6991


but will be going into storage for now as its time to pull the head off, port match and polish it, get a valve job done and install the ferrea valve train.

always nice to see some billet

Turbo
 
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:pensive::pensive::pensive::pensive:

My awesome 1" power killing exhaust restricter - damn internally braided flexi's

IMG 7002 Large
 
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Thats should stop you tearing the road apart.....
 
It was still slightly faster at 23psi with this custom exhaust reducer, than a stage 2 TTRS :)
 
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Head finally came off, had a friend visit on the weekend so offered him a beer in exchange to help me lift the head off. Couldn't be ***** to assemble the engine lift on a fresh summers day. Stripped the head down and started port matching the exhausts. Only managed 2 exh ports for the afternoon :(

1


2


3


4



and a safety selfie to ruin your weekend

IMG 7009



and lastly I bought a Honda, so I did the only thing you can do to a Honda - I gave it stance :rock:

IMG 7018


I have a long way to go to get the ports polished :grumpy:
 
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and no doubt sending EGT's through the roof when on man boost
 
And a video of the drive up the mountain road.

dash cam = RS6 V10 :wub:
front bumper cam = S3
boot cam = TTRS
and DJI drone



I LOVE that area! Those roads are so smooth and the twists would be so suited for some spirited driving. very nice!
 
Some updates on the exhaust, I have been piecing together a partly new exhaust system.
4" DP, into 3.5" "mid pipe" then into 3"
Fabricating up an exhaust on a car that's sitting on jacks, is like training for the world championship of contortionists

Its still 40deg here with about 90% humidity, winter is on its way :)

20151006 190408 resized
20151010 150813 resized
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20151010 151303 resized 1


Wastegate exhaust pipe to do then that's one more thing to mark off the list.
 
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Seen someone on a FB group say that they using these wiggen pegasus clamps, so I bought one. Waiting for it to arrive.

Anyone used these type of clamps for intercooler charge pipes?
123
 
Last time I looked they were a fortune!
Look cool tho, and a great idea

Yeah, they $40 each !! So I just bought 1 to test. Plan to fit it to the turbo outlet. If they reliable, I might get a lerger one for the throttle body.
 
Is that vid showing its good or bad? Is it showing it will flex and still seal or that they aren't very secure
 
Is that vid showing its good or bad? Is it showing it will flex and still seal or that they aren't very secure

These clamps have a degree of flex in them, I'm not completely sold on the idea of them still sealing while they flexed but I will test this out.
 
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