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Dane's Hybrid Conversion Thread

Dane Apr 11, 2011

  1. <tuffty/>

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

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    Looking on AEM's website they don't appear to quote flow rate but nozzle diameter... .0155, .0315 and .0630 so Dane is running the .0315 at the moment..

    <tuffty/>
     
  2. Welly

    Welly VX220 SC Driver :)

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    I think the AEM mid size is about ~5 GPM - the equivalent of the DO DO5 nozzle.
     
  3. slappy_dunbar

    slappy_dunbar Let's Do This

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    Well, I think it's easiest to dial this in by trial and error. Sure, there are calculations available but there are just too many variables to consider.

    So we're going to put on the manifold at the end of the week and run dual nozzles with 375cc and 225cc. I'm also looking into a proper 3bar MAP sensor so we can accurately measure boost when it gets above the car's 2540mbar limit.
     
    Last edited: Jun 15, 2011
  4. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    Genuine BW hotside has arrived from CR this morning. Bored for the RS6 turbine and stock wastegate hole which I will port appropriately.
    Heads being reguided now... should get it back in a couple of days.

    regards
    bill
     
  5. Dane

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

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    Nice Nice! cheers for the update Bill, looking forward to getting it finished now
     
  6. Westy

    Westy Well-Known Member

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    You back in the micra :racer:
     
  7. Dane

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

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    No I'll be vehicluarly challenged while the work happens as my brother has reclaimed his beast. lol
     
  8. jojo

    jojo Looking for Boost! Staff Member Moderator Team Daytona Audi S3 quattro Audi A6 Audi Avant Owner Group

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    You can borrow my BMW 1-series if you want, just a small, non returnable deposit of £5500 will do. :)
     
  9. Dane

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

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    Thanks for the offer, but lifts off Liam are free! If I had a spare 5.5K I might be using a slightly bigger turbo :)
     
  10. Barks

    Barks Member

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    Hello Dane, we haven't had any updates for over a week!!!

    I have a K04 to be hybrid'ed and big box of bits to be fitted by Bill, so can you hurry up and get it finished so I can copy!!

    Cheers and keep up the good work! (making the tea)
     
  11. Dane

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

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    Lol thats because there haven't been any :)

    I'm driving mine to Bill's tonight for the head and turbo swap over the next few days and that'll be when we find out where we've got to with the set up. SO there will be updates abound hopefully by the weekend if my car behaves!

    I wont really be there for my tea making duties apart from on Friday where I will take up my responsibilities :) maybe not for Westy though ;)
     
  12. Westy

    Westy Well-Known Member

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    Right then! No M&S cookies for Dane :)
     
  13. Welly

    Welly VX220 SC Driver :)

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    See, I knew I liked you. :thumbsup:
     
  14. Dane

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

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  15. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    okies.. in case peeps thought nothing was going on in the background..
    An Actual update!! yea really!

    F23 does'nt come with an EGT port.. (currently, but will do shortly probably)... So, with aid of my good friend CNC Nige, a couple adaptors were magic'd up and the turbo spot faced and drilled to accept this mounting boss

    some "special" welding rods later (1Kg and used 1/2 of one rod-lol) and cast to mild steel boss was joined.
    [​IMG]

    And Assembled
    [​IMG]

    Magically now holds an EGT sensor in an F23
    [​IMG]
     
  16. Welly

    Welly VX220 SC Driver :)

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    Good old Nige, a legend. :)

    Some SERIOUSLY pretty welding there mate. Your skills are amassing.... :)
     
  17. Westy

    Westy Well-Known Member

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    Dane's build is just one issue after another lol
     
  18. Welly

    Welly VX220 SC Driver :)

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    Been there. :(

    My last (with the exception of the head problems after fitting) was OK, however my hybrid build was a bit like that.
     
  19. s3dave

    s3dave TFSI Hybrid Supporter

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    I know hes very Needy....
     
  20. Westy

    Westy Well-Known Member

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    Tell me about it. Plaim digestive buscuits are no good for Dane, he wants M&S! Posh sod ;)
     
  21. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    off Topic Warning
    how about a nice 4" intake and 4" MAF - eh? :)
    [​IMG]

    4" MAF
    [​IMG]

    Or a Full 3" turbo back exhaust with external wastegate
    [​IMG]

    Been a busy badger
     
  22. Dane

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

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    Looks very smart Bill, thank you.

    As for the rest of you 'orrible lot im shaking my fist at you virtually! :friends:

    Hopefully this time it will yield some useful results that can help Bill out :)
     
  23. Westy

    Westy Well-Known Member

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    Jesus Bill, these MAFs just keep getting bigger!
     
  24. Dane

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

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    To be fair Bill I think this should be in the thread title in a NSFW stylee :lmfao:
     
  25. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    yea.. this is an LCR racecar I am working on. hybrid GT35 in it.. eak!
     
  26. Welly

    Welly VX220 SC Driver :)

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    Dude.

    Skills.

    :applaus:
     
  27. Syvo

    Syvo IF IN DOUBT GO FLAT OUT

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    holy S**t that is one big exhaust and he maf and pipe :sign_omg:
     
  28. <tuffty/>

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

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    Better save some for me... will drop in on the way home from work around 4pm :)

    <tuffty/>
     
  29. Barks

    Barks Member

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    Oooooo!!!! Big Shiney Welded Stuff, Nice...

    Was the F23 turbo purchased from Franken with their K04 manifold??
     
  30. Speedy Steve

    Speedy Steve Active Member

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    Thats some lovely work Bill as always!
     
  31. Dane

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

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    I don't think so, the f23 will be going on Bills mani
     
  32. Barks

    Barks Member

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    Ah I see, look forward to the results!
     
  33. Westy

    Westy Well-Known Member

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    We'll probably be gone by then mate but I'll save you a biscuit ;)
     
  34. Prawn

    Prawn My other car is a MINI!!!!

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    Bill, forgive my stupidity, bit how does that exhaust clear the rear beam? It doesn't appear to kink up before the back box, or is it just perspective?
     
  35. <tuffty/>

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

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    Better pic Nick to make it clearer :)
    [​IMG]

    <tuffty/>
     
  36. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    its apart..
    Ex Mani is looking fine.. :)

    no blowing evident from anywhere..
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  37. Westy

    Westy Well-Known Member

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    And Dane tested it extensively at the weekend.
     
  38. <tuffty/>

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

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    That he did but I think his face cracked from all the grinning.... lol!

    <tuffty/>
     
  39. Dane

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

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    Yeah man!

    LETS TURN UP THE HEAT lol
     
  40. Prawn

    Prawn My other car is a MINI!!!!

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    does this mean I can have my new turbo soon :p
     

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