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2008cc 20 Valve Turbo Stroker Build

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

  1. Voigty
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    Voigty New Member

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    [Aug 30, 2010]
    Wow just read the whole of your thread very interesting read!

    Thanks and good luck! :icon_thumright:
  2. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Aug 30, 2010]
    Cheers matey, I'm sure this time the re-rebuild will be sound as I will lock myself away from the world for a few hours! That 350Z is sick, but if I'm honest its almost too good if you know what I mean, you would'nt want to thrash it would you, bit of a show pony really. I've also gone off the idea of a wrap, Ive seen a few matt black wraps and they always have greasy hand prints all over them, looks like a right nightmare to keep clean.

    :thumbsup: Cheers, glad you enjoyed the read, I'm sure it will be fine once I get it back together.
  3. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Aug 30, 2010]
    OUCH !!

    Gutted for you, such a simple mistake, expensive, but simple.

    A few more weeks won't hurt her, i am sure you will make sure she is right this time.
    PS is the turbo ok after having been starved of oil?
  4. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Aug 30, 2010]
    I see great minds think alike! that was my first thought when I realised it had run without oil pressure. Everything seems to be fine, the shaft still spins like a good'an without any play, I will just have to see what happens when I fire it up again, as I'm sure you know you can't repair the bearings in Garretts GT turbos so I hope I've got away with it. The strange thing is that when it ran it wept a small amount of oil around the oil restrictor so it didnt run dry which is really strange, plus I did put fresh oil directly into the turbo before turn on, I hope that saved it. Im sure it was still circulating oil, just not enough pressure as it was obviously internally bleeding oil back into the sump! Give me another week or so and it will be back together, all the parts are ordered now.
  5. DaveB1970
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    DaveB1970 New Member

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    [Sep 6, 2010]
    Bump for the best project on here....

    Keep the faith bud - the night is darkest just before dawn!! :zen:
  6. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 6, 2010]
    Cheers Dave, I sometimes wonder what I've started! Damn thing owns me now. I try to keep my chin up and crack on, sometimes things just make it hard work!

    I was hoping to get everything back together this weekend and start driving again but no such luck. My parts are stuck in customs and have been for a week now, God knows what takes them so long! As soon as they arrive I can re-assemble the engine again and have another go!

    the night is darkest just before dawn!! - I hope your right.

    :icon_thumright:
  7. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 7, 2010]
    Right I've just about finished kicking myself!

    Time to get this thing finally creasing some tarmac. I've have meticulously cleaned & inspected every single component in that motor including the head as well as the crankcase obviously, I've been high for a week on solvent based cleaners and I feel great! Good news is that everything looks tip top, the block is prepped and ready to build, all the ancillaries are fitted. The rods, ARP bolts & bearings finally cleared customs this morning, only £27 duties lol, I will collect these tomorrow so I can crack on plastigauging all the main & big end radial clearances, fingers crossed everything checks out and I can assemble it.........again. All being well this weekend should see it all together and in the car.

    Some random pics



    [​IMG]

    Crank still needs the gearbox input shaft needle bearing fitting as well as drilling & reaming to fit the timing belt pulley save your ass shear pin!

    [​IMG]

    Thought I would tack the timing wheel bolts in this time, shouldn't ever have to remove it and this has claimed its fair share of high horsepower 1.8T's as has the OEM timing pulley shearing its key hence the save your ass shear pin.

    [​IMG]

    Everything cleaned up and ready to go, I even cleaned each and every thread with my finger nail and cleaned out all the socket heads on the studs, everything is spot less.

    [​IMG]
  8. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 11, 2010]
    Good news, all the clearances checked out, I have spent the day assembling the motor in pure isolation. I'am 100% certain everything is torqued correctly, turns over very smoothly and I'm happy with the re-rebuild.

    Some interesting (well if your a bit of a geek like me!) differences in my new rods from Integrated Engineering:-

    [​IMG]

    Old rod at the top, new one on the bottom.

    You can see that the boss around the big & small ends is more substantial, with additional support where the caps mate to the rod. I can see why there heavier now hence the reason I had to buy 4 rather than just replace the 2 knackered ones. At first I crapped myself thinking they may be wider! There really isn't much room left in my crankcase! Luckily there dimensionally identical, whew.

    [​IMG]

    [​IMG]

    [​IMG]

    The small end is also different, the bush no longer has an oil groove, but has additional holes instead. This is better in my opinion, the bush has a bigger surface area now.

