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2008cc 20 Valve Turbo Stroker Build

Discussion in 'The Project Room' started by IN 2 Deep, Oct 14, 2009.

  1. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [May 31, 2010]
    Christ! I could talk your ear off all night with the projects I've been involved in both for business & pleasure. I'm 30 this year and have been in the Engineering arena since I left school. I'm a timed served electronics engineer and spent a couple of years at uni afterwards learning how to solid model using Autodesk Inventor & solidworks. I spent nearly 5 years in South Africa as an engineering project manager / designer / commissioning engineer mostly for water treatment plants but I've designed & built caustic dissolving plants, syrup tank automated cleaning systems, reverse osmosis plants, DI plants! The list just goes on & on so I've learnt a thing or two along the way. My welding interest came about after supervising welding teams in Kenya building a coca cola factory as well as working for a company that built aluminium boats. A good friend in SA was a very competitive super bike racer so I was his crew! I kept the bike in tip top condition for him even changed his damn tyres needless to say he won the 2 seasons I was able to help him, I myself use to ride alot of MX and enduros and always rebuilt my own engines and they are 1/4 of a superbike nowadays. I also repaired gearboxes for a year, from everything from trucks to race cars. I have always worked on cars from the age of 15 and they are my real passion, I've just never had the time to build one really. My job at the moment is working for a military hardware manufacturer as a project manager, I'm in the middle of developing a new machining process to hold the wings & tails on a plane!!!!! No pressure, I'm using the same machine they use to bore than Maclaren SLR blocks. So as you can see I have been very fortunate in my employment and have had some awesome jobs that have taken me into all manner of industries and processes.

    I hope that doesn't make me sound like a knob!?! Its just an insight to what I have been involved in without going into the boring details. But I think if you know how to torque a bolt and use a micrometer you can build a motor, if you can change a head gasket your on to a winner and welding is just practice, I taught myself!

    Thats right, But its a lot of work to get it in there and I can't really recommend doing it. I don't know my S3's but if it has the 058 block you could use that crank but like I said its a bitch to get in, certainly not for the faint hearted. The rod stroke ratio is right on the limits of what you want aswell. If your going all out fella and you have an 058 block considered swapping for a tall deck block and go 2.2, better rod stroke ratio and obviously more potential or if your a proper badass go for an R32 motor with a silly turbo and destroy some gearboxes! Just like this thing:-

    http://www.youtube.com/watch?v=4Id2O0vC7Lk

    I see you've already had a VR6T so you would be well in your comfort zone.:icon_thumright:

    If I could start again I WOULDN'T build the motor I now have!
  2. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [May 31, 2010]
    the ABF is a better fit in the 06A motor as used in the later A4s and all A3's S3s etc as the block doesnt need clearencing or mods to the oil squirter etc

    oooopppppssss MY bad
    Last edited: May 31, 2010
  3. phoenixv6quattro
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    phoenixv6quattro staylowmovefast

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    [May 31, 2010]
    Fair play mate fair play!! Anything to do with BAE systems? I used to be on a team that tested a lot of their more "experimental" products..... ; - )
  4. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [May 31, 2010]
    Got it one
  5. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [May 31, 2010]
    That will need a 2.0 FSI crank if its anything like an 06A. You wont get that crank in a later bottom end that's for sure, like I said I don't really know the engine codes in S3's, TT's etc.
  6. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [May 31, 2010]
    EDITED, Sorry
    my Bad
  7. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [May 31, 2010]
    thanks very much for the info :icon_thumright:,ive been researching allot and the amount of cost and work involved to get a 20vt to the 400hp mark,its expensive! I know a stock 12 valve VR6 motor ,spacer plate and strap a gt35r will produce 400+ easy with 18psi of boost and are rev happy......but i still would prefere to mod the current motor and still utilise the haldex and esp etc....this thread just keeps on teasing me ha ha
  8. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [May 31, 2010]
    No worries, I forgive you.

    Dude, I've just had a sneeky peek at few pages of your build thread, 65 pages!!!!!! you need to do the R32T thing and use the haldex lol, But if you dead set on using the 1.8T the quickest thing to do is figure out which block style you have, to my knowledge there are only two, easiest way of distinguishing them is see weather the water pump is an external unit or internal to the block, then your options are pretty clear. I can help you get motor internals at very good prices, not egging you on or anything, and no I'm not a salesman! But your right about the VR6's though, much cheaper than these 20 valvers and the noise is pure :rock:
  9. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 6, 2010]
    :tumble:

    LOL

    Update.

