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Another hybrid conversion thread....

Welly Sep 14, 2010

  1. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    Good work mate... hoping to start mine in the morning and have the head and turbo off ready to port the wastegate... if I don't waste any time gassing I may get it all done ready for fitting on Monday!.. although I doubt it tbh lol...

    <tuffty/>
     
  2. Plunky

    Plunky Member

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    Welly, I have some serious respect for you! you seem to be able to do everything yourself! and Im guessing your not a mechanic by trade, mentioning fixing computers?
    In all honesty, how difficult is it to remove and refit the head? I would have a go on mine as i need to drill out a broken mani stud in the head, but get slightly scared when it comes to refitting and a small issue of timing the thing!
    I've fitted turbos etc but timing scares me! :S
     
  3. finesse

    finesse Active Member

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    yeah Welly should open up shop & fix cars & computers
     
  4. Essflee

    Essflee Well-Known Member

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    Patience of a saint.
     
    Last edited: Feb 6, 2011
  5. Mpathe

    Mpathe 1st gear

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    how do you reset the belt tensioner welly as ive got the head off at the moment and it will be going back soon as I've got it pressure tested.

    sorry for the off topic
     
  6. Welly

    Welly VX220 SC Driver :)

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    Using a vice or a G clamp mate. Put pressure on it gently, then it will slide back in. Use something as a pin through it, and then it's good to refit.
     
  7. Welly

    Welly VX220 SC Driver :)

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    So far today, good progress....

    Photo of the head last night ready to fit...

    [​IMG]

    Started today with taking the engine mount off, resetting the tensioner and refitting.

    [​IMG]

    That's all sorted now, combined with the new belt on waiting to be fitted.

    Took my intercooler pipe up to Bill so he could weld in a boss for my WMI... (thanks Bill - again :thumbsup:). Anyway, he had that done in a very short time indeed, so I was off home before long.

    [​IMG]

    [​IMG]

    Refitted the intercooler pipe to the car, and threaded in the WMI nozzle and check valve with a bit of instant gasket to help it seal.

    [​IMG]

    [​IMG]

    I started running the pipes then, and fitted the WMI pump to it's new home. Made a bracket to make it fit, and bolted it in to see how it fits. Really pleased with the result :thumbsup:

    [​IMG]

    [​IMG]

    Then decided to see how easy this head would be to get back on with the manifold bolted up, and more importantly, how hard the nuts would be to get onto the studs...

    Difficulty - easy. Time taken - ages.

    This was easy once I had devised the right tool for the job. I went and mangled an old 17mm spanner into the right shape for the job... Photos below for reference.

    [​IMG]

    [​IMG]

    One of the nuts is very hard to do up as we know, I have got it as tight as possible, however only time and the engine running will tell if it's tight enough... Fingers crossed.

    Finishing up the night, the engine bay looks like this:

    [​IMG]

    There is tons of space where I modified the heat shield, so I am really pleased with that. Tons of room, but it's still protecting all the important stuff... Shibby

    Shouldn't take long to get it to the point where she will be able to run, but then I've got to drop the sump afterwards and change the pickup pipe.
     
  8. finesse

    finesse Active Member

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    impressive
     
  9. S3 Nattie

    S3 Nattie Quattro ist für sissies

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    Very nice work dude, looking forward to seeing how it performs compared to the INA mani and what figures you will be running with WMI
     
    Last edited: Feb 7, 2011
  10. cecilthesausage

    cecilthesausage ...It's Never Finished...

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    What is a WMI
     
  11. s3dave

    s3dave TFSI Hybrid Supporter

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  12. DaveA3

    DaveA3 Audi A-Trizzle!

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    busy weekend for u mate glad its sorted and fingers crossed everything is ok for ya. top work mate.
     
  13. s3gazz

    s3gazz Well-Known Member

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    nice work pal and good look
     
  14. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    wellys now fitted his Xs Power tubular manifold..
    WMI to come tomorrow..

