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Audi S3 - Stroker Big Turbo build.

Scullies Jan 7, 2013

  1. Scullies

    Scullies Well-Known Member

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    Thanks Karl :thumbsup:


    Here is a time lapse of seating the inlet valves - I only used the fine grit paste as the valves were seated properly on the first build.
    Once I have finished the exhaust valves, the head with get a good clean an all the supertech valves, valve springs and titanium retainers will get fitted back into the head.

     
    Last edited by a moderator: Aug 15, 2014
  2. Kuvi-S3

    Kuvi-S3 Active Member

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    Amazing build bud! Gona be watching this closely
     
  3. Scullies

    Scullies Well-Known Member

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    Thanks bud, I won't be going so in depth like some of the other builds. It's all basically the same.
    time lapse is easier for me. I can leave the camera recording, than having to stop and take pictures.
     
  4. JUS3IN

    JUS3IN 14.0 @ 98mph 2s 60ft

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    insane build man, and i thought you owned normal yellow s3 lol!-)
     
  5. Scullies

    Scullies Well-Known Member

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    It is normal yellow :sly:
     
  6. Scullies

    Scullies Well-Known Member

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    Today I put the head back together after giving it a wash to get all the grinding paste and dust off of it.

    Here's all the supertech valves ready to be put back into their respective area.

    [​IMG]

    and the "special" valve tool

    [​IMG]

    and then a time lapse of assembling the AEB head with supertech valve train. Head is waiting for VVT and cams to be fitted.

     
    Last edited by a moderator: Aug 15, 2014
  7. Scullies

    Scullies Well-Known Member

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    Nothing too exciting today. Cleaned the carbon off the pistons and fitted them to the IE rods.

    Ready to be assembled..

    [​IMG]

    Assembly..




    Things are on track to get the motor assembled this weekend :yes:
     
    Last edited by a moderator: Aug 15, 2014
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  8. MIGGZ

    MIGGZ nanananananananan BATMAN

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    so much win dude!!!!!!!!!!!!!
     
  9. Kuvi-S3

    Kuvi-S3 Active Member

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    I love it!!! Very informative build
     
  10. Scullies

    Scullies Well-Known Member

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    Started assembling the engine, here's the time lapse video of fitting the crank and checking the main bearing clearances.


     
    Last edited by a moderator: Aug 15, 2014
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  11. Scullies

    Scullies Well-Known Member

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    Finishing off the engine build,




    Waiting for bits from the engine that's in the car at the moment, then the cams can go in.

    [​IMG]
     
    Last edited by a moderator: Aug 15, 2014
  12. Sam_

    Sam_ Down under

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    Nice! How does the full race manifold line up the downpipe in regards to the master cylinder? Is yours LHD?
     
  13. Scullies

    Scullies Well-Known Member

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    Yeah, mine is a lhd, so the MC is on the opposite side to the downpipe. also its not a full race mani but the same design type. I fabricated it myself and welded by someone else, I had to bring the t3 flane closer to the head to fit the turbo in, as well as tilt the turbo over a bit to allow a 4" TIP to be fitted. It it was straight the TIP would of hit the MC.
     
  14. Scullies

    Scullies Well-Known Member

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    If anyone is looking for AN fittings to fit the Bosch 044 fuel pump, I found this place that does them for $14 complete.

    Bosch 044 Inlet/Outlet Fittings

    [​IMG]
     
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  15. Sam_

    Sam_ Down under

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    Good fair price
     
  16. Scullies

    Scullies Well-Known Member

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    Hot here today
     

    Attached Files:

  17. g60leigh

    g60leigh Well-Known Member

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    Ouch! That is hot
     
  18. chemicalboy

    chemicalboy New Member

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    Nice buid man!!! There are some s3 with stroker kit. Look at s3 stratis on youtube.
    Will you use WMI??
     
  19. Scullies

    Scullies Well-Known Member

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    Geeeez, that's crazy power. I don't think I will be heading down that road. Tha'ts Andrews@A.L.D department :scared2:

    WMI is definitely going to be part of the setup
     
  20. chemicalboy

    chemicalboy New Member

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    I am playing with hybrid K04 in my S3 and you with that toys!! Hahah. You are the luckiest man in the world of the s3's 8L!!
     
  21. Andrew@A.L.D

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

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    :iagree:
     
  22. MIGGZ

    MIGGZ nanananananananan BATMAN

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    Hey hey hey..... Where's the updates bra?
     
  23. Scullies

    Scullies Well-Known Member

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    Absolutely **** all, its been pretty warm and I dont have the energy at the moment to swop the engines out in 45+ degs.
    I was hoping to get it down before things got hot here but I think I have missed that cut off date.

    My mate here is going back to the US for a few weeks at the end of June and he said I can use his workshop when he is gone.
    So hopefully by the end of the month it will be in, but then I'm going to need the WMI to do the mapping as things will be cooking by then. Will have to be midnight/early morning logging but its still warm then, around 30 deg
     
  24. MIGGZ

    MIGGZ nanananananananan BATMAN

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    Dude that's hectic hey! Its winter here now but the days I'm off work its 28'+ and I can't dyno to get a reading.
    What wmi kit you gona run?
     
  25. Scullies

    Scullies Well-Known Member

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    Its going to be a DIY hybrid kit :arco:
     
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  26. Scullies

    Scullies Well-Known Member

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    Taking advantage of the last of the "cool" weather with an early morning blast through the mountains.

