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Another hybrid conversion thread....

Welly Sep 14, 2010

  1. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    omg that gaskets fugly!
     
    Inertiauk likes this.
  2. S3 Nattie

    S3 Nattie Quattro ist für sissies

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    Aww I see what you mean now, that pretty annoying lol.

    Any maps Bill.

    Nathan
     
  3. DaveA3

    DaveA3 Audi A-Trizzle!

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    lol when i saw that gasket i thought that was like some sort of mock up template for the proper one. dont matter tho aslong as it works ey!
     
  4. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    I am too good to you :p
    [​IMG]

    let me know what you think the axis are in unit wise please, the scan i received cut them off
     
  5. Welly

    Welly VX220 SC Driver :)

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    Exactly. Function over form. Seems to be spot on to me!! lol.
     
  6. Welly

    Welly VX220 SC Driver :)

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    OK, test drive last night confirms all OK. Big sigh of relief.

    Boost creep is now gone completely and the turbo produces a steady 23 PSI boost, as opposed to 23, then creep to 25.

    Awaiting my injectors and we're good to go....
     
  7. Prawn

    Prawn My other car is a MINI!!!!

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    Happy days Welly!

    really looking forward to seeing how you get on.

    How does it feel to drive now?
     
  8. Welly

    Welly VX220 SC Driver :)

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    Quick - lol. In seriousness though, it's hard to explain. That manifold has changed the way it drives significantly. Seems to be a little more laggy, but to be fair, I haven't really given it the beans to fully test. (Well maybe a little).

    Obviously, it's not going as it was as there is now less boost on tap because the wastegate's not creeping. I'm leaving it like that now however as the fuelling isn't right, and in that case, less boost is a good thing.

    Can't wait to get these bloody injectors now. I've found why they are taking so long. I ordered them to be sent via FedEx, however they sent them via USPS by mistake. IE have refunded my costs accordingly, but it sucks they aren't here yet.
     
  9. Speedy Steve

    Speedy Steve Active Member

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    Wow what the Hell did he use to cut that gasket His Teeth ? Im currently saving so i can bring the car down for clutch manifold and WMI fitting all in one go not an easy save with crimbo coming ever closer and Mr Tax man hitting me with a nice bill for having a company van
     
  10. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    evil tax man commeth...
    and 20% vat in the new year too.. oh joy :(
     
  11. Welly

    Welly VX220 SC Driver :)

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    Yeah, glad I got all this worked nailed down this year really. As frustrating as it has been....
     
  12. S3 Nattie

    S3 Nattie Quattro ist für sissies

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    Thats awesome Bill Thanks. Is that for a hybrid K04 or a standard item.

    Nathan
     
  13. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

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    Hmm forgot about that, might try and collect parts before the end of the year.
     
  14. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    the hybrid larger wheel k04
     
  15. Welly

    Welly VX220 SC Driver :)

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    Got home to pick up my car at lunchtime and was greeted by an unexpected surprise....

    [​IMG]

    Yay :)

    Look good, O rings look to be the right size, and the VAG harness adapters fit. 550cc with a 6 hole spray pattern...

    Booked my motor in with Bill on Saturday morning for the (hopefully) final instalment of mapping.
     
  16. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

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    Yes mate! I'm excited about this, so I can only imagine how you're feeling.
     
  17. Welly

    Welly VX220 SC Driver :)

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    Yeah, I'm looking forward to seeing what happens with it. So much of my time and hard work has gone under that bonnet in the last 12 months. I've felt joy and happiness, but I've also felt misery and suffering. Lots of misery and suffering.

    However, I've kept going with it, despite repeated threats of burning the damn thing, and hopefully all that hard work will come good with a pleasing result, not that the results are not already pleasing enough to be fair.
     
  18. superkarl

    superkarl MAN OF STEEL

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    at last it'l be sorted for you dude, your car will be awesome and hopefully nice and reliable power for you, no more worries of failing internals!

    well jealous, wish i could know how its going to drive! sh*t hot!
     
  19. Welly

    Welly VX220 SC Driver :)

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    I'll video it a bit on the road.... just for you dude. I love filming cars (on private roads) giving it a bit of beans.... :)

    She flames quite a bit.
     
  20. JD09

    JD09 I'm not modding, I'm improving VCDS Map User

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    Whoop, cooking on gas!
     
