Today's dyno results

Time will tell if we got it wrong. A significant number of favours have been called in on this project and all parties have done their best to assist. If we have to modify the spec slightly in the future to get the best from the motor so be it.

I've had a few specialists decide as it wasn't a generic remap they weren't interested.
 
The -005 and -015 are basically the same housing, the 015 was jsut machined out by the factory.

Mines on a RS6 wheel machined out on an 005 housing, so its clearly possible, but the restrictive housing and manifold means it hits a wall at 280hp. I cant remember if my turbine is clipped or not.
 
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Yeh, theres also stuff like you've got a fresh engine which will almost certainly have less blowby, which in turn means less oil vapour polluting the intake charge and more timing being possible.
 
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Is that a BEX intake manifold? Is it a larger port to match a large port head?
 
I think he's talking about the BEX exhaust manifold, they appear to be a bit more chunkier than the AJL/AEB manifolds

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Yes sorry, it's the exhaust manifold.

They seem to be a bit of a weak link and although on initial site they are the same the BEX item is quite different internally. I really wish I'd had time to get comparison pics but was dropping the new one off in a very reduced lunch break.
 
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I had thought that about the site bit. Is it larger internally? I'm always a bit funny about changing exhaust manifold dimensions. The shape of it internally is important for flow of the exhaust to hit the turbine wheel and pulse wave energy, which I have totally forgotten the way of how it works.
 
I figured seeing as Audi fit it on the 190bhp 1.8T it was a tweak worth trying. Can't see it stuffing things up but we'll see, not hard to swap back again if it doesn't work.
 
Yes your right there. I was thinking of if your doing a self porting job yourself. I know the small port engines generally develops more torque than the large port engines earlier in the rev range but that the large ports can make more power and higher up the rev range. I wonder does the exhaust manifold have the same effect or is the exhaust maifold back pressure more important. Something for me to google I suppose. Sorry for digressing.

One interesting bit of information and one which I do comprehend can be found over on the seat cupra forum. It's a thread which Bill Badger started or at least posted on and it looks at the effect upon bhp development in relation to surface condition of the intake manifold. The surface has had different types of marks machined in to it. Dimples on one, scores on another. It has a big enough of an improvement on the top end with no negative impact on the bottom end or midrange. That's one I'll be trying for myself.
 
Sadly made no progress with the mapping as my brother has been ill, not even seen the car for over a week :(

Decided to cheer myself up and thanks to Aragorn providing me with some much needed info I picked up a half leather Recaro interior this afternoon.

Screenshot_20170222-191728_zpsdoxplb4l.png

Screenshot_20170222-191713_zpsnz7wxhko.png
 
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Mate they're so nice

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I've been after seats that style for years but never properly pursued it

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Finally managed to get a morning and fit the seats.

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Motors are nice and quiet and they are comfy. Now they are in though I'm in 2 minds whether I prefer the original cloth interior. May consider having the bolster repaired on the original seats and refitting.
 
Get the pics of both up and we'll take a vote for you lol.
 
I do like those Recaros tbh

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Recaros all the way

Although which are more comfy and which are better for holding you whilst cornering or does the recaros win on both counts?
 
I do like the recaros, and half leather is my favourite interior style. I quite fancy some of the RS4 "hi-tech" seats for mine, but they appear to be rocking horse poop and super expensive :(

Whats put you off them?
 
That's the funny thing, I'm really not sure. I don't dislike them as they are comfy I just find myself leaning towards the cloth seats.

Will give it a fee weeks and get my old seat mended then make a final decision which set get sold
 
I would consider taking the Recaros off your hands. I have the half leather sport seats with the same material that are great but would be tempted by the Recaro versions.
 
Well after swapping out some of the shonky hoses from the intercooler kit we are all systems go. Dropping the car off tomorrow night ready for mapping on Thursday.
 
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Well after a day on the dyno with my mapper we have some results. Saddle the intercooler has shown itself to be not quite up to the task at hand and with charge temp soaring he had to be conservative. In saying that though we are now making 257bhp with 264lb/ft of torque.

Mapper seems pretty confident that with a proper cooler we shouldn't be far shy of the magic 300bhp barrier.

Right now for some intercooler shopping, any suggestions?
 
Good results. Got a graph at all? I will have to review your turbo spec.

Intercooler could be toyosport 300*600*75mm. I got an evo one where the inlets and outlets are angled ever so slightly down and backwards which makes it easier to pipe up. I'm not sure what space you have up front but the a6 can accommodate it nicely behind the crash bar and minimal trimming of the bumper is only required.
 
Have a graph here, will scan or photograph in a bit. Only shows power and torque as time ran out before my brother got to add the AFR and boost curves.

It was lively on the drive home :) and not over working anything, well apart from the intercooler.
 