    Ran it tonight to check afr's ok...
    Impressive gains.... above and beyond 034 hi-flow mani, faster spool by 400rpm, more power more torque.. and without WMI running :)

    hopefully tuffty can upload the video.. much glowage

    [​IMG]
    [​IMG]

    Best Number before:
    331.7bhp / 277.4lbft
    Tonights run:
    343.8bhp / 302.1lbft

    12.1bhp gain and 24.7lbft gain over and above best previous 034 ex mani

    WMI comes tomorrow..
    350+bhp within reach now.

    Well done Welly.
    fingers crossed the mani lasts. It certainly works flow wise. better spool than 034 is nice.
     
  15. Welly

    Welly VX220 SC Driver :)

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    Thanks for your time dynoing it dude. Again. lol.

    ^^ What Bill said - the graphs speak for themselves. Tired out, even after 2 cans of Monster Energy but f**k me I am sooo happy with that output.

    Few bits to finish up tomorrow, then will take some photos of the manifold fitted and the water meth install.

    I'm a very happy boy :thumbsup:
     
  16. Dane

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

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    Way hey! Nice results there, you must be well chuffed
     
  17. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    <tuffty/>
     
    Last edited by a moderator: Aug 15, 2014
  18. finesse

    finesse Active Member

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    wow
     
  19. Welly

    Welly VX220 SC Driver :)

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    Yeah, she gets a bit hot.... water meth will help that thank god.

    To be fair, that's how hot the OEM mani used to get. The stainless mani's heat fades so much faster then the cast item used to, as you would expect.
     
  20. Speedy Steve

    Speedy Steve Active Member

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    Holy glow sticks batman.:applaus:


    Good to see it fade so quickly and awesome results well deserved mate!
     
  21. Barks

    Barks Member

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    Thats some cracking work there Welly, well done!!
     
  22. Prawn

    Prawn My other car is a MINI!!!!

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    Properly awesome Welly!

    Never throught 340bhp+ would be possible from a ko4 hybrid to be honest, that's some pretty mental power.

    Torque curve looks amazing too! Not typically 20vt like, it just holds so late in the revs!
     
  23. superkarl

    superkarl MAN OF STEEL

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    It must pull like a frickin train!!!
     
  24. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Thats amazing, cant believe the power and torque your making mate.

    Would you not heat wrap the mani?
     
  25. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    I hope it proves to a long lasting and fruitful project matey.

    My hybrid is 100BHP down on that, and i am scared for how long it's gonna last.
     
  26. S3 Nattie

    S3 Nattie Quattro ist für sissies

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    Good figures dude and nice torque curve. Lets hope the XS mani is bit more reliable than the INA one.
     
  27. Prawn

    Prawn My other car is a MINI!!!!

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    Problem with heat wrapping as I understand it, is that it stops the heat getting out to damage other stuff in the bay, and actually keeps the heat within the manifold, so makes it MORE likely to crack!
     
  28. s3dave

    s3dave TFSI Hybrid Supporter

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    Excellent figures there welly/bill it makes the labour worth it when you get nice results......
     
  29. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    Nice work and impressive figures for that diddy little turbo!

    You'll find the manifold wont get nearly as hot when actually driving, as there will be a lot more airflow over it.

    I just hope it lasts, you've taken a huge risk fitting it, especially as you're proper fed up with removing the cylinder head.
     
  30. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    you have'nt seen welly drive have you :p

    "diddy" little turbo which has a 35lb compressor wheel in it..
    GT28Rs..... same flow abiltiy compressor to put things into perspective ;)
    just faster spooling in a k04 wrapper.

    I think we're all hoping it lasts for Welly...
    shows, if you allow the hybrids to breathe they can and will breathe... and unlock their flow potential.

    Its all about the flow - Badger5 Mantra
     
    Last edited: Feb 8, 2011
  31. Welly

    Welly VX220 SC Driver :)

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    OK, so after last night's happiness, normal service has been resumed... with epic failure. lol.

    WMI installed today... and when I say installed, I use the term loosly. It would seem that this pump being gravity fed for the inbound water is a necessity.

