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BAM S3 full rebuild for Hybrid or BT

Discussion in 'A3/S3 Forum (8L Chassis)' started by hoffmanvp3, Sep 18, 2013.

  1. Prawn
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    Prawn My other car is a MINI!!!!

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    the thing with Dan (BBT) is that he has many fingers in many pies at present! Hybrids for the 1.8T, 2.0 TFSI, and even TFSI fitment turbos onto 1.8T's like mine!

    it doesn't help that both the 1.8 and 2.0 use 'k03' and 'k04' turbos as standard, when there is no link between them at all, a tfsi k03 and k04 are not at all similar to a 1.8T k03/4, it's all very confusing!

    In summary, BBT has made a k04-023 hybrid for a long while, and to my knowledge ALL the very good results from hybrid turbos in the past 2 years have been BBT units, with this latest one Bill mapped last week being one of the best I've ever seen.
  2. Prawn
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    Prawn My other car is a MINI!!!!

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    haha, Dan's confusing me now, giving all these things new names :laugh:

    Good choice man, on a well built engine that will perform very nicely indeed! mine was absolutely fantastic.
  3. hoffmanvp3
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    hoffmanvp3 Active Member

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    Well i still feel very disapointed not going Garrett as i made a bomb proof engine (well i hope i did lol) and now going Hybrid BUT this will make the car feel very lively and a back road weapon:)
    Just need to source a good manifold or try porting my oem one
  4. badger5
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    badger5 RIP S3dave Site Sponsor

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    why not going garrett btw?
  5. hoffmanvp3
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    hoffmanvp3 Active Member

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    ran out of money lol and my missus paitents
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  6. hoffmanvp3
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    hoffmanvp3 Active Member

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    Well some thing came in the mail today:)
    [​IMG]
    [​IMG]
    [​IMG]
    LOBA stage 2 SMF...good for over 503NM :)
    Sam_ and Westy like this.
  7. Prawn
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    Prawn My other car is a MINI!!!!

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    370lbft, not THAT much more than a hybrid could produce :racer:

    Looks dead smart! is the flywheel alloy?
  8. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator

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    I'd assume not, as theres no bolted on steel friction ring!
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  9. hoffmanvp3
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    hoffmanvp3 Active Member

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    As far a i know the Flywheel is billet so would asume an alloy of sorts??
    390.91 Ft Ibs to be precious lol:)
    Its a Sachs race kit basically
  10. hoffmanvp3
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    hoffmanvp3 Active Member

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    There is some kind of wafer thin metal spacer thingy on the oem dmf, will i need to transfer that to the new smf? no instruction inside lol
    Also Elsawin suggests you tighten up the pressure plate in a clock wise direction, Thought you`d tighten up in a criss cross patern like you do with your wheel bolts?
    Cheers
  11. Prawn
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    Prawn My other car is a MINI!!!!

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    If you want to be precious, it's 370.99, hence why I said 370, not 390 :laugh:

    Still, plenty for you, looks nice.
  12. hoffmanvp3
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    hoffmanvp3 Active Member

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    That **** app is getting binned lol
    Sorry Prawn your right lol fecking iphone
  13. Sam_
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    Sam_ Down under

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    I was looking at those Loba clutches. They look good. Low torque ratings but I've heard they underestimate quite a bit. Where did you get it and how much?

    They're billet steel flywheels by the way.
  14. Jason.s
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    Jason.s Active Member

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    Thing is without launching the standard clutch can hold 350ft-lbs+

    Welly managed alright and Karls going by the same facts too. So a clutch like the CGMotorsport stage3 kit for instance which is 40% over standard is going to withstand a fair bit over that.
  15. Sam_
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    Sam_ Down under

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    True. I'd just hate to get the thing together and have a "weak link" for the sake of a few hundred bucks. Taking the car back off the road, taking the box off and changing clutches doesn't make it viable really. If I had the space to do it myself it might be different...
  16. hoffmanvp3
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    hoffmanvp3 Active Member

