Time for a build thread....big turbo

[S3Alex]

****** hope so maybe u just have legs like arnie lol I'm expecting it to be heavier but hoping it's not brutal

Don't think so....

All the people at AMD who have driven it commented on how light it felt for the torque rating.
I've had a few that felt like a workout every time I drove it but not this thing..

 

[Smirky]

Don't think so....

All the people at AMD who have driven it commented on how light it felt for the torque rating.
I've had a few that felt like a workout every time I drove it but not this thing..

I'll leave no later ,getting off your build thread now though lol

 

[HHS3]

Awesome build thread you've got here, it's highly informative and a very interesting read. Sounds like your S3 is an absolute beast! I can only imagine what she's like to drive, great job!

 

[S3Alex]

Awesome build thread you've got here, it's highly informative and a very interesting read. Sounds like your S3 is an absolute beast! I can only imagine what she's like to drive, great job!

Thank you!

It's great fun,and an everyday drive....off to BCS soon for the 90mm exhaust and then back to Storm for a bit more ECU work.

 

[Smirky]

Thank you!

It's great fun,and an everyday drive....off to BCS soon for the 90mm exhaust and then back to Storm for a bit more ECU work.

You gone powervalve or straight through Alex ?

 

[S3Alex]

You gone powervalve or straight through Alex ?

Twinvalve.....whatever that means...LOL.
I think it means 2 X 90mm pipes with valves somewhere....I was leaving that to BCS to design!

 

[Smirky]

Twinvalve.....whatever that means...LOL.
I think it means 2 X 90mm pipes with valves somewhere....I was leaving that to BCS to design!

Twin 90mm that is going to look and sound epic !!!
Can't wait to see the pics

 

[S3Alex]

Twin 90mm that is going to look and sound epic !!!
Can't wait to see the pics

I honestly have no idea what the system will look like.
One of Nige's colleagues is designing it,and has all of the pics from the Nortech exhaust manifold and turbo to start from.

The current one is very loud around 3-4000rpm and has really had it's day.

 

[raffhussain]

Wow
Nice build and a very interesting read.

 

[Craig-P]

This new system sounds interesting Alex, Be sure to get some pic's up when it's done....

 

[S3Alex]

This new system sounds interesting Alex, Be sure to get some pic's up when it's done....

Yes for sure....I think BCS will be quite keen to get some pics up as well.
It's a custom build,and having the valve system should help preserve low end response,and allow more top end.
The turbo has a Tial turbine housing with 0.82 A/r to get a compromise between flow and response,so getting a decent exhaust should be interesting.

 

[Gops]

I honestly have no idea what the system will look like.
One of Nige's colleagues is designing it,and has all of the pics from the Nortech exhaust manifold and turbo to start from.

The current one is very loud around 3-4000rpm and has really had it's day.

Have you seen the system Bill had made for me? 3" with a mid silencer into a backbox with twin 2.5" (3" piping outlet) and one pipe with a boost valve? I used to get some real drone on the motorway but this has helped me massively!

 

[S3Alex]

Have you seen the system Bill had made for me? 3" with a mid silencer into a backbox with twin 2.5" (3" piping outlet) and one pipe with a boost valve? I used to get some real drone on the motorway but this has helped me massively!

That's very nice.

I have to say,Bill deserves all of the credit he gets for his work.
I'm very impressed by what he's doing.

 

[Gops]

That's very nice.

I have to say,Bill deserves all of the credit he gets for his work.
I'm very impressed by what he's doing.

Definitely, the work he's doing is really good. Hoping the TT makes some good figures as mine is also in for bigger bore manifold, dimpled head and garrett hotside. Lets see what comes from this!

 

[S3Alex]

Definitely, the work he's doing is really good. Hoping the TT makes some good figures as mine is also in for bigger bore manifold, dimpled head and garrett hotside. Lets see what comes from this!

Definitely.

That thing was a pure piece of car-porn.
I need to get moving on mine again soon....it's been so busy this year I've just not been able to spare the car some down-time.

 

[S3Alex]

A couple of odds and ends...

This needed a bit of adjusting...



I'd forgotten it was still set up for the last turbo(Thx to @Alex_Wil and @Smirky for asking about WMI there),with it starting at about 0.5bar and topping out at 2.2bar,which was well off for the 3582,which is already producing good power at 0.5bar and held to 1.9bar,so these little pots need the smallest Philips screwdriver in the world to adjust.