  21. superkarl

    superkarl MAN OF STEEL

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    argghhhhhhhh flamesssss! thats cream pants material!
     
  22. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    vid on the dyno... see the glow... :)
     
  23. Welly

    Welly VX220 SC Driver :)

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    I'm not convinced it will do it any more dude. Not like it did at least. It used to glow under normal(ish) driving conditions, but doesn't now that the 034 is installed...
     
  24. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    dyno will win the S3 vs dyno battle :D

    goods news is if its not glowing like it was' its not being choked like it was.. which is superb to hear
     
  25. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

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    having just driven along side Welly's motor I'm even more convinced I need some of this in my life
     
  26. Welly

    Welly VX220 SC Driver :)

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    LOL, small world and all that....
     
  27. Welly

    Welly VX220 SC Driver :)

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    Planning on fitting the new injectors either tonight or tomorrow night. I'm anxious to get the 4 bar regulator off the car so it stops over taxing the fuel pump.

    Also think now that the turbo has been heat cycled a few times I will need to check the tightness of the bolts between the turbo and manifold... Still no blowing from it which is good - my fugly gasket has worked a peach. :thumbsup:
     
  28. IbanezDan51

    IbanezDan51 Member

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    Looking good mate! Keep me posted on the injectors lol!

    Where can I get an 034 manifold? Are they on the website yet?

    Cheers
     
  29. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    you got unisettings welly yea?

    downloadable from here> http://www.unitronic-chipped.com/downloads/UniSettingsBoschME7.zip

    works with vag-com cables (mostly)

    see what block 001 does once warmed up on idle and cruis throttle... see its % and adjust fueling by 80% of that number in ch10, so if block 001 is reading 20% adjust ch 10 down from 100% to 84% and relog...
    remember this is only applicable on yours Welly, on idle and cruising throttle.. open throttle lambda is not being used... (on yours)

    this will get it close..., but stay off the loud pedal until saturday, as we must confirm full load throttle/boost fueling to ensure its not too lean.
    regards
    bill
     
  30. IbanezDan51

    IbanezDan51 Member

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    Bill is that essentially lemmiwinks?
     
  31. Welly

    Welly VX220 SC Driver :)

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    Yeah, I've got unisettings dude, I used to use it to advance my timing etc before.

    That's fine, I shall give that a go and see what we come up with.
     
  32. Welly

    Welly VX220 SC Driver :)

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    **sigh**...... OK :(
     
  33. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    it does same job yes -
     
  34. Welly

    Welly VX220 SC Driver :)

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    OK - injectors are in.

    First to be changed was the 4 bar regulator, swapped out for the 3 bar regulator. I could almost hear the fuel pump's sigh of relief.

    [​IMG]

    Awwww :bye:

    Bosch injectors fitted to the rail...

    [​IMG]

    [​IMG]

    It turns out that these injectors are spot on for the 1.8T rail. The don't need spacers to fit like the VXR injectors, or many other injectors that get used.

    I'm not convinced that the VXR injectors O rings were a very good seal into the inlet manifold injectors seats. Block 032's short term trim was climbing before without any real reason as there were no air leaks in the pipework. Now that the Bosch 550s are in (and they are a pukka fit - just like the standards), that fuel trim is steady, well as close as needs be.

    This is a shot of the 550s against the standard S3 injectors to show comparative size:

    [​IMG]

    I've had to remove 13% from the primary fuel enrichment to get them somewhere close to being right, and I quote Bill, 'thats ok for now...'

    Will be good to see what's what come Saturday....
     
  35. superkarl

    superkarl MAN OF STEEL

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    your signature is brilliant. as always
     
  36. IbanezDan51

    IbanezDan51 Member

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    Time to place a set of those beautys on order! Cant beat em at that price! Tempted to wait to see what your mapping session brings though! Hmmm!

    Dan
     
  37. Welly

    Welly VX220 SC Driver :)

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    Yep, mapping will show them for what they are, but as of now, I'm very happy with them fitment wise.
     
  38. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    I will have some 440cc green giant ones for sale soon as i plan to use my 630cc ones with a GT Turbo now
     
  39. Welly

    Welly VX220 SC Driver :)

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    :sign_plug:

    lol

    [​IMG]
     
    Last edited: Oct 22, 2010
  40. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    630cc wont stretch to gt35 usage tho...
     

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