    Some more rebuild pics.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    I hope tomorrow is dry enough for me to get this back in the car, at least its just a straight forward engine install this time, no surprises. I'm still waiting for some gauges to arrive before I fire it up, not taking any chances this time! can't wait to hear that turbo whistling again, very tempted to buy a go pro camera to capture all the fury in HD.
    :whistle2:
  9. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Sep 11, 2010]
    hubba hubba i do love the look of that motor!
  10. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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  11. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 12, 2010]
    Cheers guys, Lets hope it all works out this time! Just off to get some fluids then its install time. Hopefully the gauges will arrive on Monday then I can fire it up and start tuning.

    :racer:
  12. crazy88
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    crazy88 Loving the anonymity

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    [Sep 16, 2010]
    Any news on the build then dude? Surely it's finished now...:p

    Good luck with it all. I'm genuinely excited for you, ha.
  13. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 16, 2010]
    Alright fella, Well the motor is back in the car and connected up, just needs the front end putting together. I've been waiting for the oil pressure gauge to arrive before I turn the key again, I think its waiting for me at the post office, I haven't managed to fetch it all week as I'm at work before the PO opens and by the time I get home its dark, feels like winter already. I'm hoping to get it moving this weekend if I don't get to pissed on Friday night!

    The last pics I took.

    [​IMG]

    [​IMG]
  14. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 21, 2010]
    Well its about time! She fired up straight away! 4 BAR oil pressure while cranking, 5 BAR at idle with cold oil which dropped off to 2 BAR at temp which is right going of OEM specs, Vacuum at idle was roughly 20 inches and the crank timing wheel is syncing perfectly with the ECU so the vitals are looking good. I have to admit the tappets are still a bit noisy!!! I'm hoping after a few miles they will bleed and quieten down? The exhaust note sounds very sinister :busted_cop:. I blipped the throttle a bit and that Tial BOV sounds naughty, not chavy which is what I feared. I can't wait to hear this thing spool that turbo!

    I desperately need a pair of those S4 front bumper bar mount jobbies before I can hit the road or my intercooler is gonna go bye bye, I'm not paying the ridiculous price Audi are quoting for them, please someone help me out here I've searched and called everywhere, pleeeeeeeeeeease :anbet:

    I had another box of goodies arrive of the goodshit variety today, I will save that for another post though!

    So bumper bars before I can drive it, anyone?
  15. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Sep 21, 2010]
    bet your glad to hear it fire again and will be good to see some miles on the new motor,well done matey i would love to hear/see this on the move :yes:
  16. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 21, 2010]
    Cheers dude, Its a big relief to hear it run, its always a scary moment but I'm not out the woods yet I guess. I can't wait to hear this at WOT and feel that torque hike, should make it all worthwhile. I will gladly take you for a fully spirited drive in it at the first opportunity, I'm sure the chance will come around. I've almost ordered the Go pro HD motorsport camera a few times now, just £300 quid is a bitter pill to swallow especially since I have to pay for a fair bit of paint yet, but I will get some videos soon somehow.
  17. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 22, 2010]
    HOLY ****!!! Over 500 views since my last post last night and not 1 single offer of bumper mounts, come on chaps someone must be able to help? Oh and feel free to comment, criticise & pi55 take if you feel the need, it is very eery in this project forum.
  18. phil76
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    phil76 Active Member

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    [Sep 22, 2010]
    First time i have seen this thread because normally go straight in to the A3 8p section but amazing work mate a really top job,so nice to see people doing this kind of stuff rather than the normal remap work,hope this all goes to plan mate,what is it your after exactly from an S4?,going to keep a close eye on this thread from now
  19. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Sep 22, 2010]
    Oh i will defo take you up on your offer on a spin out if i ever manage to meet up at any point and there is no need for criticism only praise mate :salute:
  20. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Sep 22, 2010]
    Good man, excellent work.

    The bumper bars from your A4 will work, you just need to add spacers to the top as long as you use the longer S4 bolts
  21. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 22, 2010]
    Cheers matey, its been a long, taxing & expensive project, I've very nearly taken a jerry can to it on occasion but fingers crossed the light isnt far away now. I will post a picture up of the parts I need as I realise my description of the part isnt the best lol. Stay tuned as the post should only get better from here on out.

