Time for a build thread....big turbo

:D i'm interested in the flywheel part number, and the little piece of plastic that goes on the selector arm on the gearbox so please note it down Alex!

I think I sent storm an email asking about the DQ500 swap but so far haven't come back to me which may be that yours is the guinea pig to find out exactly what's needed before they come back to me - or it's in their junk mail as my email address starts with "dunno" lol

Good luck with the swap Alex, keep us updated :D
 
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GMballistic said:
Sounds awesome & exactly what your car needs I'd imagine. :sunglasses:

I don't know a lot about those boxes, ...with it & the Syvecs ECU does it/can it do "rev matching" on the downshift?
Click to expand...

I only know what Andy has told me,in terms of what is the best box to get hold of,and this has the best torque handling.

The Syvecs has a list of capabilities a mile long almost a mile long but some of the important ones are here...

  • Flat Shift
  • Rolling Antilag / Pit lane limiter strategies, great for building boost on a roll.
  • Super fast connection via RJ45 Ethernet port for live tuning anywhere in the world or evenremotely if on track if connected to a wireless unit.
  • Adjustable traction control strategies based on lateral g and individual wheel speed monitoring.
  • 4 programmable and selectable target slip maps. An immediate torque reduction can be applied by the ECU via ignition ****** or a fuel cut.
  • Fuel pump control of both main, and sub pumps, as well as Relative fuel pressure monitoring and limiting in the event of fuel pressure dropping on boost.
  • 4 different Pedal to Throttle Angle maps with multipliers for different parameters e.g. speed. Again adjustable via steering wheel buttons
  • Configurable individual cylinder closed loop knock control, to suit any cylinder modification with adjustments to frequency, windows for listening and gains for each cylinder. Ability to trigger full cylinder shutdown in severe knock conditions.
  • Change torque reduction levels on shifts. Essential for very high power applications where the maximum reduction available via the stock ECU is not enough to prevent damage to components
  • Ability to change Torque ramp in after launch
  • Change throttle blip requests to match your torque band. Especially useful on oversized turbo installations.
  • Run up to 7bar map sensors.
So it allows torque ramping to protect the box during shifts,and goes beyond the stock ECUs ability to control torque.
Also control of clutch clamping pressures,shift speeds etc.
 
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grainqey said:
:D i'm interested in the flywheel part number, and the little piece of plastic that goes on the selector arm on the gearbox so please note it down Alex!

I think I sent storm an email asking about the DQ500 swap but so far haven't come back to me which may be that yours is the guinea pig to find out exactly what's needed before they come back to me - or it's in their junk mail as my email address starts with "dunno" lol

Good luck with the swap Alex, keep us updated :D
Click to expand...

Andy has done DSG conversions before,but mine will be the first S3 with a retrofit on this ECU.
DeckedS3 has done a DSG fit using the 6 speed box on the stock ECU.
 
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Could you please ask Andy if it's possible to go from DQ250 to DQ500 on FWD for me when you see him if you don't mind?
Thanks in advance if that's ok
Alex
 
grainqey said:
Could you please ask Andy if it's possible to go from DQ250 to DQ500 on FWD for me when you see him if you don't mind?
Thanks in advance if that's ok
Alex
Click to expand...

Will do.....please remind me if I forget!

Also,don't forget that doing this with a Syvecs is easier than with the stock ECU.
 
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S3Alex said:
Will do.....please remind me if I forget!

Also,don't forget that doing this with a Syvecs is easier than with the stock ECU.
Click to expand...

Thanks Alex

P.S your having your effect on me - ordered an atp manifold from 034 which is on its way from sunny America haha!
 
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I hope the effect isn't too bad!

Modding is like a disease...
 
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I'm sure you will love the dq500 box the 7 speed stronic makes the RS3 imho.

Any plans for a stronger cardan shaft?

They have been known on occasion to break the bolts at the Haldex end or the middle CV joint particularly on remapped RS3's.

Bolts are upgradable, but the question is what is the next weakest link and may break
 
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PaulRS3 said:
I'm sure you will love the dq500 box the 7 speed stronic makes the RS3 imho.

Any plans for a stronger cardan shaft?

They have been known on occasion to break the bolts at the Haldex end or the middle CV joint particularly on remapped cars.

Bolts are upgradable, but the question is what is the next weakest link and may break
Click to expand...

Totally agree.

I'll leave that to Andy I think,as they've had a number of cars now that they've retrofitted,and they did recommend RS3 driveshafts etc.
I know a few people who've habitually broken driveshafts!

Next point is the Syvec's ability and capacity to ramp torque on gearchanges to deal with this sort of issue,so I'm happy that Storm will have it covered.
 
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Another nice detail...the adjustable resonator tube....

 
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Looks cool, what are the benefits of this? Changes in exhaust sound or any performance benefits?
 
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leshkin said:
Looks cool, what are the benefits of this? Changes in exhaust sound or any performance benefits?
Click to expand...

No performance benefits,but it's there to adjust the tone etc of the exhaust,and tune out droning etc.

I have to admit I haven't heard the sound of my own car for a while now,and I won't for a good time yet,but Nige says it sounds amazing on this car.
 
