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Dane's Hybrid Conversion Thread

Discussion in 'A3/S3 Forum (8L Chassis)' started by Dane, Apr 11, 2011.

  1. s3dave
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    s3dave TFSI Hybrid

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    Joys of motoring..... Be interesting to see what cr says ..... No doubt it will be sorted in the end
    Not nice wasted time/ money ....
  2. Dane
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    Dane Faster than a V12 Q7

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    So the car feels absolutely friggin awesome dispite being in safe running mode. Its so urgent and it makes a suuuweeet noise.

    However it's even fighting me now, its now started missfiring AAARRRGGGHHHH! Not under load like before just all the time. Pretty sure it's cylinder 4 which popped up with a fault code a few times on the dyno.

    So I'll get a coil pack tomorrow and hope it sorts it out.

    And I um... Ran out of water meth already.... In fairness I think I had under half a tank left the medium nozzle must hoof it in! Lol
  3. Lee172
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    Lee172 GT3071

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    You have had the car for a night and already run out of water meth? lol how long is a tank supposed to last?
  4. Dane
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    Dane Faster than a V12 Q7

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  5. Welly
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    Welly VX220 SC Driver :)

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    One of those jobs mate :-(. Sorry to hear all the aggro that CR have been giving you.

    I feel it might be worth giving them a wide birth here on in, their performance this time around has been sub par to be nice.

    Oh dear....

    Bulls**t..... :p
  6. Dane
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    Dane Faster than a V12 Q7

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    It's not a coilpack so I'm limping it to Bills later, some crazy shiz happening.

    I'll put the kettle on Bill!
  7. Welly
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    Welly VX220 SC Driver :)

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    That will be a hateful drive, but it will sound cool :)
  8. superkarl
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    superkarl MAN OF STEEL

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    Hope your luck turns around
  9. Dane
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    Dane Faster than a V12 Q7

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    Yeah don't I know it! It'll still be better than the micra. It sounds amazing already with the milltek etc. and the Forge short shift feels ace too!

    Although it does seem to have a bit of dv chatter...

    Time will tell, although if everything else is anything to go by it wont be simple.
  10. Dane
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    Dane Faster than a V12 Q7

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    Cheers dude!
  11. badger5
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    badger5 RIP S3dave Site Sponsor

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    your wiring problem again I suspect. short to plus on #4 injector is whats poppped up a few times whilst here
  12. Morgan-VAGCHECK
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    Morgan-VAGCHECK Foot to the floor

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    Hi Bill,

    Wow thats some bad run of luck, hope things improve for you.

    I am guessing the actuator rod on the Forge unit is binding on the little blue guide/spring retainer ?

    I have previously had this occur with a brand new Forge K04 unit after the engine/turbo had seen a few heat cycles..

    Is the hotside not Wellys originally ported one, or did CR open it out some more ?

    Regards
    Morgan
  13. Dane
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    Dane Faster than a V12 Q7

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    Bill seems to have cured the misfire, the positive supply wire's insulation had perished and cracked, taped it up with a bit of relooming and it hasn't done it since :)
  14. slappy_dunbar
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    slappy_dunbar Let's Do This

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    Diabolical might not be the right word after all.
  15. badger5
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    badger5 RIP S3dave Site Sponsor

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    sadly not.. CR replaced it as they reported it was cracked.. (stupidly I had'nt checked before I sent it, it was always cracked slightly from 1st refurbished and wellys)
    CR's bored out chinese housing! is shyte.

    From what I now believe, I must have lucked on the magic size and porting on wellys as it ran mint. Boring a sodding great 29mm hole right into the hotside however is just ****!

    CR's *cough* porting - bore it out right thru
    [​IMG]

    Std k04 hotside
    [​IMG]

    Wellys original one I ported
    [​IMG]

    Hmmm - spot the difference

    turbines:
    Std turbine
    [​IMG]

    clipped CR turbine
    [​IMG]
  16. slappy_dunbar
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    slappy_dunbar Let's Do This

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    Bill -- what trim is that clipped turbine wheel? Is it a stock K04 unit at 50/42 or possibly a 50/45 from an RS6?
  17. badger5
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    badger5 RIP S3dave Site Sponsor

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    its supposed to be a 7 degree clip, on an RS6 turbine wheel
    Dani_B19 likes this.
  18. slappy_dunbar
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    slappy_dunbar Let's Do This

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    You realize of course that this ham-fisted "clipping" procedure is motivated by a surging issue seen on a small, different turbine rotor, right? Clipping an RS6 wheel? Why do that?
  19. badger5
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    badger5 RIP S3dave Site Sponsor

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    hiya, not quite right doug.

    roberts (rsmith on scn) LCR was smallport, 2283/k04 with unclipped RS6 turbine, and his was the one which had issues and surging..

    Wellys was "just" on the edge of surging, when it ran initial boost spike of 24psi, and almost none when it ran 22psi

    It was on the basis of this that the clipped turbine was thought to be a cure for surge. robert had the v2 unit which ran rs6 turbine with 13 degree clip and 2474 comp wheel, but this neither surged nor made power & would'nt hold boost, being quite flat in comparison to the V1. Roberts fmic did however have a higher pressure drop across it, which would of hindered flow (hampered surge) imho. fixed now however by a big fmic he now has.

