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Large Plenum Intake

Discussion in 'A3/S3 Forum (8L Chassis)' started by s3dave, Oct 11, 2012.

  1. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    Had a few hours spare this week so i thought i would make myself a large plenum intake.....

    This is a 3.9 Litre Plenum (Thanks to Karl for sourcing one)

    [​IMG]


    I only had a an AGU mani available so used that.....

    [​IMG]

    All in all i dont think it turned out to bad....

    [​IMG]

    Just need some new injector seats now as AGU are not the same size as s3 fitting?

    I will fit it at the weekend and see if they are any gains...im hoping it gets rid of a little bit of surging i still have left.. ;)
    #1
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  3. superkarl
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    superkarl MAN OF STEEL

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    [Oct 11, 2012]
    will it pipe up to your existing TB pipe?
    #2
  4. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Oct 11, 2012]
    I likely. Dis you make the plenum yourself dave? Would you be able to knock some more of these out?
    #3
  5. StaceyS3
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    StaceyS3 Well-Known Member

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    [Oct 11, 2012]
    Looking sweet mate good effort ;)

    Will be good to see how these large inlet mani's fair up on various turbo setups, with tuffty's being the most obvious recent one :)
    #4
  6. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    Dont know Karl... my MOT is tomoz so im not buggering about with stuff until the weekend...
    #5
  7. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    Wasnt planning to Dani no, just a diy and a few hours spare..:p
    #6
  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 11, 2012]
    The small port bungs won't fit... they are physically larger to accept the bulgy bit at the bottom of the injector..

    Not tried to make 'newer style' injectors fit AEB/AGU bungs fit as yet... did have it in my mind that fabricated bungs would be needed or modding the existing ones a bit by filing some of the plastic... don't know how feasible that would be though...

    You may also have to make spacers for the fuel rail... the positional differences may well be slight but the spacers for my 630's that I used on the small port mani were too tall for the AEB runners/bungs..

    <tuffty/>
    #7
  9. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    Cheers Stacey, yeah it will be interesting i think the sem one is a lot bigger? this will suit my set up im sure....
    #8
  10. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    whoo i may have a problem then..spacers wont be a problem but the injector seats maybe... Thanks for the Heads up...
    #9
  11. superkarl
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    superkarl MAN OF STEEL

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    [Oct 11, 2012]
    tuffty what seats did you use in your AEB?

    but then obv you have different injectors. doh
    #10
  12. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 11, 2012]
    I just used std AEB ones... (ones that came with the donor manifold...)

    For reference...
    Facelift S3 injectors (APY are a little different)
    [​IMG]

    APY injectors
    [​IMG]

    My 630's and the std S3's
    [​IMG]

    Deka 630's
    [​IMG]

    Bosch 550 EV14's
    [​IMG]

    AEB injectors..
    [​IMG]

    Bung differences..
    [​IMG]

    <tuffty/>
    #11
  13. Prawn
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    Prawn My other car is a MINI!!!!

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    [Oct 11, 2012]
    Looking good dave!

    I found that plenum on ebay a few weeks ago and spoke to tufty about it, good to see someones actually gone ahead and tried one though!

    Are those AGU or AEB runners?
    #12
  14. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    Agu mate...

    looking at the inserts again, tuffty have you psychically tried to change them? as the agu inserts have a flange on the top making them appear to big?
    #13
  15. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 11, 2012]
    AEB are smaller than my AMK ones fo sho... can't say for sure on the AGU ones as I have only every used larger injectors in one so has never presented itself as an issue...

    Suck it and see is all I can say...

    <tuffty/>
    #14
  16. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Oct 11, 2012]
    Did you make the plenum yourself then or buy it? Fancy making me one :).
    #15
  17. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    Ok just taken one of my injectors out (genesis 550s) and... they fit perfectly into the seats!...

    [​IMG]


    showing is a agu injector next to mine...
    #16
  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 11, 2012]
    Cool... forgot you were on those... just watch the installed height... I did a dry fitting ans mine poked out the bottom of the bungs..
    [​IMG]

    [​IMG]

    <tuffty/>
    #17
  19. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    Yeah looked at that, these cannot physically go any lower because of the housing on the injector...

    [​IMG]


    My fuel rail will need lowering unlike yours that need spacers, the 630s are pretty tall though...
    #18
  20. Prawn
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    Prawn My other car is a MINI!!!!

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    [Oct 11, 2012]
    Dave: I have a set of injector spacers on the shelf at home, specifically for fitting 550 injectors into AGU runners! They space the back of the injector up so you use the standard fuel rail with no mods at all.