Anyhow,now starting at 0.4bar and topping out at 1.8bar.

And some new tyres.....the PS3s have finally had it,and I'm getting TC cutting in at 60+mph on boost...LOL...they have to go.

 

[grainqey]

Might have missed the boat with this reply tbh but, I'm looking at a duplex downpipe to eliminate drone - as when I had Volvos, everyone used to complain about drone on the BSR exhausts (they were a single pipe) They did a duplex version for the S60R as it came with a duplex exhaust system from the factory - top and bottom was that I ended up with an S60R exhaust on a T5 (it was very loud as i'd cut the backbox off but had very little drone)

 

[Smirky]

Might have missed the boat with this reply tbh but, I'm looking at a duplex downpipe to eliminate drone - as when I had Volvos, everyone used to complain about drone on the BSR exhausts (they were a single pipe) They did a duplex version for the S60R as it came with a duplex exhaust system from the factory - top and bottom was that I ended up with an S60R exhaust on a T5 (it was very loud as i'd cut the backbox off but had very little drone)

Drone on your s3?

 

[S3Alex]

Might have missed the boat with this reply tbh but, I'm looking at a duplex downpipe to eliminate drone - as when I had Volvos, everyone used to complain about drone on the BSR exhausts (they were a single pipe) They did a duplex version for the S60R as it came with a duplex exhaust system from the factory - top and bottom was that I ended up with an S60R exhaust on a T5 (it was very loud as i'd cut the backbox off but had very little drone)

Mine's loud,but the whole system from the downpipe back needs sorting out.

The only drone at the moment is from me droning on about getting it up to BCS.
It needs a load of things doing as I just haven't had time to do anything.....full service,exhaust,tyres,ECU setup as a few things need doing,and then to round it off in a few months an MOT.

 

[grainqey]

Drone on your s3?

No, I have just a 2.0 TFSI but I used to have Volvos and the single pipe exhausts drone, the resonators get rid of a lot of it but its the problem with large bore downpipes - they tend to drone, the idea of the fancy APR catback is to allow flow and cancel out the low frequency sound, if the downpipe was a smaller bore then it wouldn't be as bad but wouldn't allow enough flow! you can stop it by using two pipes which split then join back together so that the sound waves cancel each other out as they rejoin!

 

[grainqey]

Mine's loud,but the whole system from the downpipe back needs sorting out.

The only drone at the moment is from me droning on about getting it up to BCS.
It needs a load of things doing as I just haven't had time to do anything.....full service,exhaust,tyres,ECU setup as a few things need doing,and then to round it off in a few months an MOT.

Is it just not flowing enough Alex?

Lol I'd disagree on you droning, if you do drone it's usually about something interesting, involves spending money and worth reading - anyway you've set us a nice bench mark so you need to try and part us all from our money haha!

 

[Smirky]

No, I have just a 2.0 TFSI but I used to have Volvos and the single pipe exhausts drone, the resonators get rid of a lot of it but its the problem with large bore downpipes - they tend to drone, the idea of the fancy APR catback is to allow flow and cancel out the low frequency sound, if the downpipe was a smaller bore then it wouldn't be as bad but wouldn't allow enough flow! you can stop it by using two pipes which split then join back together so that the sound waves cancel each other out as they rejoin!

I run a full 3" bcs and get 0 drone it's a very clever design ,I always thought the drone came from the cat back section ?

 

[grainqey]

I run a full 3" bcs and get 0 drone it's a very clever design ,I always thought the drone came from the cat back section ?

Hi Smirky,
What resonator boxes does your BCS have?
Tbh, I thought the drone came from the larger diameter of the pipes as the gas travels slower so you end up with lower frequency rather than smaller and high frequency.

I don't know that it's created from the catbacks, I think it's probably the fact that the catback is further from the turbo so you get the biggest gains in sound suppression etc - If you notice you gain a lot of low frequency by just adding a DP and the standard ones run a brief piece of duplex pipe but are also a smaller diameter

Thanks

 

[S3Alex]

Is it just not flowing enough Alex?

Lol I'd disagree on you droning, if you do drone it's usually about something interesting, involves spending money and worth reading - anyway you've set us a nice bench mark so you need to try and part us all from our money haha!

Basically yes.

At low-mid power it's fine,although I think the backbox may have blown a bit,but at full power Storm had to turn the boost down to get around that,so it will turn over 600bhp,but they don't feel the exhaust is up to the job long term.

