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Stacey's Belated Yo Yo Build Thread

Discussion in 'A3/S3 Forum (8L Chassis)' started by StaceyS3, Feb 7, 2012.

  1. StaceyS3
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    StaceyS3 Well-Known Member

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    Yeah remember you saying was deliberate placement of boxes to get it to sit tight to thw floor pan.....so I can now slam it on some air bags :undewech:

    Not sure about the wastegate as suppose its a balancing act between something being capable to keep it shut for response and having a low boost setting?

    What would you reconmend? 1 bar?
  2. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    I will aim for a bar yea.. same as tufftys
  3. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    WG springs adjusted from 25psi opening!!!! down to 15-18psi now.. 3 springs in there, now 2.

    [​IMG]

    Just ordered 2" vband clamp kit to make the joiner for external gate off flexi to the rest of the system.. will chase supplier see if they can do a next day delivery.. fingers crossed. Will weld up top piece to gate finish welded this afternoon.. Everything is uber tight, but we do have some clearance. Definate sequence of assembly required. Lost count of how many times on and off the wg and turbos been this morning, and ramp up ramp down... Very time consuming job.
  4. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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

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    Looks brilliant and is all very snug :D

    Cant remember where I read the info for spring combos but know I aimed for around 1 bar but obviously no where near that lol
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    I think Tial make their figures up from fairy dust... They are always miles off. I am mean Miles off! lol Used to it by now but its a pia to need to change springs from what you ordered because they get it so wrong.

    anyhows.. tial gate pipe as far as I can do until 2" vbands arrive tomorrow (hopefully)
    [​IMG]
  7. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    PIA job this is.... hot, sticky day... Boo

    [​IMG]
  8. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [​IMG]
  9. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [​IMG]

    [​IMG]
    Last edited: Jun 28, 2013
    Gizmo20VT and Sam_ like this.
  10. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Top work bill

    when will you be mapping her? I bet she beats mine on power
  11. StaceyS3
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    StaceyS3 Well-Known Member

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    Looks wicked Bill :thumbup:

    So I suppose thats the exhaust finished now :)

    I hope it beats you previous results Andrew but will wait and see.....500 would be an absolute result :D
  12. Scullies
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    Scullies Well-Known Member

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    Did you start it up. Huh....huh... Did you? :hubbahubba:
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  13. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    oil and water lines next.. oil drains going to be a proper cnut to fit in... kinda busy all around the turbo. lol

    weekends mission..
    wish us luck
  14. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    It should do

    I really need to get round to getting my new down pipe and system done also i'm going to step up to a 44mm wategate as the 38mm one is on its limits with mine i think?, funny as i have never seen any boost creep with my set up but i don't want to risk it anyway
  15. Jason.s
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    Jason.s Active Member

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    Pics of rear with oval tip needed lol
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  16. StaceyS3
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    StaceyS3 Well-Known Member

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    Good luck

    It looked challanging without the DP and wastegate pipework so can only imagine what its like now ;)
  17. StaceyS3
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    StaceyS3 Well-Known Member

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    Cant wait to see what yours will do when pushed :)

    Would have thought you would be alright as from what I have read the higher the target boost the smaller the wastegate can be used and that people generally have problems with creep when trying to run lower boost?

    The bigger gate on mine was purely down to james lcr having creep on his 38mm gate, but I think a lot of it could be down to mani design
  18. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    True i just want to get mine running 35/38psi
  19. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    I believe yours is choked by CTS's 2.5" downpipe outlet section. When you get the larger one done I think you will be surprised quite the difference it makes to everything.
  20. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    The 2.5 downpipe has done well so far but it has to go now

    I do hope it makes a massive differents with the 3 inch plus downpipe
  21. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    Why so high? That's race/Quatermile type boost and they don't care about drive ability or longevity

    I don't even blow my tyres up that much...
  22. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    The gtx3076 is more efficient at them pressures. The rest of the engine has now been built to cope with it now
  23. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [​IMG]
  24. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    If any of what I have shared with you on your post links has sunk in, you will realise the difference back pressure on the turbine vs its effect on the efficiency of the setup, you 'know' the 2.5" would have been like blowing thru a straw... and would have been significantly more power for 'same' boost levels you ran.

    total flow.. you know this

    New revision should be mental... look fwd to seeing it
  25. StaceyS3
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    StaceyS3 Well-Known Member

