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Lets get it on then, My 2.1 conversion

Discussion in 'A3/S3 Forum (8L Chassis)' started by Andrew@A.L.D, Dec 12, 2009.

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

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    [Apr 17, 2013]
    Bigger valves not really need as I managed it
  2. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 17, 2013]
    they wont hurt for a 500bhp level build spec..

    std's have been ok... but I use ARPs everything currently
  3. Sam_
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    Sam_ Down under

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    [Apr 18, 2013]
    Yeah I didn't really have much choice in that. It's been a bit annoying but I'm doing a site for a local VW specialist and he's just got the engine specced without asking me. Hoping I can get some ARP bits in there. Hoping to future proof it a bit more.

    Cheers all for the help.
  4. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 20, 2013]
    Very small update

    I didn't like the design of my BSH catch can so i thought i would make my own. I know its major over kill but i'm very happy with how it came out. Had it powder coated in a crackle black along with the inlet and cam cover.

    [​IMG]
    [​IMG]

    Where it will sit in the engine bay. Right next to my small battery in the battery box. It even has room for a cold air feed to the air filter from the front grill

    [​IMG]
    [​IMG]
    [​IMG]

    The head is all built up and ready to go, It now has a set of custom cams, New Inconel exhaust valves, seals and tensioner

    [​IMG]
  5. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 20, 2013]
    Cracking job mate looks brilliant, and very tuffty oem hidden style mod :)
  6. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 20, 2013]
    Bloody thing is massive, but thats not a major problem.

    just have to wait for the baffled sump kit to come then fit and may fit a new oil pump seeing the sump will be off and then the engine is done.

    Ordered my 1600cc injectors also and should get then in a couple of days now

    Going to a new multi gauge that reads EGT, Water Temps, Air Temp, Pressures etc etc
  7. jezzy
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    jezzy Member

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    [Apr 20, 2013]
  8. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 20, 2013]
    When running big boost 30+ psi you get more than normal blow by, Blow by is where the boost passes the rings and into the crankcase casing more pressure, I have add more outlets the cam cover and in the catch can. The more outlets the less pressure.

    Not tried the small battery yet but they rate them on vortex
    jezzy likes this.
  9. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 22, 2013]
    Your mentioning of what boost you were planning on running got me thinking..
    I know mines set on 26psi max currently, running 22psi for race meeting with a press to pass button on the steering wheel.. I do plan on winding it up to the 35psi levels I used to run my normal gt3582 to on this hybrid... BUT, looking at comp maps.. and pressure ratio calcs.. worth considering what the comp map is on your turbo..

    knocked this up as a ready reckoner..
    [​IMG]

    A couple of comparison garrett specs.. My weird thing is'nt there but is probably something along the lines of the GTX35.
    [​IMG]

    If you are planning on 38psi gauge in plenum, thats 3.6 Pressure ratio.

    What diameter is your downpipe from turbo outlet? Is it as CTS supplied still at 2.5" top section?
  10. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 22, 2013]
    Yes 2.5
  11. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 22, 2013]
    I reckon thats going to hold you back Andrew.. Not ideal for your power/flow goals.. but I know it is what it is with cts kit base.. We had the same with it. :(
  12. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 22, 2013]
    I'll see what happens?
  13. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 22, 2013]
    Last edited: Apr 22, 2013
    Pedrosousa likes this.
  14. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 22, 2013]
    Is it the down pipe that will be the problem or the exhaust housing or both

    I will have a read of the link Bill thank you
  15. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 23, 2013]
    downpipe.. discharge side of turbo...
  16. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 23, 2013]
    Right pipewerx will making me a new down pipe and system using a 2.5 to 3.0 conversion from the turbo
  17. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 23, 2013]
    it can only help your turbo dude..
    good call
    :)
  18. Sam_
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    Sam_ Down under

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    [Apr 23, 2013]
    They should make a load and sell them to replace the dodgy ones in the CTS kits
  19. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 23, 2013]
    I will let them know
  20. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 23, 2013]
    hell yea Sam! RHD kit ones are booo :(
  21. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 23, 2013]
    Would have thought that will make a nice difference on yours mate :)

    In pretty sure it was them that jase was having talks with about doing an off the shelf 3" system?
  22. Scullies
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    Scullies Well-Known Member

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    [Apr 23, 2013]
  23. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 23, 2013]
  24. Jason.s
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    Jason.s Active Member

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    [Apr 23, 2013]
    Was Piper i was talking to about an off the shelf 3" system but they said they`d be looking into the Audi range this year but still havent got back to me so i doubt they ever will.