     
    Last edited by a moderator: Aug 15, 2014
  27. Andrew@A.L.D

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

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    Nice long open roads you must love getting your foot down

    In the uk we have more donkeys, Not the animal type but the type that can't drive
     
    Last edited by a moderator: Aug 15, 2014
  28. Scullies

    Scullies Well-Known Member

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    There are plenty of those creatures this side too, that's why we go early as they still sleeping.

    That road is awesome and let's just say I'm glad there are no speed cameras on the route :D
     
  29. Scullies

    Scullies Well-Known Member

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    collecting parts for wmi
    Tank and level sensor for $25 - gotta love the forums.
    Missed out on a new AEM pump and boost switch for $75 :banghead:

    [​IMG]
     
  30. Chlippo

    Chlippo Member

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    I might go to Dubai soon, I should visit :)
     
  31. Scullies

    Scullies Well-Known Member

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    So some more bits arrive

    WMI pump, was looking for a 300psi pump but this new one came up for a deal.

    [​IMG]


    An a small catch can with AN fittings. The plan is to run black braided hose from the IE breather kit to the catch can. I want to run 2 separate lines, one for the crankcase breather and one for the valve cover breather. Will see how the oil smell is, so at the moment it will vent to atmosphere.

    [​IMG]

    Then got some of these 6an fittings that are said to clip onto the stock fuel line fittings that come into the engine bay. Then AN lines to a surge tank and fuel bump.

    [​IMG]
     
  32. g60leigh

    g60leigh Well-Known Member

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    Your WMI pump looks just like my AEM one
     
  33. Scullies

    Scullies Well-Known Member

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    Yeah, it seems these 200psi all look pretty similar. Probably same manufacturer. Even the 300psi one looked the same.
     
  34. Scullies

    Scullies Well-Known Member

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    So today I braved the heat and did I little bit of trial fitting to familiarize myself with the setup again.

    So AEB runners fitted along with fuel rail and TIP. I wanted to see if the breather lines would like better going under or over the TIP to the catch can. I think it will look neater going under, bearing in mind all aluminium pipes with end up black.

    [​IMG]

    Since the spare oil filter housing I have is from a N/A car, I found a nifty brass adapter that will allow me to extend the oil pressure switch and add an oil feed line to the turbo. Aftermarket oil pressure switch will be fitted to the filter housing in the spare port on the top. Xcessive plenum is on order but the people in the US are celebrating their independence day so shipping will be delayed a few days.

    [​IMG]

    Now been looking where to fit the DV, I previously had it located near the TB but have decided to change it to the OEM position, except having the DV sit closer to the charge pipe and then dumping into the TIP with a straight hose and not the one thats fitted in the picture. Its all I have at the moment. Again waiting on piping and silicone for charge pipe.

    [​IMG]
     
    Last edited by a moderator: Aug 20, 2014
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  35. superkarl

    superkarl MAN OF STEEL

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    Looks good. i dont know where to put my dv yet, but i like the idea of it close to the charge pipe, but then it'd be more of an arse to change coil packs.
    what maf sensor housing is that? Is that a 4 inch tip?
     
  36. Scullies

    Scullies Well-Known Member

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    The DV would be fitted to a nipple off the charge pipe, so it would only need to loosen a hose clamp and pull DV out. But my setup requires, DV off, charge pipe off and heat shield off to access plugs or coil packs. Fsi coil packs will be bolted down so they wont be popping off.

    something like this - Universal 2 5" Type H RFL Blow Off Valve Adapter Turbo Aluminum Flange Pipe Tube | eBay

    The MAF housing is a B7 S4, which is the same as the B5 RS4

    http://www.audi-sport.net/vb/a3-s3-forum-8l-chassis/172611-fyi-maf-sensor-housing.html

    TIP is a 3.5" with a 3.5" - 4" elbow on the compressor housing. Also there is a nylon spacer pressed onto the filter side of the MAF to increase the MAF diameter to 100mm so the air filter can be clamped down.
     
  37. superkarl

    superkarl MAN OF STEEL

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    Thats the perfect maf for me then. Ive got a 3-3.5 inch coupler on my turbo inlet, and want 3.5 inch all the way to filter.
     
  38. Scullies

    Scullies Well-Known Member

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    I have received the last of the bits for the WMI setup. Will use a single nozzle setup on the k04 engine for now and it couldn't have arrived any sooner as its been 50deg the last 2 days, not that I drive the car as it has no AC atm :banghead: and the holy month of Ramadan has started, so thats no eating/drinking in public from sunrise to sunset as per the fasting rules :tumble:

    All that is needed is to get a bung welded into the IC piping and find the energy to install the system.

    Now introducing my SNOW DEVIL MIST water/methanol system :lmfao:

    [​IMG]

    Plan to use the 2nd nozzle, check valve and boost switch along with a solenoid as a 2 stage setup with the BT engine. Will see how that works out.



    Saw this on FB - love it
    https://www.facebook.com/photo.php?...64913212.34366.150566708367481&type=1&theater
     
    Last edited by a moderator: Aug 20, 2014
  39. MIGGZ

    MIGGZ nanananananananan BATMAN

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    Very curious to see how the twin nozzle setup works you gona do before turbo or before cooler?
     
  40. Scullies

    Scullies Well-Known Member

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    Before turbo??

    Been advised to use the larger nozzle just after IC, as normal. Then the smaller nozzle near the TB.
    So the idea is stage 1 starts off 15-18 psi going flat out, then stage 2 kicks in at a high boost, thinking 28-30psi. This will need to be tested at different boost levels first to see if it all works out as planned :)
     

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