Droning.....I can say that the backbox has a lot to do with that,as we tried a system with no back box for a while,and apart from being pretty loud,there was a real drone around 3500rpm.

 

[S3Alex]

A couple of odds and ends...

This needed a bit of adjusting...



I'd forgotten it was still set up for the last turbo(Thx to @Alex_Wil and @Smirky for asking about WMI there),with it starting at about 0.5bar and topping out at 2.2bar,which was well off for the 3582,which is already producing good power at 0.5bar and held to 1.9bar,so these little pots need the smallest Philips screwdriver in the world to adjust.

Anyhow,now starting at 0.4bar and topping out at 1.8bar.

And some new tyres.....the PS3s have finally had it,and I'm getting TC cutting in at 60+mph on boost...LOL...they have to go.

Selfie quote here,but the picture is useful.....

Those little pots for setting WMI start and max boost level are neat but the calibrations are way off.
I checked them against the Syvecs boost feed to the touchscreen,and they're out by around 2-3psi,which does make a difference at both ends of the scale.
Now it's set properly,I've got it starting at 0.4bar and topping out at 1.7bar.

 

[Smirky]

Hi Smirky,
What resonator boxes does your BCS have?
Tbh, I thought the drone came from the larger diameter of the pipes as the gas travels slower so you end up with lower frequency rather than smaller and high frequency.

I don't know that it's created from the catbacks, I think it's probably the fact that the catback is further from the turbo so you get the biggest gains in sound suppression etc - If you notice you gain a lot of low frequency by just adding a DP and the standard ones run a brief piece of duplex pipe but are also a smaller diameter

Thanks

Bcs has full suit case type box at the back but it has a valve so when your on boost it by passes it becoming a straight through system ,it also has 2 boxes in the mid section allowing it to sit nice and high so clearance isn't an issue , on tick over and motorway cruising you wouldn't even know it's on there

 

[S3Alex]

I need to get on with this...summer is on the way at last,and the car needs some presents.

Tyres first.....hopefully at the weekend.
Then it can undergo some surgery.

 

[Alex_Wil]

I need to get on with this...summer is on the way at last,and the car needs some presents.

Tyres first.....hopefully at the weekend.
Then it can undergo some surgery.

DSG Conversion

 

[Alex_Wil]

Just don't eat through the gearbox like i managed to on mine haha

 

[Smirky]

It really is a superb piece of workmanship but like all the best bits it's tucked away where no one can see it ,
My friends miltek looks like someone's school project compared to that

 

[Shapin]

Waiting for the dsg conversion too, its like BT all over again speedwise.

 

[S3Alex]

If/when we do the DSG conversion,it'll be done properly.

Storm can do it,and have already done it with the RS plus a Syvecs,so I'm not worried about that,but not sure I want to do it until everything else is just right.

 

[grainqey]

out of curiosity, if you went DSG conversion, would you go for the DQ250 or the (DQ500 is it from the TTRS)? I don't see how you could really run the DQ250 as isn't it only meant for 550-600NM give or take where as isn't the DQ500 meant for about 750NM?

I think I need the DSG map looking at on mine as mine now hesitates just after shifting which I think could be the route of the boost hose problem with it repeatedly popping off! it's only been noticeable since fitting the silencer delete and better boost pipes

Alex

 

[Shapin]

DQ500 of course, the dq250 cant handle that tq and with the price of a decent clutchpack its not worth it.
DQ500 FTW.

 

[Smirky]

I wouldn't put it past Alex saying neither and coming out with something from left field

 

[S3Alex]

DQ500 of course, the dq250 cant handle that tq and with the price of a decent clutchpack its not worth it.
DQ500 FTW.

The DQ500 is supposed to be the best,and there are clutchpacks available to extend the torque rating to 700lbs.

The same packs are available for the DQ250,so that discounts the issue re the 250,other than the extra gear...LOL

 

[Smirky]

Sounds very expensive when you can get a spec rated to near on 700ft lb for $800

 

[S3Alex]

Sounds very expensive when you can get a spec rated to near on 700ft lb for $800

It is,but the plusses are quicker shifts between gears,with less boost drop-off during those shifts.

It's the difference between dropping 5-600rpm as opposed to only a couple of hundred.

 

[Smirky]

Agree on the speed front ,loose a bit of envolvement though I think

 

[Shapin]

Less action and driver mod, but faster and with launch control