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

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    [Apr 23, 2013]
    Thats what i have been looking at but from ATP as its shorter than the one above

    V-Band Adapter Module, Smaller 4 bolt (T31) 2.5" to 3" V-Band : atpturbo.com
  26. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 23, 2013]
    Ahhhhh of course you have the 4 bolt hotside... forgot that lol...

    <tuffty/>
  27. Scullies
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    Scullies Well-Known Member

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    [Apr 23, 2013]
  28. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 24, 2013]
    if you read the links I posted the garrett guy suggested creating turbulant flow from swirl was advised..
  29. Scullies
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    Scullies Well-Known Member

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    [Apr 24, 2013]
    Is this the link from koracing? Took me some time to see it, I didn't notice it under the graph.

    KORACING :: High Quality Automotive Parts - Products

    "The exit diameter of the ct26 and ct20b are about 2.4" -- this means that running 3" piping can cause more flow loss right at the exit of the turbine due to turbulent 'eddy' effects"
  30. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 24, 2013]
    damn.. I missed posting the correct link looking at this thread again.. FFs. Senior moment.. Soz.

    This is the link which says the adding of turbulance (from swirl out of turbine wheel) from going larger on turbine exit is beneficial over the small losses from the abrupt sectional change

    Technical: Turbo exhaust design theory by Garrett. - The FIAT Forum

    ^^^ linky ^^^
  31. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 24, 2013]
    the abrupt change yes.. suggested angle sub 15deg for transition is the suggested blend.. Not a step for the above reason.

    Stolen from the link..
  32. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 29, 2013]
    These turned up today

    [​IMG]

    1600cc injectors or so it seams but there not

    Genesis II 1600cc - High Impedance : USRT, Usually Sideways Rally Team

    I could see that they are Bosch Injectors and us rally team have scrubbed of the parts number, Lucky for me they missed some of the numbers on one injectors and could still make it out, the part number are 0280158827. Turns out they are 1700cc injectors and can be 2000cc it run at 4 bar.

    Also i finished my sump after getting the kit off ebay

    [​IMG]

    Fresh out of the parts washer
  33. superkarl
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    superkarl MAN OF STEEL

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    [Apr 29, 2013]
    Usrt's genesis injectors are just modified injectors, they use bodies of existing items
  34. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 29, 2013]
    I see. never mind still plenty of fuel for me anyway
  35. Prawn
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    Prawn My other car is a MINI!!!!

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    [Apr 29, 2013]
    haha, 1700cc?

    1 of your injectors is the same size as all 4 of mine put together! and I thought I had a powerful car.

    Haha, you absolute nutter.
    AVLO and Goubo1 like this.
  36. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 29, 2013]
    They are big i know. I was after 1200cc ones ob bigger

    The 870cc one were maxing out for me at over 90%
  37. Prawn
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    Prawn My other car is a MINI!!!!

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    [Apr 29, 2013]
    will these go low enough to actually idle at all? in theory at the same power as before you'll only be at 50% max DC won't you?
  38. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Apr 29, 2013]
    A few people on the us sites are running them without any problem and getting perfect idle

    that I'm not sure of as I have no idea at all when it comes to mapping.
  39. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 30, 2013]
    The bosch ones stand a chance but really depends on how linear they are... siemans 630cc like I used to have seem to suffer a little on idle... while the engine 'idles' fine the swings for the live lambda adjust (wideband) can be quite large as the linearity drops off after a certain ms... Bill tried a set of ASNU injectors on the Lupo as the company supply a wide range of injector size so could be useful as an alternative source of injectors... however... ME7 did not like them at all and getting the fuelling stable at idle was impossible...

    asnu.jpg

    If you look at this data sheet for the 600cc injectors they do you can see where they become massively non linear at just below 2ms on time... when I ran my 630's at 4bar they were 1.3-1.7ms on idle... this was similar to the ones tried on the Lupo (IIRC, Bill will know the exact figures)... once the injectors drop into this zone then ME7 will struggle to keep fuelling stable...

    <tuffty/>
  40. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 30, 2013]
    your mapper will likely want to see the data sheets for these to dial them in tvub, krkte etc...

    Big ole things..
    I think fkkvs may be busy trying to linearise their response across the range

    Funny how things evolve is'nt it.... My 870's max'd same as yours did a few years ago.. but I had some 750cc I was using before so decided I would use all of them, 750cc + 870cc with staged/blended switch over on my dta. I did have concerns single big ass injectors would be a pia to tune on idle, part throttle so chose this route. This is on stand alone not me7 tho, so who knows.. it could work..

    Good luck tho..

    Going to be a mental motor when running at full chat

    Woo Hoo

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