    No worries chief it would be pleasure, doubt it will feel anything like that VRT of yours though, I could never have parted with it, that rado was stunning but your S3 is also uber clean, a very nice motor indeed and they have some serious potential, I know exactly what I would do if I had a clean slate & still might :)

    Any who I'm just having a look at the bumper mounting bars and wondering if I couldn't fabricate something myself that might also make fitting the bumper with the intercooler pipes fitted a bit easier!?! my A4 ones are pretty much useless to me now so its worth a go, plus its about time I broke out the TIG again anyway!
  22. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Sep 22, 2010]
    :thumbsup:

    I had tried this and either my fingers are too fat or its a major ball ache to get spacers in there while trying to protect the intercooler and I can't be doing with it, would prefer a better solution tbh, I have the longer S4 bolts already, if only the cross member brace was'nt aluminium this wouldn't be a problem. I think I have a plan!
  23. andys2
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    andys2 New Member

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  24. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 3, 2010]
    Yeah dude, it's all together, I've covered about 30 miles and it absolutely rips! It still needs some serious tuning, it's running pig rich but more miles and logging should get that sorted, I've avoided cracking the throttle right open thus far. I want to break the motor in a bit first, all the wot tuning will be done on a dyno. I need to get some video!!!!!! But all seems well, what a relief

    :rock:
  25. tompearson
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    tompearson It's all in bits

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    [Oct 4, 2010]
    Good stuff, been silently watching this one.

    Looking forward to seeing some plots.
  26. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 4, 2010]
    :thumbsup:

    Over 100 miles now & getting better all the time, I changed the break in oil & filter at about 40 miles for some mineral oil. I need to get an EGT probe & gauge now. Should be on the dyno in 2-3 weeks for some low boost tuning and get the timing dialled in, it has proper lazy curve at the mo. Lets see what she does at 1 BAR with more aggresive timing. Can't believe how well it drives as it is, I'm lovin it!
  27. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 25, 2010]
    Update.

    She's breaking in very nicely, I check the mileage after every outing, here's what I saw the other night.

    [​IMG]

    Bit eerie.

    Non the less It does seem to be getting better all the time. Still only at 7 psi, lame timing curve & not revved passed 5.5K but I swear its damned quick with it. I removed that stupid little bit of an air filter strapped right on the front of the turbo as it was just cooling the manifold and inlet temps were getting a bit silly and its ws obviously a bit gay, so I managed to rig up a better solution for the time being, I've got some better ideas now but the inlet temps are alot better, especially with all this cold air were gettin up norf!

    [​IMG]

    [​IMG]

    [​IMG]

    So all being well with the motor it was sadly time to insure this thing with every modification divulged, estimated 450HP, fully comp, commuting, 3 points & 8K miles a year :sadlike:. As you can imagine most people were just baffled that I had done this to an old Audi, they laughed and I got nervous! Quotes came in that really made me wonder what I had created. Anyway hours of hold music and automated menu's later I got thee quote I needed :eyebrows: a flat £1K, happy days I'll have some of that and thank you very much, job done.

    Now the MOT has expired :banghead: I presented if for test and it obviously failed. No cat in place & erm emissions! But it does spit them at you in liquid form! Not to worry though I've got it covered.

    Im going to book it in for a proper mapping session and serious dyno tuning and strangely MOT'ing:laugh:, can't wait to see what it puts down though, then hopefully straight in for paint so I can fit everything properly then it will at least look respectable.

    While I'm gathering funds for that lot I'm going to make a start designing my inlet manifold, should have the stock large port baseline tune data to compare it with by the time its done and if it survives I will post the graphs to compare it with. I think this one is Isaam's creation, very nice and may be the inspiration for mine.

    [​IMG]

    Spare large port mainfold, I'm going to use these runners and remake the plenum chamber with some nice CNC'd stacks I think, time to reacquaint myself with solidworks now its getting cold.

    [​IMG]

    It's always shocked me how compromised cylinder 1 looks on the underside of the stock manifold, surely can't be good when trying to push 250HP per litre.

    Ooh and its just over 800 miles now :kissmyrings:
  28. tompearson
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    tompearson It's all in bits

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    [Oct 26, 2010]
    Glad to hear it is still going strong.

    Quick question - what did you use to hold the crank still when torquing up the crank pulley bolt?
  29. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 26, 2010]
    Gettin there fella, its getting booked in for a full tune tomorrow.

    I fabbed a tool that worked at the time, bloody useless on a car with ancillaries though!

    [​IMG]

    Don't forget its a new crank bolt every time :thumbsup:
  30. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Oct 27, 2010]
    Thats a nice tool to have, i will be fabbing something similar myself shortly as i have to do my front seal when i do the cambelt kit.

