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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. MIGGZ
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    MIGGZ nanananananananan BATMAN

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    [Apr 13, 2013]
    That's boss dude well done.... Like the 600bhp lol
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  2. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 13, 2013]
    lol

    Well i have learnt a lot with the last engine and i know the JE mild steel wrist pins can't cope with 30psi and my rod angle ( I think ) as the crush under the pressure

    The standard mains stretched on me at over 500 bhp so ARP's all round now

    Custom cams made up for me by Newman cams

    Tigged the trigger wheel in place as mine started to come loose

    Everything i had problems with have now been sorted, I have even made up a new breather system that now runs 3 ports from the cam cover and one from the block. I dropped the new catch can/breather off with the powder coaters along with my can cover to be coated in crackle black powder coat, the inlet will get the same treatment next weekend.

    Also 1600 cc fuel injectors will be ordered at the end of the month
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 13, 2013]
    Good work dude... glad to see it coming together again...

    Some peeps are using the 1.9 tdi blocks to make 2.1's... requires a little modding of the water/oilways of the 20v head so I understand but better rod angles etc as the block is taller... lazy buggers VAG... ;P

    I shall stick to a run of the mill 2ltr stroker I think when the time comes lol... although we may have to have a chat about exhaust ports ;P

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

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    [Apr 13, 2013]
    ooooh, I think you should have a big can of awesomesauce!

    Did the pistons not get damaged when the wrist pins got bent? I would of thought there would of been some play and caused some wear on the pistons
  5. voorhees
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    voorhees Moderator Staff Member Moderator

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    [Apr 13, 2013]
    You big power S3 guys are made of different metal :salute: I salute you
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  6. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 13, 2013]
    I was lucky really, they didn't bend as such but more like a crushed pin where the rod is

    tuffty

    i looked into using the tdi block back in the days but there is a lot of work, I know I could engineer the block to be taller and then sleave the block but that's costly

    Lugnuts in the US managed to get 900 bhp from a 2.1 done the way I have so I'm happy to keep mine the way it is

    We shall talk ports when the day comes
  7. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 13, 2013]
    Big turbo = Big balls ... or is that the other way round?
  8. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 13, 2013]
    Nice one mate pretty sure you've covered all angles :)

    It will be a monster
  9. Scullies
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    Scullies Well-Known Member

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    [Apr 13, 2013]
    Did you assembly the bottom end on the table? How did you hold the block while you torque'd things up?
  10. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 14, 2013]
    Laid the block on the back side

    The hard bit was torquing the flywheel bolts lol i ended up making a pulley holder to get the bolts torqued up to 85 lbs/ft
  11. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 14, 2013]
    I just have to order my 1600cc injectors and get he boost turned up to 35/38 psi
  12. Prawn
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    Prawn My other car is a MINI!!!!

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    [Apr 14, 2013]
    and get it mapped safely on a rolling road instead of the M1 :laugh:

    All very good stuff dude, I hope you reach your 600bhp Goal soon!
  13. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 14, 2013]
    It will mapped by Unicorn off the public road or down at Ric woods this time.
    Last edited: Apr 14, 2013
  14. Davjon747
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    Davjon747 New Member

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    [Apr 14, 2013]
    This is one hell of a build I take my hat of to you, it's been like reading a great novel once I started could not stop and now I have come to the end so far. But not the close so come I need more input its fantastic I wish you luck for 600bhp ( not that I think you will need it)

    Dave
  15. Slammedorion
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    Slammedorion Member

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    [Apr 15, 2013]
    Can't believe your still spending in this!!! :thumbsup:
    Keep up the good work...
  16. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 15, 2013]
    I hope i do hit 600 and i have spent more time a development on head work

    R&D mate

    My goal was to hit 600 and i didn't do it last time due to small injectors ( 870cc )

    Had some hiccups in between and now back on track
  17. Slammedorion
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    Slammedorion Member

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    [Apr 15, 2013]
    Fingers crossed for you... Your not one to scrimp on a build... :salute:
  18. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 16, 2013]
    Big £££
    Andrew@A.L.D and voorhees like this.
  19. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 16, 2013]
    And that..... I do try and forget that bit
  20. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 16, 2013]
    We all do dude lol...