    I imported them from USRT for my conversion, then ended up using different injectors.

    let me know if you're interested :)
    #19
  21. s3dave
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    s3dave TFSI Hybrid

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    [Oct 11, 2012]
    Cheers Mr.Prawn ..PM.ed.....:icon_thumright:
    #20
  22. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Oct 11, 2012]
    Plenums are made by a lad near me in Bradford
    #21
  23. s3dave
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    s3dave TFSI Hybrid

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    [Oct 16, 2012]
    Fitted...
    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]


    The upper IC hose to throttle body was miles out so had to be fabricated..testing to follow... :eyebrows:
    #22
  24. Yohan87
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    Yohan87 Member

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    [Oct 16, 2012]
    That thing looks huge in the second last picture!
    #23
  25. 16Klappe
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    16Klappe Princess Clap.

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    [Oct 16, 2012]
    Not totally related to this but kind of.

    Some bloke on the Clio forums made his own plenum like this, everybody told him it would be a wastw of time.

    It made a 17bhp difference on his cammed 172 engine.
    #24
  26. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Oct 16, 2012]
    That's sexual David, good work. Cant wait to see what you get with your testing.

    As for the IC hose, what hoses/joins did you use to cobble it together?
    #25
  27. s3dave
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    s3dave TFSI Hybrid

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    [Oct 16, 2012]
    Just been out for a test drive and it feels very strong, wheel spin in 3rd gear but there are leaves all over and it is pissing down.... probably not ideal, some nice pops on changing gear too...;)
    #26
  28. s3dave
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    s3dave TFSI Hybrid

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    [Oct 16, 2012]
    Chopped it in half, then took an inch off each bend at the end, then used a 63mm joiner about 9" in between... its very tight to the battery box but i could not go any further left towards the charge pipe so thats it....
    #27
  29. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 16, 2012]
    Same... ignore the crapness of the curves as this was very much a pre-boost work in progress map but was a direct comparison of the std inlet vs the large port one I made...
    [​IMG]

    <tuffty/>
    #28
  30. coatesy
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    coatesy poking badgers with spoons

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    [Oct 16, 2012]
    Awesome work dude, looks like you have made it wrong though my throttle body isn't on that side of the car... :p (Secretly wants to know how much and when)
    #29
  31. s3dave
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    s3dave TFSI Hybrid

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    [Oct 16, 2012]
    Damn the throttle body WAS on the other side when i started too....:p
    #30
    coatesy likes this.
  32. Yohan87
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    Yohan87 Member

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    [Oct 16, 2012]
    Samesies
    #31
  33. s3dave
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    s3dave TFSI Hybrid

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    [Oct 16, 2012]
    Im not sure if bill is doing a kit or doing them himself ?

    They are a bit of labour of love to be honest, the time zooms bye doing these....
    #32
  34. Reesy
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    Reesy Well-Known Member VCDS Map User

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    [Oct 16, 2012]
    But if you guys really want one, paypal me £300 and I can sort it for you :lmfao:
    #33
  35. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 16, 2012]
    Bill is looking at doing these based on the xcessive manufacturing plenum but could potentially use this plenum as an alternative... on this plenum you have the extra machining costs of the throttle body hole etc....

    They are very labour intensive to make...

    <tuffty/>
    #34
  36. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Oct 16, 2012]
    plenums I would be using would be excessive ones.. I prefer the look & design of them (no offence)
    backplate profiles and throttle adaptors and some fab to join it together
    #35
  37. Prawn
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    Prawn My other car is a MINI!!!!

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    [Oct 16, 2012]
    Love it Dave.

    Have you drilled / tapped your VAC ports into the back plate? what about the IAT sensor?

    Does the bonnet shut Ok?
    #36
  38. Yohan87
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    Yohan87 Member

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    [Oct 16, 2012]
    Would you be making small and large port ones Bill?
    #37
  39. coatesy
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    coatesy poking badgers with spoons

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    [Oct 16, 2012]
    :eek: deal breaker send me your email address ASAP ...
    #38
  40. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Oct 16, 2012]
    yep if required..
    most interest would be for largeport I imagine but I could draft up the smallport backplate if desired..
    large plenum smallport would be a curious test to do if the opportunity arises.
    #39
  41. AARON77
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    AARON77 Active Member

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    [Oct 16, 2012]
    Good work
    looks the nuts and would defo be up for one of these
    as soon as I get my car sorted
    #40

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