    After a frustrating week I haven't finished everything I wanted. The exhaust is 99% there now, I just can't find a female 3" V band flange that mates to the 034 Motorsport downpipe, very frustrating. Here are some random pics from my iPhone, I had to the cut the exhaust and extend it as I hadn't fitted the ARB and it was obviously in the way! What a douche :keule:

    [​IMG]

    But it did allow me to check on the penetration I was getting though.

    [​IMG]

    [​IMG]



    [​IMG]

    [​IMG]

    [​IMG]

    The last pieces to put together once I get my hands on a flange that fits!

    [​IMG]

    [​IMG]

    I've also given up on getting these Mk5 R32 rear discs to fit, its not that I'm defeated its just the time needed to get it right. So I'm going to buy my way out of the problem and get the RS4 rear discs, this way everything will just bolt up and its a done deal and I can get behind the wheel sooner, my RS4 calipers are away being stripped, cleaned & painted, new seals fitted ready to bolt on.

    I did manage to finish off a few other little bits and bobs, obviously the rear ARB! all the braided rear brake hoses are re-fitted, Wideband sensor fitted and the front end all stripped down. I've put my A4 rear bumper back on for now, I can't get the pre facelift S4 rear bumper on without a bit of butchery and that's not how I roll so its for sale and I will just get the S4 facelift from Audi, getting discount there now although not enough!

    Next task is intercooler mounting and piping, should be easier going than the exhaust, I've been under the car and fitted / removed the exhaust hundreds of times which is literally a pain in the arse. Then tow it up the road to get the alignment done and wait for the ECU & loom to arrive as 034 Motorsport are incapable of delivering against there promised delivery date thus far, so who knows when that will arrive. I ordered this stuff in February!
  10. sam80quattro
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    sam80quattro Member

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    [Jun 6, 2010]
    looks the business that, i've had stuff from 034 a few times now and both times its arrived within 1 week of ordering???
  11. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 6, 2010]
    Sam I have ordered lots of there products and there mostly off the shelf items, I would normally receive stuff within a week or so but I believe its the loom that's holding things up as they actually have to make it themselves! Wish I had bought another ECU now and made the loom myself, I went this route to try and save some time :banghead:
  12. sam80quattro
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    sam80quattro Member

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    [Jun 6, 2010]
    aye thats **** that, surely its only a few hours work to make the loom? i know i made my own loom for my 1b ecu and it didnt take to long, obviously wont be as nice as a pro loom but it works lol what do they say when ya ask what the hell is going on? lol
  13. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 6, 2010]
    It is a bit out of order really, but they just promise me another date and it still doesn't get done. I'm stupid as I can make looms to MIL spec's so should have just made my own, thought this would have been quicker and less hassle!
  14. sam80quattro
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    sam80quattro Member

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    [Jun 6, 2010]
    should get money off for every day late it is, they'd owe you money at this rate lol
  15. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Jun 6, 2010]
    fantastic fabrication/welding skills mate,love to hear this fire up!
  16. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 6, 2010]
    If only, that might make up for the frustration I feel. As far as they know the car is waiting for the ECU & loom but that doesn't seem to induce any urgency from them. The last promised finish date came & went and they now say they have started it! Not sure I believe anything they say anymore.

    Cheers fella :icon_thumright:

    Hopefully won't be long till I post videos rather than pics, can't wait.
  17. phoenixv6quattro
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    phoenixv6quattro staylowmovefast

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    [Jun 6, 2010]
    As usual nice work mate. You probably have mentioned it, but what rearbox/backbox is that you are using?
  18. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 6, 2010]
    That back box is just a cheapo universal silencer, Its not very big I know 5" x 350mm, I wasn't going to bother with it but thought it might just be too loud with just the mid box. My plan all along was to play with the exhaust once its up and running, the layout of the exhaust will allow for different mid sections to be swapped easily using V bands so cat, de-cat etc will be minutes of a job with no horrible bolts or gaskets. I also want to do some dyno tests and try out some ideas like a big anti-reversion chamber and see if it helps spool / power.
  19. crazy88
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    crazy88 Loving the anonymity

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    [Jun 8, 2010]
    Amazing thread dude. It's always a joy to read the updates. I quite liked reading the CV paragraph too!

    I've recently finished uni in electronic engineering myself, but have gone back to manchester uni for a PhD...who knows why!? Your job list sounds ace though, very impressive.