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    Yea LOBA run this clutch on a 600nm+ car and holds fine
    if you speak to Mark Brodie @ Brotek he'll give you full prices:)
    Well today I fitted the new clutch kit and got the gearbox and block mated back together and ran the first bolt in before I released id forgotten to fit the metal gasket between the gearbox and block....Doh!!!
    so off it came again and was even harder to put back on as the fecking metal gasket kept coming off and fouling the 2 dowel.
    The head is completely remanufactured and for £450 cash if you know what I mean:):)
    needed 2 new exhaust valves as they were burnt to feck and. A light skim and it's sparkling so will be fitting tomorrow and hopefully back in the car by sat and start running in.
    Also BBT has acquired a good condition KO4 for me today for his hybrid make over:)
    [​IMG]
    [​IMG]
    [​IMG]
  17. hoffmanvp3
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    hoffmanvp3 Active Member

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    That's the head back. Practically brand new:)
    so it's head on, a few hoses, turbo and back in the S3.
    Tomorrow's gonna be a long day then I'm in Kuwait on Sunday so hope to have the engine running toot sweet by end of play sat:)
    [​IMG]
    [​IMG]
    £400 in the end so happy with that:)
    Brazuko and slowcoach3 like this.
  18. Prawn
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    Prawn My other car is a MINI!!!!

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    Whilst it can and has been known to do so, I'd sincerely hope that nobody would actually assemble such a setup, but more likely just inherit it through not having to change a clutch as part of an upgrade path.

    surely karl isn't fitting a stock clutch with his super fancy new build?
  19. slowcoach3
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    slowcoach3 Active Member

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    I killed an oem luk dmf in 10k with only 320lbft :( just saying. Think some get lucky some don't.
  20. hoffmanvp3
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    hoffmanvp3 Active Member

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    All down to the map I would imagine. How the map produces the torque
  21. superkarl
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    superkarl MAN OF STEEL

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    sure am. Brand new stocker that will be abused till its death.

    Too many people stress about clutches, 'what clutch for 3/4/500hp?' etc etc.
    Its a wear and tear part, strike a balance between affordability and life (i got this new oem one SUPER cheap), even when it dies i wont replace with anything super fancy, no clutches 'rated' to 500nm for me, they ALL wear, hell even some 'uprated' ones wear faster when they arent used for their intended purpose.

    Some people are too succumbed to the marketing bs of clutches. If i had the time and money id test an uprated one next to an oem one and show how quickly both can be destroyed.


    P.s. 10k out of a clutch and il be over the *** moon, hell, 5k il be happy.

    P.p.s sorry for my ramblings, was only supposed to be some bedtime reading
  22. hoffmanvp3
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    hoffmanvp3 Active Member

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    oooooo some ones in a mood lol :)
    well mines a organic friction disc with an Uprated pressure plate. Read that sintered ware like nobody's buisness and are not the easiest thing to work for every day use especially in traffic
  23. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    More down to the way you drive tbh... 500ftlbs won't kill a clutch if all you do is cruise on a motorway at 70mph

    I still think the clutch setup I use is a tough one to beat... SK has a point in that its a consumable which it is but it also depends on if you can change the clutch yourself or have to get a garage to do it...

    A consumable that only costs 150 quid but 500 quid to fit is not a nice thing to have to do every 10k tbh...

    My clutch plate has survived numerous launches and my previous rat run of hill starts and slow moving traffic although the paddle plate is pretty much end of life at 20k in my case... but thats down to how I drive and the type of driving I do to get me from A to B...

    Clutches are massively subjective as is the wear... if you can nail a std clutch (on any level of tune) in 10k miles or less then an uprated one won't last that much longer tbh...

