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S3 PE1820 big turbo build

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

  1. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 5, 2011]
    Soon see mate... should be getting my new FMIC this week so curing the pressure drop issue I currently have leaving the last restriction as the std inlet mani... see how it goes I guess...

    <tuffty/>
  2. Dane
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    Dane Faster than a V12 Q7

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    [Apr 5, 2011]
    Oh yes! its all go in our neck of the woods!
  3. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Apr 5, 2011]
    Lol s3 festival down your way
  4. Welly
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    Welly VX220 SC Driver :)

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    It appears that Gloucestershire is the world's S3 capital.
  5. Dane
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    Dane Faster than a V12 Q7

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  6. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
  7. Dane
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    Dane Faster than a V12 Q7

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    [Apr 5, 2011]
    Maybe, although having the k04 hybrid inside sticker could almost be like having a tdi badge on the back if it ends up like Bills Ibiza back in the day...
  8. Welly
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    Welly VX220 SC Driver :)

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    I'm not convinced that is going to be true mate to be honest. That hybrid will be hard to beat in the respect of power delivery.
  9. Dane
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    Dane Faster than a V12 Q7

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    [Apr 5, 2011]
    yeah it was pretty awesome, but fingers crossed that the IHI does it for you.
  10. S3 Nattie
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    S3 Nattie Quattro ist für sissies

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    [Apr 5, 2011]
    Ye I do agree it is a very expensive mani but it does work but weather the gain is worth the price, probably not. I would have thought a SEM mani on yours or Pauls setup would give very good gains.

    Ye defo get that sticker. I have never seen that on a S3, seen loads of hybrids and 1.8T etc sticker but not a IHI.
  11. superkarl
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    superkarl MAN OF STEEL

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    [Apr 5, 2011]
    If I lived in glos, I would have the smallest testicles In the world and require sponsorship by Kleenex.
  12. Welly
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    Welly VX220 SC Driver :)

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    [Apr 5, 2011]
    That took me a couple of reads to work it out....
  13. superkarl
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    superkarl MAN OF STEEL

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    [Apr 5, 2011]
    It's like an s3/1.8t gang bang down there.
  14. Welly
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    Welly VX220 SC Driver :)

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    [Apr 6, 2011]
    So... I won't having that AJH manifold then. Turns out the bloke is cock knocker and has decided he wants more money for it.

    To be fair, it looks like a bit of an arse to fit. The runners, being slightly curved, means that the entire manifold sits a little to the left of the OEM one. I'm concerned that on fitting, there will be space issues with the charge pipe.

    Also, all the attached sensors to the manifold will have to have the wiring extended to make them fit into their new holes - the IAT being the main one.

    Not worth the hassle, I will just port mine....:ninja:
  15. finesse
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    finesse Active Member VCDS Map User

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    [Apr 6, 2011]
    So what options do you have?
  16. Welly
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    Welly VX220 SC Driver :)

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    [Apr 6, 2011]
    Assuming you mean with regard to the inlet manifold? Two realistic ones. Port my own out as much as possible, mainly the inlet port to try and produce less of a step on the way into the head. Also, I could look at buying an after market inlet manifold - however this is going to be VERY costly, and it's money I don't have.
  17. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Apr 6, 2011]
    could you use an AGU one but cut/weld the throttle body onto the right end?
  18. Welly
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    Welly VX220 SC Driver :)

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    [Apr 6, 2011]
    I did think about this, however the problem would be that you would have to weld it directly onto the plenum to achieve the best effect, and that would be a bit of a pain TBH.
  19. Barks
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    Barks Member

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    [Apr 6, 2011]
  20. Speedy Steve
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    Speedy Steve Active Member

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    [Apr 6, 2011]
    its for small port heads!
  21. Barks
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    Barks Member

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    [Apr 6, 2011]
    Yep that one is, but they do mention in the description that they do a design for large port heads and/or the runners do look 'large'
  22. Barks
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    Barks Member

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    [Apr 6, 2011]
  23. Welly
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    Welly VX220 SC Driver :)

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    [Apr 7, 2011]
  24. Dane
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    Dane Faster than a V12 Q7

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    [Apr 7, 2011]
    Your poor dremel.:nyah:
    Last edited: Apr 7, 2011
  25. Welly
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    Welly VX220 SC Driver :)

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    [Apr 7, 2011]
    LOL, it's done a cracking job on the oil return pipe mind....