    V1.2 (this one) is 2283 and 7 degree clip on RS6 turbine, AND, massive wastegate porting (aka bored out to hell)
    no hint of surge, and on spool and airflow plots it did seem to compare well to wellys original one. no dips in airflow like seen with surging units.

    the lupo's k03/2283 also has 7 degree clip and has no surge.. my two gauge cars I can relate to. wellys original, danes current, and lupos hybrid

    would i want a clip again? I dont think so.. and would manage its tendancy to want to surge by suitable boost mapping.
    Last edited: May 31, 2011
  20. Dane
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    Dane Faster than a V12 Q7

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    Man I love this thing and it isn't finished :)

    [​IMG]

    I found a tunnel - just for the sound
  21. Pedrosousa
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    Pedrosousa Member

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    Great sound :D
  22. Dane
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    Dane Faster than a V12 Q7

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    Cheers man,

    Right you lot are goin to be so proud of me, I actually fixed something!

    So my exhaust starts blowing, it's done this in then past and it's been the egt sensor jumping out of the turbo, a quick call to bill ( sorry for interrupting your evening dude) and I think I can do it.

    So off comes the tip and low and behold the egt sensor is sitting on top of the gearbox. But I can't see where it goes in and everything is chuffing boiling. After a quick call to Welly (cheers dude) I put on a pair of gloves remove the charge pipe, strut brace and heat sheild so I can kind if see what's happening and try and find holes to put the sensor in - I only bloody did it!

    Proper proud of myself I start putting everything back together, get to tightening up the jubilee clip for the red charge pipe and.... Click! F-ing bullsheet motherfecker found another one after half an hour and now every things groovy!

    All that time spent at bills must have rubbed off on me!
  23. s3dave
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    s3dave TFSI Hybrid

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    Are the threads gone on EGT? why does it blow out?
  24. Dane
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    Dane Faster than a V12 Q7

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    It tightened up well enough so there must be some thread there, but it's done it on 2 turbos now.

    If it weren't so expensive or didn't work I'd replace it.
  25. badger5
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    badger5 RIP S3dave Site Sponsor

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    the probe threads are there and look undamaged, and tightens up ok every time.. but it also works its way out every time.
    this is now on 2 different turbo hotsides its wound back out from.. Weird.

    Well done on the fix Dane.. my heart sunk when you called last night (1st night I have taken off for weeks) as I though "oh no manifold I made has croaked" - Phew it was'nt, and I hoped it was the egt probe.

    with whats on the way to me turbo wise, I will need to do something re the egt fitment, so will "fix" it so it cannot unwind when we revisit it.

    T-boy and now actual spanner monkey :D

    (only need to remove TIP tho dude, as you can reach round to get the egt probe)
  26. Dane
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    Dane Faster than a V12 Q7

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    :lmfao: Getting there hey! I had no idea where the hole was when the turbo's in situ so I took it all off so I could sort of see what hot bits I was nearly touching lol
  27. Speedy Steve
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    Speedy Steve Active Member

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    Next youll be changing the oil every 5000 miles Dane. I know what you mean though having all the work done makes you happier to work on it yourself
  28. Dane
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    Dane Faster than a V12 Q7

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    Happy doesn't even begin to describe it, I did a little ' I actually fixed it' dance
  29. slappy_dunbar
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    slappy_dunbar Let's Do This

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    How much "slack" does the lead have for that EGT probe? You mentioned it resting on the transmission when it fell off. Is there enough wire to make it possible to re-locate that probe to the manifold perhaps?
  30. Dane
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    Dane Faster than a V12 Q7

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  31. badger5
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    badger5 RIP S3dave Site Sponsor

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    the issue with the factory egt probe is it sits into a counterbore and is clamped into the counterbore by the m12x1 nut. not like usual 1/8" npt type fittings. to fit this probe into a.n.other location an adaptor would need to be made to replicate the factory fitment (like I have done on tufftys)
  32. slappy_dunbar
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    slappy_dunbar Let's Do This

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    Bill -- a photo was posted earlier in the thread. Here it is again.

    The hole here is M12 x 1.00 thread, yes? The probe casing carries this thread as well, with a locknut that then spins down to the machined surface, securing it. Am I right?


    [​IMG]
    Last edited: Jun 2, 2011
  33. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    Yeah that's him, the probe bit itself bottoms out to create "the seal" and the nut secures it in place.
  34. slappy_dunbar
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    slappy_dunbar Let's Do This

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    Here's a good look at it. Like you said elsewhere, it has a sort of ferrule which is shaped to seat into the countersunk hole.

    [​IMG]
  35. badger5
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    badger5 RIP S3dave Site Sponsor

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    thats it doug.. the nut clamps it to the counterbore which has the slight chamfer lead angle on it.. It cant be too deep else the nut bottoms out on the thread on the turbo housing and the ferrule is not pushed into its seal face (like the CR/chinese housing on Danes currently is..) - I have 3 x M5 plain stainless washers packed under the ferrules head to make up the machining error gap..
  36. Welly
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    Welly VX220 SC Driver :)

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    Hmmmm, not ideal. One of the issues with those housings, that and the threads for the manifold bolts....
  37. slappy_dunbar
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    slappy_dunbar Let's Do This

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    A sample turbine housing w/ EGT bung is coming to me now. If you can get me a depth dimension for that countersink I'll check to see how it compares.
  38. badger5
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    badger5 RIP S3dave Site Sponsor

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    will do.
    FedEx delivered today also - thanks for the t-shirts.. nice touch. :)
  39. Barks
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    Barks Member

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    Hello Dane,

    Glad to hear you are enjoying the car, did you have a finished figures or is there still work to be done??
  40. Dane
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    Dane Faster than a V12 Q7

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    What? Reporting that, only I'm allowed to spam my thread, take that, bam!

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