    Keep going though mate, getting so close now!!
  20. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 9, 2010]
    Cheers pal, its always encouraging to hear that.:icon_thumright:


    Talking of CV's I'm off to Germany for the next week to expand that list of projects! Just down the road from Ingolstadt at a factory where the first Audi was born, they have some pretty awesome Audi memorabilia but I'm not allowed to take pic's. Anyway that unfortunately means nothing will happen to the car for a while. On a positive note though, I had a decent chat with Christian at 034 Motorsport this evening regarding the whereabouts of my loom & ECU and the timeliness of its delivery, He assured me it was on his bench and about to be built and that I should have it ready to collect from DHL when I return from my travels. That will make me a very happy man indeed, my RS4 calipers will also be ready so it will be nose to the grind stone when I get back. There should be nothing much holding me back, then its party time! Vids soon :icon_thumright:
  21. DaveB1970
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    DaveB1970 New Member

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    [Jun 13, 2010]
    Andy , I hope you dont mid me saying that after having a good read you are a total lunatic.

    Awesome though....se you soon
  22. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 21, 2010]
    Aye up Dave, how's it going. Of course I don't mind you saying I'm loony, It can't really be denied! I do often wonder what I've started, bit late now though ;)

    Don't worry I will defo swing by and take you for a blast when its done, I'm sure you'll call me alot worse then lol.

    How are those RS4 calipers coming along? I will give you a bell when my head stops spinning from the amount I've got on at work.
  23. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 13, 2010]
    Well its been a while, works been hectic, my 20 year old type 89 Coupe decided to have a proper paddy and has had me on my hands a knees wrenching on a filthy motor. But testament to Audi durability and tank like build quality it survived surgery after a massive overheating and a mangled water pump, dont know how it kept cam timing! The thing just won't die!

    Anyway back to business, first off a big thanks to DaveB for turning these RS4 calipers into something beautiful, I can't tell you how chuffed I'am with them. Dave is the man when it comes to brakes, what he doesn't know about brakes isn't worth knowing and always has some automotive jewellery to temp you with, if your after some nice anchors for your VAG car he's your man, He's supplied all my brake components and is a top bloke. I hope you don't kill me for the lame picture it certainly doesn't do them justice, I will post better pics when there fitted.

    [​IMG]

    Nickel plated handbrake linkages, cadmium plated pad sliders, powder coated to match the fronts all new seals etc, happy days.

    Engine bay is coming along now, all vac hoses are in, catch can & N75 on a custom bracket, coil cover, Innovate wideband, decided to use the stock viscous cooling fan for now, saves time, money and frees up an ECU output. Made a start on the intercooler mounting brackets and piping which will be finished off this weekend weather permitting.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    But most importantly the ECU & loom arrived today!!!!!!!!! Can't tell you how happy I'am to see it and put and end to my frustration. Only took 5 months! The delivery was incomplete though but thats business as usual with 034! But it does mean I can't finish the exhaust or hook up the coolant feed to my turbo so It can't go anywhere just yet. Lets hope its not another long wait for a Vband flange & coolant fitting! I have to say they have done a nice job on the loom, no complaints there thankfully.

    [​IMG]

    A few more weekends!!!!
  24. Foxmeister
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    Foxmeister Fired Up!

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    [Jul 15, 2010]
    Slow n steady wins the race, coming along nicely now mate. Like the look of the bay, very nice but also not to wild.

    Loom looks nice aswell, will look mint when put together
  25. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 15, 2010]
    Cheers mate, almost there! Just need the rain to stop so I can play!

    Just busy working my way through this lot, I'm going to remove all the redundant wiring because there is so much of it. I'm pinning out every wire before cutting out the big foam thing in the middle then rewire the bits I need, just tedious work but hopefully worthwhile.

    [​IMG]
  26. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Jul 15, 2010]
    ooooooo thats shiney.

    Does it come with a base line map?
  27. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 15, 2010]
    It sure does! Latest firmware as well and upgraded to a 4 BAR (absolute) MAP sensor.
  28. satans child
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    satans child project...satans child

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    [Jul 17, 2010]
    im so glad its all coming together for you now bud....

    im so so sorry it took me so long and was such a nightmare.... but all ends well.... :icon_thumright:


    speak to you soon buddy...
  29. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 19, 2010]
    Not quite!

    I know you did everything you possibly could to get that loom fella, no worries. I know it was our friends across the pond that drop the ball, things just don't get any better..............


    Update of progress.

    I finally made sense of the stock ECU loom and began butchering it! In the end I only needed 17 of the wires that enter the engine bay!

    So from this

    [​IMG]

    To just these :yes:

    [​IMG]

    The stock harness is now in one piece and installed, the 034 looms were in & I discovered they ain't long enough to reach the inside of the car despite being absolutely certain on the phone and email with pics where it was being mounted & the coil plugs are positioned back to front aswell! i.e. Cyl 1 plug is in cyl 4 position. Nice! you could connect everything up but it would look **** trailing wires over the rocker cover and either having to chop up & splice or make extensions to the looms just ain't happenin. I think its time to make my own loom and return this one for a refund, can't believe it after all this waiting around. I'm also still waiting for my missing parts. Not happy. And just to add insult to injury I ordered my rear RS4 brake discs today, Damn there expensive. I can fetch them tomorrow though.