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

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    [Apr 16, 2013]
    yep, innit.. lol..

    i dread to think what £ has been spent on mine over the years
  22. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 16, 2013]
    You've got test and development with yours so 7x more that me?
  23. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 16, 2013]
    lol.. and yea... dont even go there. lol
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  24. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 16, 2013]
    Question for you Bill

    What are your thoughts on my engine/turbo running at 35 to 38 psi?

    I've now covered all my problems that i have had. Tool steel wrist pins, ARP head bolts ( was running them anyway before ), ARP flywheel bolts and main studs, IE Riffle drilled rods with race coated bearings and HD main bearings, Double dowel crank to flywheel, GTX3076 turbo, JE Pistons 8.5:1 compression. New block with JE recommendation ring gaps, New 4 port breather system/catch can, Tig welded trigger wheel in place, Tig welded oil pump bolt to gear.
  25. Scullies
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    Scullies Well-Known Member

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    [Apr 16, 2013]
    have you double pinned the crank timing gear? Im sure you have :laugh:

    I think you should also weld the cam pulley bolt too, in fact weld or pin any rotating part that gets bolted to the engine :arco:

    600 is a lot of hp, how are your drive shafts??
  26. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 16, 2013]
    Standard
  27. Scullies
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    Scullies Well-Known Member

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    [Apr 16, 2013]
    interesting..... what do you think they can take before they twist or snap?
  28. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 16, 2013]
    700 bhp i think? or should say hope! but i don't launch my car hard most of the times as it can spin all 4 wheels when really pushed
  29. superkarl
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    superkarl MAN OF STEEL

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    [Apr 16, 2013]
    why the psi goal andrew?
    obv the gtx turbos really come into their own at higer pressures but, if your car makes the target figure at a lower boost are you bothered? Or do you just want to see what the turbo can do?
  30. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 16, 2013]
    The GTX3076 is at its most efficient at 2.5 bar or 36.2 psi
  31. superkarl
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    superkarl MAN OF STEEL

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    [Apr 17, 2013]
    do you have a compressor map against rpm and your displacement?
  32. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 17, 2013]
    there should be one on garrett's website
  33. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 17, 2013]
    I should say that all 20v engine need lots of boost to get good power, i've had some cams made up for me and spent lots of time on the head but the downside to my set up is the down pipe. I would like to see how it goes when remapped with the new set up.

    Should do a lot more than 531 bhp
  34. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 17, 2013]

    One word Andrew EGT's

    Closely followed by Cylinder Pressures

    Where is your egt sensor located?
  35. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 17, 2013]
    Something I need to get and fit bill
  36. Sam_
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    Sam_ Down under

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    [Apr 17, 2013]
    Is there a guide as to what's needed at certain power levels? I'll be aiming for 500hp (eventually, GT2871 first) and I've had a 2.0 stroker engine built but it's just got JE pistons and IE rods. Head wise it's an AGU head with +1mm Supertech valves. What else should I add to the shopping list? Head studs? It'll be running an IE inlet with R32 TB.
  37. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 17, 2013]
    supertech valve springs.... ARP head bolts

    not everyone will agree on the list of advised/required parts
  38. Sam_
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    Sam_ Down under

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    [Apr 17, 2013]
    Cheers bill - ARP main bolts too ?
  39. Scullies
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    Scullies Well-Known Member

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    [Apr 17, 2013]
    do as Andrew has done, upgrade everything, it's what I have done too and will also be expecting over 500hp with my pte6262.
    there is no point in building a high hp engine and scrimping on one or two parts.
    and let's just be honest now, when you get to 500 are you really going to say that's enough :p
  40. Scullies
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    Scullies Well-Known Member

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    [Apr 17, 2013]
    arp everything but don't buy from IE unless you have a big jar of lube :laugh:

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