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S3Alex said:
No performance benefits,but it's there to adjust the tone etc of the exhaust,and tune out droning etc.

I have to admit I haven't heard the sound of my own car for a while now,and I won't for a good time yet,but Nige says it sounds amazing on this car.
Click to expand...

Alex, you need to come out to some meets some time and charge for rides or something :) Would be cool to see and hear the beast in person!
 
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leshkin said:
Alex, you need to come out to some meets some time and charge for rides or something :) Would be cool to see and hear the beast in person!
Click to expand...

Not until I've had some time with it first!

Nige said it sounded as if something was trying to be let loose,so I can't wait.....unfortunately until it has a gearbox,it's not going anywhere.
 
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Is it me or your coilover springs are getting rusty? If so please have them checked with the sort of power you're running just to be safe. I had one snap in half not too long ago.
 
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S. said:
Is it me or your coilover springs are getting rusty? If so please have them checked with the sort of power you're running just to be safe. I had one snap in half not too long ago.
Click to expand...

They are pretty mucky,but they're OK.
That yellow paint doesn't help.
 
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What's the current work being done then Alex, have storm started the actual physical gearbox swap yet? It's like Christmas with the anticipation! I was never good with surprises :p
 
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That resonator pipe reminds me of those trumpets with the extendable pipe... you just need an umpa lumpa sat behind the bumper :p
 
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grainqey said:
That resonator pipe reminds me of those trumpets with the extendable pipe... you just need an umpa lumpa sat behind the bumper :p
Click to expand...

No...that's sat behind the wheel.....LOL

I so want my car back......the DS3 is nice,and so easy to drive,but it doesn't go.
 
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grainqey said:
Have you been given an estimated date for completion?
Click to expand...

No....to be honest I don't want to try and tie them to a time,as they're busy,and I'm happy to wait until Andy has space in his schedule.

No work I've ever had done on this car has gone easily,so I'm not about to jinx this either!
 
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Fair point, wasn't sure what the crack was as I usually get an estimated time for custom maps but I know that it can be quite flexible depending how busy my mapper is
 
S3Alex said:
No....to be honest I don't want to try and tie them to a time,as they're busy,and I'm happy to wait until Andy has space in his schedule.

No work I've ever had done on this car has gone easily,so I'm not about to jinx this either!
Click to expand...
Sounds just like my S3 lol
 
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Alex have you drove a dsg car yet. Gavin a manual I thought I wouldn't like it but I was very wrong I now have a manual and dsg s3
 
S3jcp said:
Alex have you drove a dsg car yet. Gavin a manual I thought I wouldn't like it but I was very wrong I now have a manual and dsg s3
Click to expand...

My car is a manual,and yes,I've tried a DSG before.

The reasons here are straightforward:

1.Less rpm drop between shifts = less boost loss,which is important with a turbo the size of this one.
2.Clutch needs replacing anyway,which means either another Spec 3+ at £1.4k now,plus a gearbox rebuild as it's getting a bit noisy again.
3.Clutch packs on a DQ500 will hold the torque we're looking at.....DQ500 has been tested to 900Nm,or nearly 700lbs,and after the mapping etc,we'd be looking at over 600bhp/600lbs.

The final point is the most important......the Syvecs ECU was designed with running a DSG in mind,and has better control of shift points,torque ramping,and traction control than the stock ECU has.

I do like manual boxes,but the pluses outweigh the few minuses so much that it's impossible to ignore.
 
I really couldn't believe how quick the response on the s3 dsg is so the one your going for must be on another level. I have also bit the bullet and decided to go big turbo with my manual as it needs an engine rebuilt and new turbo. I would love to run the syvecs but don't think I could afford it as I'm already looking at 10-15k to get it up and running plus I have a mk3 Ibiza with forged engine and vf34 turbo that I want to put a cage and buckets in for a track car
 
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Anything at all I can help with please let me know.
 
I think you have given me enough inspiration on this thread and already have an idea of setup that I want only difference is I might relocate battery and fuse box then bring the turbo to the side of the engine or use the nortech kit. Will most probably be a precision pt6262 turbo and run 8v rs3 injectors and standard 8p s3 injectors in the manifold. I think my main problem is the gearbox and clutch kit to use
 
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S3jcp said:
I think you have given me enough inspiration on this thread and already have an idea of setup that I want only difference is I might relocate battery and fuse box then bring the turbo to the side of the engine or use the nortech kit. Will most probably be a precision pt6262 turbo and run 8v rs3 injectors and standard 8p s3 injectors in the manifold. I think my main problem is the gearbox and clutch kit to use
Click to expand...

Placing the turbo at the side of the engine is likely to cause you a mountain of problems with exhaust fabrication and heat management,which is difficult enough with the turbo placed where it is.

The PT6262 isn't far off the GTX3582,but what I'd advise you to do is to take a scan through this huge thread.

http://forums.vwvortex.com/showthread.php?5546027-Golf-R-build-an-incredible-journey

http://www.exelixis.ro/golf6r/

Stefan is someone I know well,and a very good guy.....I think he's moved on from this project now,but it will give you an idea of what expense and trouble are involved in moving the turbo(in this case a top mounted PT6262,if I remember).

