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S3 PE1820 big turbo build

Discussion in 'A3/S3 Forum (8L Chassis)' started by Welly, Mar 29, 2011.

  1. Dane
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    Dane Faster than a V12 Q7

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    [Apr 3, 2011]
    Nice nice! Did you enjoy the wine with the old girl? Lol
  2. Welly
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    Welly VX220 SC Driver :)

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    [Apr 3, 2011]
    LOL, yeah. Well, it was a saturday night after all....
  3. Welly
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    Welly VX220 SC Driver :)

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    [Apr 3, 2011]
    Yeah, Mark suggested I should velcro it on for ease of removal....

    I literally have a stack of head gaskets now from this and last year alone. Most of them have done less then 10K.
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 3, 2011]
    Slowly catching up with you mate but I suspect you will still hold the crown for the most head changes in a year... lol

    Good work mate, reeeeeeeealy need to get mine done :(

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

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    [Apr 3, 2011]
    Hmmm.
    pretty inconclusive thread there..

    "some have issues, some dont" - on same injectors, that make no sense.. but again its not on a 1.8t platform or inlet mani, so bordering on irrelevant. Having "actually used these myself", there was zero downside or running issues.

    Main thing being choose the right bloody size injector for the duty and not fitting fire hose size injectors on small k04 tubos

    I have some EV14 550's here for the hybrids, as they're well priced.. but I have not had any issues with siemens either.
    Last edited: Apr 3, 2011
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 3, 2011]
    why?
    he has a Pe1820 which is more powerfull and roller bearing cartridge, and runs P20 housing
  7. Speedy Steve
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    Speedy Steve Active Member

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    [Apr 3, 2011]
    Hat's off to you welly i wish i could A. Do the work B. be arsed to go out and work on my car of late. Bloody garden is taking to much of my time lately.
  8. Welly
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    Welly VX220 SC Driver :)

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    [Apr 3, 2011]
    OK, have done some further work on it today - not much however due to it being mother's day etc etc etc...

    Turbo actually fits really well - as it turns out, the inlet is pretty much in the perfect place for the TIP to slot in between the matrix pipes, which makes life a lot easier to be fair. Result. No modification required there then.

    Manifold also fit really well, once I had disposed of the Turbo Support Tracker (those of you who read my rebuild thread will know how much I hate this already....:mad:), and the turbo fits really well in the bay which is nice...

    I spent about 25 mins just stood there looking at it and smiling once I had mock fitted - which was a bit sad I admit.

    Coolant lines and oil lines shouldn't be the end of the world to be fair - however only time will tell.

    I have mocked up a TIP using the B5 3" TIP and some other odds and sods - looks like it will fit nicely.

    Photos...

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
  9. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Apr 3, 2011]
    Looking good, Is the Ko4/tube manifold for sale? or are they going to be selling the revised one...
  10. Welly
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    Welly VX220 SC Driver :)

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    [Apr 3, 2011]
    I will most likely send my revised one back to them so they can replicate, and then they will sell the revised models I would think.
  11. Welly
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    Welly VX220 SC Driver :)

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    [Apr 3, 2011]
    PM Sent Dave, Thanks.
  12. Speedy Steve
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    Speedy Steve Active Member

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    [Apr 4, 2011]
    yeah good to know you'll be sending it back but how do we know if we are getting a new one or one of the older "before Welly" designed one
  13. Welly
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    Welly VX220 SC Driver :)

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    [Apr 4, 2011]
    It's a good point dude, I shall put that to them.
  14. Speedy Steve
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    Speedy Steve Active Member

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    [Apr 4, 2011]
    As i am finally looking at getting the manifold the last thing i want to do is get one of the old ones:asskicking::asskicking:
  15. Welly
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    Welly VX220 SC Driver :)

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    [Apr 4, 2011]
    Here is the basic plan of how I want it laid out:

    [​IMG]
  16. finesse
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    finesse Active Member VCDS Map User

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    [Apr 4, 2011]
    Nice Welly - Turbo & manifold ordered yet?
  17. Welly
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    Welly VX220 SC Driver :)

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    [Apr 4, 2011]
    Ummmm, yeah. They're at my yard currently - post 128 has pictures of the turbo and manifold mock fitted to the car
  18. S3RYE
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    S3RYE Interior Next!!

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    [Apr 4, 2011]
    looks very interesting mate, keeping an eye on this one! from the dark side!
  19. Alex C
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    Alex C Well-Known Member VCDS Map User

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    [Apr 4, 2011]
    + 4 days.....:superman:

    Boooom! :gun2:

    Awesome work, nice to see the head where it belongs Welly!
    Last edited: Apr 4, 2011
  20. Welly
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    Welly VX220 SC Driver :)

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    [Apr 4, 2011]
    I presume you mean on the floor, as opposed to on the car?? lol.

