superkarls overhaul

Could your exhaust leak be the blanking plate for the external wastegate?
 
Best of luck dude! It's been a long road with this car but it's nice to see her running sweet :)
 
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Scullies said:
Could your exhaust leak be the blanking plate for the external wastegate?
Click to expand...
Possibly, but I'd expect some sooting where the leak is. I even tried squirting wd40 into the inlet manifold in an attempt to get it to smoke abit.

Another problem is with it running, you only have so long to fee around until it's too hot to bare.

I'm stupid really, I should've had all faces milled flat, another rookie error.
 
You could "smoke test" the exhaust system when its cold :)
 
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Tighter than that. Mine don't budge.
 
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And then
 
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Awesome figures bet your well chuffed I bet the drive home will be interesting
 
very nice build thread, just spent an hour going through it all!
 
Nice work! I bet you're over the moon with that :)

So, tell us, after 2 years of hard work how did it feel to finally plant your foot and feel 380bhp for the first time?

Must have been awesome :) go and enjoy it!

Got any plots?
 
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Prawn said:
Nice work! I bet you're over the moon with that :)

So, tell us, after 2 years of hard work how did it feel to finally plant your foot and feel 380bhp for the first time?

Must have been awesome :) go and enjoy it!

Got any plots?
Click to expand...

Id imaging the last 2 years for Karl have been kinea like this

2015 09 01 20 37 59 385341031


This for 2 years

2015 09 01 20 38 07 1129095102


This on the first big road home!





Great news man hope your pleased!!
 
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I'd first like to thank a few people as finally getting to the end wouldn't have been possible without them. The help I've had over the past couple of years, from both close friends and family, as well as this amazing community has been astounding.

I'd first like to thank my dad, who has been there every step of the way helping me and making sure I don't **** up, he's worked on the car whilst I've been away also.
My girlfriend for her patience with the whole thing, she still thinks it's a piece of **** and hates it, but I love her more.

Then there's ASN, too many names to mention,
Ben
Reesy
Westy
Dave
Stacey
Sandip
Tuffty
Bill
Scott
Paul
Chez
Jay
Scullies
Phil
Prawn

There is loads more who have given sound advice and words of encouragement and I am massively grateful for this.

So final results were a peak figure of 379.9hp, which was a cool run after a long chat following plenty of other runs, there were figures of 377, 368 etc, variable given the beating it took pull after pull.
And 360ftlbs torque which hits at 4000rpm.

It boosts to 1.8bar on the dyno, but this is a tad more on the road given the extra load. It feels incredible when it hits. I've only floored it once to overtake someone and I laughed out loud as I did it. Traffic was terrible on the way home so I've got a lot of driving to do!

Comments about the car were very good, flows very well considering the hardware. Injectors are maxed with 90% duty. Iat are very good considering no WMI, it takes a lot of timing, 20 degrees I think he said. Egts peak at 770 degrees as measured in the downpipe right after the turbine housing, again very good considering the setup and lack of WMI. Boost holds incredibly well, due to the gtx being well within its efficiency, duty cycle of 80% I think he said. Lots of details Rick talked me through that I may not remember correctly.


For more power, should it allow any, WMI and larger injectors are needed, but I'm not too fussed right now.

Only issue was a very slight misfire above 6k which was only picked up by the extremely sensitive dyno lambda sensor, it isn't picked up by the car or ecu. This is evident in some of the graphs at the top end, correlating to a drop in power, however some runs were making good useable power up to 7k. Plugs will be the first port of call for this with a slight close in gap.

Unfortunately launch control, no lift shift, and switchable maps weren't possible today due to my ecu not playing ball early on, and so Rick had my ecu out he car for a while. However I am to return to him when I can for this to be sorted as well as more runs.

Ricks service and professionalism is what shines. Getting into good technical discussions of what's occurring, always keeping me in the loop and knowing what's going on is great. His expectations are realistic, but his enthusiasm is awesome, and the figures reflect this. He is one smart guy, with a lot of experience and I trusted him 110% with the car.

Now some pics:
462ff6d8551478a66838a644cd2ea81b.jpg
70cdc208276e1d39a545051dd49b6ad9.jpg
4e81a4fc009c20f95010fc040fd31a3c.jpg
5825eb808765c3ea0c72f356b3b3374f.jpg
16bf3c3d0a31298a6af8221681b81f03.jpg
d77ce4c99a1b4c6f480a4e57b535280d.jpg

Excuse the rpm and torque on the high power run, dyno was setup for the wrong gear. You can see the noise the lambda creates in the data, this creates what I believe he calls a phantom lean reading.

The 368 sheet is probably the best representation of the power/torque, and let me tell you, on the road, that power and torque starts more like 3000rpm all the way to 7k, is freaking epic.

I couldn't be happier, or more proud of myself for building this and getting these results with ricks final touch.

Goodnight ya'll, I'm out for a drive
 
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Congrats mate you deserve it.
 
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Nice work dude... good to see it all come together for you at last... I know that journey well :)

<tuffty/>
 
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Well done mate. Knowing you've built some thing yourself, then finally getting the enjoyment from it is so incredibly rewarding :)

Results look good, and i bet that's very fast on the road :) it spools pretty well too!
 
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Well done Karl! Your knowledge of the 1.8T and everything that goes with it is outstanding. Although you have had advice, help and support off family and friends, you have done an amazing job over the past few years building this car.

I remember when i logged your car along time ago and you told me you were going to build your own engine, i admire your patient and knowledge!

I'm sure i'll get to see the car at some point :yes:

enjoy the car and drive safe :respekt:

A photo from a few years back
 
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Great results dude! There's gonna be a fair few cars being shamed by you now! Take loads of videos giggling and shouting Lol! Torque looks epic!!
 
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Awesome dude, nothing beats the satisfaction of building your own big turbo engine yourself. Well maybe building and tuning it yourself would be the ultimate - but that's rocket science :)
Nice to see you not too far off your target hp.

Enjoy the boost :)
ps: when you get NLS, you going to feel like a kid on Christmas day - ITS EPIC
 
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audi upgrades
Karl well done, epic build, and great results! Reading threads like this is why I love modifying cars.
From utter despair, to pure awesomeness when it all finally comes together.
Enjoy mate
 
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well done dude.
long road but you got there in the end

nice results

(I thought rick had 4wd dyno? looks 2wd?)
 
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Congrats mate well deserved :)

Got some top results and exactly were you was aiming iirc

Chuffed to also see I made the thank you section... No worries was glad to help with the little I could do and drop us a line if you want anything or head down south
 
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Adolf the grumpy dictator


I'm enjoying driving this far too much. The power is addictive and takes me by surprise everytime I throttle it. The rate it boosts and hits is savage, and the spread of power is what is most impressive I have to say. All the negativity surrounding this turbo and gtx line in general had me prepared for some annoying characteristics but I couldn't be more pleased.

All I've done to the car is secure the DV vaccuum hose as this burst off leaving me with some novelty compressor stall noises for a while. And tightened the back box hanger as I found this really loose with the exhaust moving about quite a bit.

I have a knock under hard acceleration and hard braking so il get it on a ramp and check things out.

Will also make some videos of it in action, maybe just some rolling accel runs and hopefully get rev counter and boost gauge in shot.
 
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Hi Karl......well done and a great set of results.

You've put so much into this that it's great to see you back on the road,and so happy with it.

Really pleased for you.
 
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