The Nortech kit will allow you to use a GTX35 frame turbo or similar,and would easily allow up to 700bhp.

That would bring it's own slew of problems,as you'll find in my thread and that one above.....A Spec Stg3+ on a manual box would cope with at least 540lbs(as mine has)although the gearbox needs to be treated with care.

The advice I got,and am going with is a DQ500 box.

Now where I'm going with this is here....

This setup works...

Nortech turbo kit.
GTX3582 or similar
HEP or Boulekos inlet manifold

What you're describing above is a total of 8 direct injectors,and I don't see how you're going to do that.....the manifold port injectors would need to be 8L type injectors,i.e.running off the LP fuel rail.

I also think that to run that lot properly,you do need to consider a Syvecs ECU.


Before you get too stuck into a build,have a chat to the following:

Andy at Storm
Stattlers
Scott Hawkins at Owen Developments
Nortech

All of these guys will be very useful for this sort of build,and all were very helpful in sorting out the right way.
 
Thanks Alex il do some more research and speak with the above to find the perfect balance of what I want to achieve.

Did you ever look into a sequential gearbox?

So to keep me right the boulekos manifold uses 1.8t injectors but what of cc are we looking at as I have a set of tt injectors that I have just replaced with 440cc green Giants

Moving the turbo was just a thought to be different as I have seen it done on the 1.8t 20v engine and have also found a company that does them in the states. I know the stud pattern is different but they build them to your specification so possible to use a tfsi flange.

http://store.forcefedengineering.com/mobile/Product.aspx?ProductCode=FFE_SFWD_Side
 
S3jcp said:
Thanks Alex il do some more research and speak with the above to find the perfect balance of what I want to achieve.

Did you ever look into a sequential gearbox?

So to keep me right the boulekos manifold uses 1.8t injectors but what of cc are we looking at as I have a set of tt injectors that I have just replaced with 440cc green Giants

Moving the turbo was just a thought to be different as I have seen it done on the 1.8t 20v engine and have also found a company that does them in the states. I know the stud pattern is different but they build them to your specification so possible to use a tfsi flange.

http://store.forcefedengineering.com/mobile/Product.aspx?ProductCode=FFE_SFWD_Side
Click to expand...

No probs....

Yes...looked at sequentials.

Sadev is shockingly expensive.
SQS dog kits are costly and offer no increase in torque ratings.
SQS sequential shifter simply converts your stick shift to a sequential pattern.....no point at all.

OK...Boulekos manifold......excellent quality...I'm using 4 S3 8L injectors currently,but they can be swapped out for bigger if required.

The way the system on mine works is the Syvecs runs everything.....port and direct injectors.
The direct injectors run on their own up to around 360-380bhp,and the port injectors are brought in progressively above that.

Syvecs monitors fuel pressures,lambda,and a pile of other things and adjusts fuelling accordingly.
 
Just looked at that link....

Awfully long headers etc etc.....but it seems to work.

Speak to all of the guys I listed,as that lot may not be the best solution.
Put it this way,I know the issues of getting US manifolds to work on UK spec cars!
 
Yeah I've been told 390cc so sounds about right.

Alex did you have to use bigger fuel lines?
 
S3jcp said:
Yeah I've been told 390cc so sounds about right.

Alex did you have to use bigger fuel lines?
Click to expand...

Not so far....had a quick look at a few sites for calculating fuel required in L/min for 600bhp,and they vary a bit but seem to average around 1-1.2L/min which should be within what can be pushed down the stock lines....and that seems to be OK in practice.

That's using the S3 fuel pump plus a USP Motorsports on demand pump to back it up,which i'd had from before the days of the RS pumps,and it's still working.
The LP system supplies both the HPFP,and the LP injector rail,and monitoring the pressures never showed much variation under load.

On initial setup,the car was producing over 600bhp at 2.1bar,without any timing,or VVT changes,and with the old Milltek exhaust holding things back to the point that Andy didn't want to try running the car for long on that.
 
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When you say the milltek was holding it back...was it a section of the exhaust which was poor flowing ie bendy or reduced diameter or what?
I ended up removing the 2.5" joining portion from my dp and catback so it's full 3" now
 
grainqey said:
When you say the milltek was holding it back...was it a section of the exhaust which was poor flowing ie bendy or reduced diameter or what?
I ended up removing the 2.5" joining portion from my dp and catback so it's full 3" now
Click to expand...

When you compare this......





To this......



You can see the problem(s)....

The first is the old system,which was actually catching on the Haldex coupling( if it rained and the piping bent a little),and was a 70/75mm system.

The other is the 90mm BCS.
 
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I didn't realise you'd gone from 3" to 3.5" I thought the milltek was a 2.5" and the BCS was 3"

Looking at the picture, you can also run two smaller pipes both sides of the diff but I doubt there will be a hanger for the exhaust round the other side of the diff!

Is the battery in the boot on the S3 as you'd gain quite a lot of room in the engine bay if it is - I'm running out of room under the bonnet!

Thanks
Alex
 
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