    Rant over!

    Some random pics

    [​IMG]
    All the connectors on the left are redundant.

    [​IMG]

    [​IMG]

    [​IMG]


    Next job, finish off the intercooler mounting & plumbing, fit the rear brakes, bleed em up and test the pedal feel, I've been waiting to see how the pedal feels with this brake set up, the numbers looked promising anyway but we will see. More updates when the bloody rain stops.
  30. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Jul 20, 2010]
    that does look sooo good! what sort of power are you expecting with this set up? will the stock inlet flow enough for it?
  31. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 20, 2010]
    Cheers Dude :icon_thumright:

    I'm hoping for power figures of around 450-500 crank HP when fully tuned. The stock inlet mani & throttle body probably will cause a restriction. For now though they will do just fine, I plan to make further modifications once its running, at least then I will be able to see the gains or losses from the mods.
  32. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 20, 2010]
    Still raining!

    I've almost got everything I need to finish this build now, picked these up after work, they are very nice & so so light.

    B5 RS4 rears

    [​IMG]

    [​IMG]

    [​IMG]

    Just rear pads, air filter & fluids now and I'm good to go! oh and the missing parts from 034. I'm so frustrated not being able to work on the car with this constant down pour! Can't wait to see it all come together.
  33. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Jul 20, 2010]
    i hate you.......... :laugh:

    What pcd and size are they? dare i ask how much they cost?
  34. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 20, 2010]
    :jump:

    There 5x112 PCD and 312mm x 22?mm rotor size. I got these at £200 each including after shopping about. Cringe worthy I know, but I just want to get it rollin! There so nice its almost a shame to use it as a brake disc!
  35. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Jul 21, 2010]
    Expensive yes but your sure going to need all the stopping power with that blower under the hood :icon_thumright:
  36. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 21, 2010]
    I couldn't agree more, I do like good brakes :)

    There was a small break in the clouds and the rain stopped for a while, I actually saw the sun!!!! So with that I got busy with the intercooler mounting & piping for a while, I have a good feeling these are going to turn out quite nice. The weathers looking good for the weekend so I'm hoping to make some decent progress. Still no sign of missing parts yet from 034.

    [​IMG]

    A bit more work required to finish off the mounts.

    [​IMG]

    Bends all prepped, a bit more trimming here and there and were good.

    I'm just double checking the pinouts on my 034 looms in case I decide to extend it into the car, I'm contemplating mounting it behind a slimmer battery against the bulkhead? then I wouldn't need to cut into it and I can get going.
  37. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 25, 2010]
    Wee update.

    I have been trying to finish off the intercooler install over the weekend, I keep getting distracted! I also had to repair the coupe again! So welded a patch on the exhaust due to massive hole being blown through it on my way to work and had to rebuild the alternator after the rain finished it off, all seems well again until next time!

    Here are some random pics of driver side charge pipe, just needs beading on the ends and jobs a good'an. Im just finishing up the passenger side now. These were autogenously welded or fused (no filler).

    [​IMG]
    Mocked up for fitment with masking tape holding it together

    [​IMG]
    tacked together

    [​IMG]
    Purging with argon

    [​IMG]
    welded

    [​IMG]
    Installed

    Thats all folks!
  38. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 25, 2010]
    2 Updates in one day!

    Finished off the other charge pipe, Just need to tidy up the mounts and give them a coat of paint and bead the pipe ends and that's the intercooler circuit is squared away.

    [​IMG]
    Tacked

    [​IMG]
    Purging

    [​IMG]

    [​IMG]
    finished

    [​IMG]

    [​IMG]

    [​IMG]
    Fitted

    Next job will be to fit the rear brakes and bleed the system. More updates in the week. I'm on a mission now :racer:
  39. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Jul 25, 2010]
    you have made good progress! coming together well. :drool:
  40. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 25, 2010]
    :thumbsup: Yep, yep. Been hard at it all weekend. I love it when it feels like I'm inching closer to the finish line. Managed to get through quite a bit. Also found time to make a few runs to the tip as well! Just busy configuring my innovate wideband controller to the 034EFI's taste, forgot to mention that 034 haven't updated my ECU's firmware! I haven't figured out how tell which MAP sensor is installed yet, I bloody hope that's at least done, they really are useless, still waiting for the other parts I need before I can turn the key. It's not on. But hopefully they will arrive before I'm sat twiddling my thumbs. More updates in the week.

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