    It's spent as much time off the car as it has on!!
  21. Alex C
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    Alex C Well-Known Member VCDS Map User

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    [Apr 4, 2011]
    thats right! :)
  22. Welly
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    Welly VX220 SC Driver :)

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    [Apr 4, 2011]
    Yeah.... It's on and off a bit much for my liking, bolts and head gaskets not the cheapest.... I have a stack of HGs now - most of them still look new.
  23. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Apr 4, 2011]
    reuse them :D
  24. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 4, 2011]
    lol
  25. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    Already did that once out of desperation and lack of funds. Reused the HG and bolts.... (hmmm), however the engine ran strong for 8 months, made 260 bhp on a Stage 1 map.

    Not something I would advise though.... lol

    The bolts were worryingly long when they finally came out though :-/
  26. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    OK, again, made good progress last night.

    I have mocked up both the block - turbo coolant feed using hose pipe and cut up K04 coolant pipes. I have also mocked up the return feed in the same way to the sump.

    Both of these look to fit well, and live well out of the way of the manifold which is a bonus.

    I am planning to use the extremely annoying turbo support bracket for something useful - I plan to modify it, and then use it as a pipe holder.

    Some trimming and innovation required to get this idea to work, however I plan to trim it suitably, and get it to fold over better, and then run the pipework that runs underneath the turbo under it. This will keep the pipework away from the manifold, and combined with some stainless steel wrap straps, it should keep it secure as well...
  27. s3gazz
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    s3gazz Well-Known Member

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    [Apr 5, 2011]
    Good look welly hope all goes to plan pal
  28. Dane
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    Dane Faster than a V12 Q7

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    [Apr 5, 2011]
    Such quick work dude, sick skills!

    Wish I could be trusted to get mine right lol.
  29. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    Injectors are now here - a BIG thanks to S3Dave for sorting me out with those. :thumbsup:

    [​IMG]

    They should certainly help get some additional fuel in there....
  30. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    If you still want to pop down dude, then can we re-arrange for Thursday night about 8 PM?

    The missus is going on holiday for a week early hours of Thursday morning (giving me a week with no grief to get on!!:D), so I am going to see her on Wednesday night before she goes.
  31. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    :ninja:
  32. Dane
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    Dane Faster than a V12 Q7

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    [Apr 5, 2011]
    Bummer, sorry dude no can do, I have to work Thursday evening. Would be cool another time though?
  33. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    Change of plan, will be home Wednesday night from 9.30PM if you want to come over for a bit, I will be out in the garage as usual...
  34. S3 Nattie
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    S3 Nattie Quattro ist für sissies

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    [Apr 5, 2011]
    The fitment of that turbo is quite surprising considering it not even meant for that engine and bay.

    Any news on the inlet mani
  35. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    No, annoyingly. The guy hasn't got back to me which has chuffed me off somewhat....
  36. S3 Nattie
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    S3 Nattie Quattro ist für sissies

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    [Apr 5, 2011]
    His loss at the end of the day ini. If it works well im sure it will be on alot of members wish list.

    There was a good thread on the TT forum recently where a member got very good gains from a SEM mani on a K04.. Worth a look if you havent seen it already.
  37. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    Also have just spent £60 on ebay buying various bits and bobs - it's amazing how the small things that you forget about quickly mount up.

    Got:
    • 10 metres of heat wrap and SS straps
    • 2 x 50 metre rolls of silver foil heat reflective tape. (won them for 99p! whoop)
    • 2 x M12 x 1.25 banjo bolts
    • 1 x M10 x 1.5 banjo bolt
    • Banjo washers
    • 60mm - 76mm Silicone reducer (TIP - turbo)
    • 2 x 76mm couplers

    I love buying goodies :)
  38. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    Tempted with a good inlet manifold I must admit, however the cost of them is horrendous, and for this build it's simply money I haven't got.

    The missus would out right cut my nuts off if I spent £700+ on an inlet manifold.
  39. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 5, 2011]
    Hummm... yeah... not 700 quids worth of gains on a K04 which he is using but we shall see as I believe he is one of the TT guys coming over to Bills at the weekend...

    A SEM will work better on the IHI setup though... not cheap...

    <tuffty/>
  40. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    I think, with a little time and thought you could probably get comparable gains for a lot less money spent.

    On GT30 upwards, yes, I can see the point.

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