    <tuffty/>
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  24. hoffmanvp3
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    hoffmanvp3 Active Member

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    ITS ALIVE!!! After starting at midnight last night I have just blitz'd the engine install. So teething issues to sort along the way but the engines running beautifully now....apart from the howling like a banshee power steering pump.
    Couldn't get 10w40 mineral and was worried mineral wouldn't agree with the turbo so went semi 10w40 for £14 for 5ltrs. later after a couple of starts she's only half full so off for some more tomorrow but got a flight to Kuwait so won get to enjoy her till I'm home but by then bbt will be finished with my fresh hybrid:)
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  25. badger5
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    badger5 RIP S3dave Site Sponsor

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    more down to the owner's use I would suggest

    std clutch on uprated power is questionable
  26. hoffmanvp3
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    hoffmanvp3 Active Member

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    How long does it usually take for the pas pump to quiet down?
    Cheers
  27. Westy
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    Westy Double Dark Side! Diesel & 8P

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    Straight away really. Fill the reseviour then keep turning the wheel full lock left to right till the noise quietens down. Top up reseviour and repeat till the fluid doesn't disappear.
  28. hoffmanvp3
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    hoffmanvp3 Active Member

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    Cheers bud:)
  29. Gops
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    Gops 6th gear @7000rpm

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    I'm defo going for the tuffty clutch! Worth every penny!
  30. hoffmanvp3
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    hoffmanvp3 Active Member

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    Here's one of the 2 nackered exhaust valves
    [​IMG]
    Cracks right through seat seal area
  31. hoffmanvp3
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    hoffmanvp3 Active Member

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    Here`s the rest of the pics from installing the engine back into the S3
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    And the cheesy grins begin:) It fits....It fits lol
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    And the moment of truth......Vroooom:)
    [​IMG]
    [​IMG]

    And home in time for tea and medals lol
    Will be doing a comp test when im back just to make sure every things groovy
    Sam_, jojo and Westy like this.
  32. hoffmanvp3
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    hoffmanvp3 Active Member

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    Whats people thoughts on the Bosch 440cc injectors on Hybrid KO4?
    Big enough or should i go for 580cc for good measure?
    Bosch 440cc injectors 0280155968 1.8t | eBay
    I know my oem will be passed there max duty and needing new ones.
    I did do a search but really get the answer i was looking for, or if any one has for sale:)?
  33. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Bosch 550's or don't bother...

    There are plenty of fake/copy versions of those greens... personally I would touch them with a barge pole... Bosch 550's are the best injector on the market (and the genesis branded versions)... end..

    <tuffty/>
  34. hoffmanvp3
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    hoffmanvp3 Active Member

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    Cheers mate, Bill got any by chance?
  35. Prawn
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    Prawn My other car is a MINI!!!!

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    Beachbuggy is doing a cracking deal on some 630cc injectors at the moment hoff, dead cheap and future proofs you nicely.

    550's run at 90% DC ish on the best ko4 hybrids, so provide enough fuel, but the 630's are such a bargain at the moment.
  36. Prawn
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    Prawn My other car is a MINI!!!!

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    also - clutches - I couldn't give a **** how long they last, as karl says, it's consumable to a degree. For me, building an engine that will possibly overcome the clutch on the first application of full throttle seems like utter madness.
  37. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Ha ha!.. :D

    Yes, he normally has these in stock :)...

    In all honesty they are the best injectors I have used personally and there is plenty of data for them so all the decent custom mappers will know how to dial them in...

    I have run them for ages on my GT30 setup (@4bar) and love um... the 630cc dekas I had previously where complete sh*te on idle... (very non linear at low pulse width)

    I have now got the 750cc version of the Bosch injectors for my GT35...

    <tuffty/>
  38. hoffmanvp3
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    hoffmanvp3 Active Member

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    Cheers mate, will call him when im back as Dan`s almost finished my Hybrid:)
  39. hoffmanvp3
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    hoffmanvp3 Active Member

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    Well should be seeing my bbt hybrid ko4 towards the end of the week.
    Some other things turned up while I was in Kuwait
    Badger5 v2.2 tip c/w heat shield and bmc induction filter
    [​IMG]
    [​IMG]
    [​IMG]
    Cheers Bill
  40. hoffmanvp3
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    hoffmanvp3 Active Member

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    Got bored today at work so made this outta the nackered valves
    [​IMG]
    Thinking maybe a small wire rope between them and hang it from my rear view mirror lol
    superkarl likes this.

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