    Pics here:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Arse.

    So my positioning of the pump above the outlet for the screenwash tank hasn't really work as well as I had hoped... The bloody pressure produced by the pump (with all the water it can't get) is an epic fail. Having tested the theory with a Devil's Own tank held above the pump, it started spraying properly as expected....

    So, a rethink required there then. Have decided now to mount the pump in the empty space left by the driver's side original intercooler. This seems the ideal place as is directly below the screenwash tank, and I can still use the original lengths of pipework I have run, and will require very little wiring modifications. Have decided, based on the new pump pump location, to simply run the pipework across the front of the car, along the intercooler, and then around to the pump.

    [​IMG]

    [​IMG]

    Moving on, the pump housing on the union for the water in is cracked, and leaking. Bugger. Bill's words were 'Araldite is your friend'. So thats what I have tried basically. I spanked a whole lot of it on there to produce a nice coat, and will do a second lot after this has dried. Hoping that I will never need to get that union out now, as I don't think it will be coming out easily...

    [​IMG]

    Lastly, I seem to had developed a water leak from the pipe that mates to the side of the head. I knew the O ring looked a bit gammy, and the pipe is slightly cracked.

    Ordered one from Audi on the way home, to find that when I got home, the leak had decided it wanted to stop... Will keep an eye on this for a while and see what's what...

    Waiting for the pump to dry so I can recoat with more epoxy resin, and then hope for the best....

    Positive mental attitude FTW! :thumbsup:
     
  32. superkarl

    superkarl MAN OF STEEL

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    Keep it goin lad! We all wana see that bumble bee flyyyy!
     
  33. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    Good work mate, onwards and upwards... must have been the day for it as I managed to fit the cam belt pretty much first time with no hassle only to find I had forgotten to move the crappy engine mount bracket into place so had to do it all over again... what a PITA that was... then I realised I had left the old driveshaft heat shield in place when I test fitted it before putting the head back on... needless to say everything hit it and its proved to be a PITA to remove... gave up at 7:30pm as I will need to remove the driveshaft to help get it out...not the best day but hopefully start the old girl up tomorrow...

    <tuffty/>
     
  34. Welly

    Welly VX220 SC Driver :)

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    One of those days me thinks.... Waiting for the third coating of epoxy resin to dry now.... Leak? I don't think so. May slap a bit of silicone on there for good measure as well! :eyebrows:

    Not putting the engine mount back on must be due to doing too much work on Ibizas...
     
  35. Welly

    Welly VX220 SC Driver :)

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    :yes:
     
  36. Sandip

    Sandip Well-Known Member Team Nogaro Blue

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    Is the new target 400bhp? lol
     
  37. Welly

    Welly VX220 SC Driver :)

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    I wish.... sadly impossible with a 35 lb comp wheel... :(
     
  38. Sandip

    Sandip Well-Known Member Team Nogaro Blue

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    Not to worry, 370bhp? :)

    I think we should all guess where it'll be after water/meth lol
     
  39. superkarl

    superkarl MAN OF STEEL

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    359hp
     
  40. Welly

    Welly VX220 SC Driver :)

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    The grand plan is this.

    I plan to see what can be achieved with the hybrid power wise, and with water meth. It's probably worth mentioning that the MAF element which was in the S3 when it was dyno'd was underreading by around 5 g/s but I suspect that the affect on the output will be small to none. My MAF element is back in now, and am seeing what I would expect from the air flow readings.

    Once we have a figure, I plan to see what can be achieved by dropping the boost from 24 PSI down to 20, and adding timing to replace it. My engine runs a lot of timing advance as it is, but with less boost, the timing can be advanced more.

    Less boost means less heat, which ultimately means more chance of the manifold lasting. I would rather have a reliable car at 340 ish BHP running water meth, than a car which is running on a wing and a prayer, on a 'not if but when' basis.

    Ideally, I would like to see over 350 BHP, and if i can find a way to run that reliably, then fantastic. If not, I need to stop figure chasing...
     
    Last edited: Feb 8, 2011

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