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Your turbo is k04-023 turbine wheel with 7 deg cut back ? Also a 2083 compressor wheel. Is the 2083 comparable to a c5 rs6 comp wheel? They flow about 320 bhp give or take with a bit of a push. Looking forward to the graph. Interesting how your torque is down 6 lb ft when the bhp is up 30 bhp. Good stuff so far.
 
mines a 550x230x65 toyosport core. the 600x300 unit really doesnt fit the B5 that well.

What cooler are you using?

Mine was struggling on the dyno as well, there are two variations of these cheap ebay cores, some have brazed internals and some have glued. The glued ones are much poorer as you can imagine, but its quite hard to know what your getting.
 
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Samuel c5 Q said:
Your turbo is k04-023 turbine wheel with 7 deg cut back ? Also a 2083 compressor wheel. Is the 2083 comparable to a c5 rs6 comp wheel? They flow about 320 bhp give or take with a bit of a push. Looking forward to the graph. Interesting how your torque is down 6 lb ft when the bhp is up 30 bhp. Good stuff so far.
Click to expand...

The RS6 wheel is a 2275. The S3 also uses the same wheel, and its good for about 300hp.

The numbers are quite simple. 22 = compressor exducer in tenths of inches, so 2.2" or 56mm. 75 is the inducer size as a % of exducer.

Mine is a 2280 wheel. which means the inducer is 5% larger. The 2280 wheel is good for 320-330ish HP, but you wont see that in a B5 housing.

2283 is a 360hp wheel.

The torque is likely down due to the larger turbo spooling more slowly.

2283 and K04-023 turbine is an odd combination. The 2283 wheel flows about 360hp but also has surge issues. The smaller K04 turbing surely makes those surge issues worse? Mine has a smaller compressor, but a larger turbine.

Using too large a compressor just adds lag for no gain, as the hotside is unable to flow that amount of air.
 
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Oranoco said:
Have a graph here, will scan or photograph in a bit. Only shows power and torque as time ran out before my brother got to add the AFR and boost curves.

It was lively on the drive home :) and not over working anything, well apart from the intercooler.
Click to expand...

What peak boost were you seeing?
 
Running 20psi so less boost for a smidgen more power. Apparently the ECU was pulling the timing significantly due to the charge temps. There is a chunk more to come from this motor.

For now the car is up and running, and importantly safe, until I get sorted on the charge temp where we will reconvene.
 
That's a good spread of power for a hybrid with a clipped turbine. They usually are lack lustre in the lower end and a bit peaky.
 
Just thinking as a temp bodge of reinstating the side mount intercooler alongside the current non to efficient front mount. Also have an Aquamist water injection kit fitted to my Escorts which since fitment of one of the prototype Pace full width intercooler has been redundant.

Friend has offered to talk to Pro-Alloy about having something custom made but even heavily discounted will be more than I can justify spending.

The drive to work was fun:)
 
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What intercooler do you have at the moment?

I wouldnt bother with the stock cooler, its going to be very restrictive at those power levels.

WMI will help for sure, but its not a hugely great idea to tune the car relying on it, as if it fails you'll blow it up. Better to tune the car safely without it, then add it on top to help things along.
 
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Samuel c5 Q said:
That's a good spread of power for a hybrid with a clipped turbine. They usually are lack lustre in the lower end and a bit peaky.
Click to expand...

Hmm... I'm not so convinced...

Mines making 250ftlb by 2750rpm, and keeps climbing, peaking at 295lbft at 4750. This ones not making 250lbft until 3500rpm and doesnt go any higher. Oddly it also falls off by 5500ish like mine too... I thought that taking it easier would have helped it hold the power for longer.

It looks like its spooling pretty slowly to me. Probably need to be more aggressive with the boost curve? Mines hitting 24-25psi or so at 2750, and holds that to the red line.

New intercooler sorted and back for a more aggressive tune!
 
It's a cheap eBay cooler to be fair, not expecially large and half obstructed by the bumper (cosmetic surgery).

As the boost temps were so high (75 degrees) it was known early on that we had a problem. I was very fortunate that a very well known VAG big hitter helped out but the tune had to be restrained and safe so as not to cause damage or a failure. There was no point throwing hours at the software to get as much a possible knowing the spec would be changing again and the tune requiring adjustment.

We have potential for a nice chunk more from this once we have a handle on the temps.
 
yeh, there are many cheap ebay coolers in different sizes... which one do you have!

If its the "A4 specific" kit thats sold with the cooler and hardpipes, its well known to be pretty useless once your beyond K03. The core is too small, and the pipework is too small.

Plenty of them work well however. Numerous 3-400hp A3 and S3's have been built with the so called "wellycooler", which is the 600x300x75mm core.

Unfortunately that big core doesnt fit the B5 very well. Its too tall to fit in the space behind the bumper. I went with a slightly smaller version that measures around 550x230x63.

As i mentioned above though, there are unfortunately decent ones and **** ones, with very little to distinguish between them.

If you get one of those with the decent brazed core, you should be alright.
 
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