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    Would have thought a downpipe should definately make a nice difference on yours mate as im sure if a k04 gains from a bigger bore dp then that would be magnified with a turbo of your size.....theres definatley more ponies to be seen out of yours yet ;)

    Had a look at my comp map with that conversion table and that suggests that mine will peak around 28 psi which is lower than I thought really but supoose won't really know where the peak will be until Bill plays on the dyno

    [​IMG]
  26. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    Back Pressure difference on Garys MK2 I recently made its 3" full system.. from its previous 2.5" system.
    For no other change in mapping, it rose from 400bhp to 450bhp... 50bhp gains not to be sniffed at... All fixed duty cycle by its Greddy EBC.
    and that "just" runs a 3" downpipe we made when we first built it a few years ago... 3" rest of system and reduced back pressure and noise reduction just helped it run more efficiently.. and made more power. Go figure :)
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  27. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    More boost more heat to contend with.
    More boost would kick up the mid range torque, but I think the convergance of the peak torque falling away quicker @ the same kind of level of bhp.. If pushing it to hard too soon, the cyl temps will rise and when up in the revs we will see if tolerating less timing, which it will pull, increasing egt's further.. Thats my predction based on having been doing this for a while.. Balance of how hard to push vs sustained top end without it getting too upset about the temps. wmi of course will be helping stabilise the temps and combustion, so a very good addition.

    Oil drain is a proper PIA, although think we have made something which could work. Need some braided hose tho to complete and a fitting to weld onto the lower part of the oe pipe. Water pipe I have run out of it seems (metal 3/8") and have ordered some which hopefully with get there tuesday. Will try and get the oil drain pipe bought and collected somehow tomorrow. All yesterday making iterations on how the hell to route it at all.. lol.. oh joys of custom BT's eh :)
  28. StaceyS3
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    StaceyS3 Well-Known Member

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    Sounds like a right result :)

    The S3 should certainly flow...... as its all about the flow ;)
  29. StaceyS3
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    StaceyS3 Well-Known Member

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    Understand what your saying bill....more boost doesnt always equal more power and if you can get simular power for less boost and heat with more timing then thats got to be a win, will be very happy if not hitting a wall always with egts like the old setup (heat pump) when driving "spiritedly" lol

    Just caught the pics on FB and its looking good, have you decided on routing on the upper part of the drain yet as that looked rather crowded up there?
  30. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    Upper part was already done, lower part was the more challenging bit. Transfer box, drive shaft, manifold runners etc all in the way.. yay!

    you can see in this bit the top section which drops behind the manifold runners, and then curves back in and under them just above the transfer box, with a -10an fitting on the end, onto which the short flexi hose section sits. The new lower section was then fabricated to coincide with this hose, so no stress is on any of the pipes. I will cover the flexi hose in some heat wrap also given its sat under and around some very hot things inevitably.

    Mid section which joins upper
    [​IMG]

    Lower section which joines mid flexi
    [​IMG]
  31. Sam_
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    Sam_ Down under

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    I've got all this to come :(

    Going to use the TSR downpipe though I think just for ease (don't know of any decent fabricators like Bill, etc over here).
  32. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    drains upper section and complete assembled off car
    [​IMG]

    [​IMG]

    and complete thing ready to leak test before I finish assemble it onto he turbo and sump etc..
    [​IMG]

    [​IMG]
  33. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    Also the locking rings I added to it to keep hotside bolts from backing out (which they seem prone to do on Tial hotsides)
    From Owen Developments... same as badgerwagens turbo has
    [​IMG]
  34. Sam_
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    Sam_ Down under

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    Ah yeah, I just got my Pag Parts .72 vband housing and he uses those little locking tabs. Inconnel bolts too apparently.

    A shame you don't sell the oil/coolant lines as a kit ;)
  35. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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

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    Looks wicked and very professional :)

    Them locking tabs should definately help....its all the little things like that make a huge difference to the reliability and something so small could be so costly if they fail
  37. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    water lines now invented and created.. funky shape on the one.. I think I should name this build fiddly as ****.. lol

    [​IMG]
  38. Jason.s
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    Jason.s Active Member

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    Fill her up and get her fired up! Video of first start up needed too!
  39. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    will see how many leaks it has once fluided up...
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  40. Scullies
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    Scullies Well-Known Member

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    0 leaks, because this baby needs to start prowling the streets. That turbo is begging to suck up half the atmosphere and throw flames out the exhaust, while its eating exotic cars for breakfast.

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