    I cannot wait for some figures on this bad boy....
  31. tompearson
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    tompearson It's all in bits

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    [Oct 27, 2010]
    I hope you don't mind, but I'm going to nick your tool design and get my mate to fab one up for me. I had been trying to work out if I could make a plate that bolted to the block and the pulley, but there aren't really any suitable fixing points on the block (06A). It looks like a bar design like yours will be perfect though. Somehow I had missed this on one of my several reads of your thread.

    I went for a new OEM pulley and bolt. I see you went with a dowelled one (from IE ?). I don't like the idea of drilling into my crank (mostly the fact it would be me drilling into it), but then again I really don't like the idea of pulley keyway shearing and that keyway on the pulley looks seriously pathetic.

    :icon_thumright:
  32. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 27, 2010]
    Steal with pride mate, works a charm. I had mine rest against the viscous fan bearing housing on the ancillary bracket which works great when its stripped down. I'm sure a better solution could be found with a bit of eye balling.

    Yeah should of mentioned a new pulley is also a damned good idea, that keyway has got to be the weakest link of these 1.8T motors. That IE kit really is fool proof, you can't go wrong and its worth the insurance it gives you. I was tempted to also tack the crank bolt to the pulley but feared for the front seal and decided against it.

    Dyno soon and still haven't got a decent video camera!
  33. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Oct 27, 2010]
    Its a quick an easy one to fab up and a good one to hang on to.

    As for figures I'm nervous to say the least but looking forward to it, everything does seem to have come together nicely so far, its a completely different animal to the stock A4 TQS I remember. Even in its current state of tune its quick enough to expose some weaknesses in the set up. One being the stock rear ARB, its just ****! back end rolls around far to much and I think I need the race bush for my Apikol diff mount as isn't a stiff as I wanted. On a plus note the brakes are outstanding, very sharp and progressive and the car feels well balanced under hard braking. Big thanks to DaveB once again for sourcing the parts looks like we were spot on with the maths.
  34. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 4, 2010]
    Quick Update.

    She has covered an issue free 1200 miles now, I've switched over to synthetic oil and it instantly seemed much happier. I dropped the car off tonight for tuning & MOT'ing. Got to say it, I'm nervous as hell now, I just hope I get it back in one piece. I'm comfortable they know what there doing after looking over the software with them and chatting about the set up, they have tuned some serious cars, mostly drifters and timeattack cars including a hand full of seriously rapid 1.8T's that have graced the pages of performance VW. Its in for a full live mapping and WOT tuning on a braked dyno and shootin for 25 PSI, I will be along to observe the final runs on Tuesday hopefully, plots will follow soon!
  35. AudiS3-Turbo
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    AudiS3-Turbo Member

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    [Nov 4, 2010]
    awsome stuff! what numbers you hoping for?
  36. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 4, 2010]
    Anything over 400 and I will be happy. At this point in time I just want a massive improvement in driveability as it aint the easiest thing to drive at the moment. Lets just see what happens, cant wait to see home safe & sound now.
  37. crazy88
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    crazy88 Loving the anonymity

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    [Nov 5, 2010]
    Keep us all updated mate, I love this thread!!!

    Glad you have had 1200 trouble-free miles :)
  38. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 5, 2010]
    I sure will do bud, glad to hear it brings you some enjoyment to read :icon_thumright:

    Yep 1200 miles now and it can only get better, can't wait to see how it is once its tuned to 25 PSI. It was damned fast on 7 PSI and the turbo hadnt even got started down there. I need to get some videos soon, you have to hear this thing it sounds like a bloody jet engine.
  39. crazy88
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    crazy88 Loving the anonymity

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    [Nov 5, 2010]
    It sounds ace mate!!! Get a good quality video up asap, we need to see and hear this. When is the tune up gonna be finished?
  40. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Nov 7, 2010]
    Just a quick update.

    The car sailed through the MOT, so its now legit. I also had to drop off the N75 valve and banjo fittings for the other port on the Tial wastegate on Saturday. I also took the car out after the tune & timing was done for 7PSI and for the first time got to use the entire rev range, its awesome, who said the GT30R was laggy! Power comes on alot lower than I expected. I left him with the bits to start increasing the boost so I can't wait to see how it turns out. Dyno should be either Monday or Tuesday and then its done! Plots to follow very soon but unfortunately no video! That will have to wait a while, lets see if Santa can bring me a nice new camera. Next update when its tuned and hopefully a nice looking dyno plot.

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