    That's what it's made for!!
  26. MUSH
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    MUSH MUSH Developments Ltd.

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    [Apr 7, 2011]
    Another great thread from you mate. Hope it all goes well. You certainly put plenty of thought into your projects, esp with the little paintshop pics lol.

    Keep it coming!
  27. s3dave
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    s3dave TFSI Hybrid Supporter

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  28. finesse
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    finesse Active Member VCDS Map User

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    [Apr 8, 2011]
    :whip::whip::whip:

    mooooar welly
  29. Welly
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    Welly VX220 SC Driver :)

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    [Apr 8, 2011]
  30. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 8, 2011]
    I did consider this one too mate... looks a better finish than the OBX but too cheap to be an RMR unless the seller has no idea what they are selling...

    Short runners on this one but not sure it will make too much difference all things considered... I think I will hold out for a SEM myself...

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

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    [Apr 9, 2011]
    Good progress yesterday - a day off (with a few errands to run as well) an the lovely weather made me crack on.

    Did my most hated of jobs - removed the engine mount, reset the tensioner and installed the new cam belt. Thank god that's out of the way!

    Started off by taking some comparison shots of the turbos as the hybrid is going today:

    [​IMG]

    I also took my 'mocked' (or bodged) oil lines up to the hydraulics company who will be making them. Was hoping for them to be back Friday -however that wasn't to be - Monday they should be sorted.

    [​IMG]

    Then moved on to created the correct shape and size charge pipe....

    [​IMG]

    Then carried on my manifold porting work.... The first picture shows the difference between the porting of one side and not the other, and then the completed port.

    [​IMG]

    [​IMG]

    Then prepped my new TIP with the parts bought for it. I have decided the have the 007P welded directly to the 3" alloy on the TIP rather than mess about with hoses connecting it. Not sure how this will work out, however time will tell....

    [​IMG]

    Then finished a few other housekeeping bits and bobs.

    Finished up the night with this:

    [​IMG]

    Well deserved - I was knackered.
  32. Speedy Steve
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    Speedy Steve Active Member

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    [Apr 9, 2011]
    What its not finished and running yet Welly? Your slacking lmao. Looking good mate so when do you want to come up and work on mine?

    Do you think I could fit the XS manifold with out taking the head off or will it just be to much of a nightmare?
  33. Welly
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    Welly VX220 SC Driver :)

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    [Apr 9, 2011]
    I would say it is next to impossible mate to be fair. The need for studding the turbo requires the head to be off really...
  34. Welly
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    Welly VX220 SC Driver :)

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    [Apr 9, 2011]
    A few bits ordered arrived through the post today - turbo hoses and a few other odds and ends.

    The inlet manifold is finished, rocker cover repainted, turbo hoses trimmed and fitted, throttle body ported.

    Awaiting a few bits now and I can start putting it all back together...

    Some photos:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
  35. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Apr 9, 2011]
    What you used to port the manifold mate? That the standard TB?
  36. MUSH
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    MUSH MUSH Developments Ltd.

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    [Apr 9, 2011]
    Your certainly moving fast on this build bud. Mines dead in the water until i get the exhaust made this week then i can crack on with boost pipes etc as you have

    enlighten me on your turbo choice buddy, i know its an ihi but whats the spec and comparable performance expectations?
  37. Welly
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    Welly VX220 SC Driver :)

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    [Apr 10, 2011]
    My Dremel mate, with sanding bits to give a nice smooth taper. Seems to have worked really well and hoping that it will help the transition from small port to large port.

    It is the standard TB yes, I've deliberately left it with the rough finish - I think it will help the water meth atomise on the way through the TB.
  38. Welly
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    Welly VX220 SC Driver :)

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    [Apr 10, 2011]
    I like having something in hand to get on with - I get bored easily... lol

    Turbo choice was down to several factors. Availability, price and the need to do something different. With respect there are a few GT30 builds these days, however you don't see as many IHI builds.

    Also, If the turbo goes south it's very easy to get another, and very easy to fit in top mount form.
  39. MUSH
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    MUSH MUSH Developments Ltd.

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    [Apr 10, 2011]
    Yep top mount is the way forward, you may have even pulled your last head off..!! Lol
  40. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Apr 10, 2011]
    Very nice, you just use normal flap wheels? Looking into starting mine next, should be fun :) lol.

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