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Discussion in 'A3/S3 Forum (8L Chassis)' started by StaceyS3, Feb 7, 2012.
Has it been started yet?
Not bloody likely Dave, seeing as it can't hold any oil or water!
Ahh it was just on top of staceys comment that bill may want to burn it.....so combustion hasnt happened then....
nope.. and they were already weaping and fuely last week..
I am not confident in anything at this point unfortunately.
its not been a good start.
we shall see.
used sump never going to be good to weld to with ally... its crudy stuff when new.. oxide and contaminantes feck up the chances of welding without getting back to pukka metal again.. abrade or shot blast.
those welds in the picture dont fill me with confidence.
I had to weld repair my original seat sport sump and a small section had cracked... it did not want to weld well at all... Once oiled up.. even when cleaned, did not like it.
I would suggest folks use AKS Alex or forge for the 1.8t baffled sumps personally.
Its water tight now.. so should remain oil tight.
Hopefully this is the end of the issues (other than the water pipe)
Nice one Bill was it a complete arse in the end or just a matter of just filling them?
wire brush, much cleaning, and using the ac to "clean" and bring out he crud to the top and repeat cleaning.. then the new filler rod would cap it without also suffering the same crud coming thru. water tight now so somethings worked.
water pipe now replaced... with a.n.other one I had around here. -AN fitting cut off leaky one and welded on to this other one.
3 goes later I got it water tight.. braze playing havoc with the tig. You think its all off but apparently not when I leak tested it with this ACME bodgit drip-o-rama leak tester.
back together again...
another hardline coolant leak found.. and replaced..
cam timing correlation error, so cam timing fixed..
throttle malfunction.. Not sure.. will see if this comes back.
Its new filter is on and its back together again..
its Actually Run today for first time! yay
Sounds like a diesel van lol
Its alive!!! Cracking work!
So no fuel leaks from those AN fittings?
Wich ones did you get Stacey, I tried to fit mine this evening and the fuel is pissing out the fittings.
edit : FAIL - I bought the 3/8 fittings I assume you have the 5/16 fittings?
Just saw the video, good to see its running but why is it so noisy?
Dry lifters probably, will need some heat and oil pressure in them before they quieten down wont they.
Watching this with great anticipation
Great to hear it come alive ....well done all..:icon_thumright:
Dude I'm so excited for you!!!!!
Good work on it bill
Awesome. Now just to extract a billion horsepower
Big thanks to bill as it wasnt straight forward due to some numpty (me) somehow ****ed the timing
Its all sorted now and as you can see runs
Wahoo thats one hurdle down but with more to come very shortly, am hoping it should be all plain sailing from now as well as im sure bill is
Yes yes! Watching this thread like a hawk!
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Bet you hoping its ready for the weekend
I've told you it's difficult to count the teeth on the belt after 40 bottles of magners which is why I did my own belt
its quieter than in that first video now some oils got round and into the followers.. Its not quiet as std, but that seem to be the norm on anything with uprated valvetrain... always more ticky.. a lot more load in the valve train with uprated springs etc... cams in here also..
It wont be.
My diary is back to back booked... and its slot was missed because of the assorted issues.. Its a fill in job, which I can only fit in between the many other customer bookings I have. I also want rid of this car also.... Its not an armament and takes up space which should be used by another project build queued behind it.
Will be done asap...
running in next.... on a base map I need to create... heat cycle it.. check for any other issues.... then onto the actual mapping.
its moved off its perch and sat over dyno now.. exhaust video and moving over on FB >> https://www.facebook.com/Badger5Ltd
running it in tomorrow..
Lots of time and effort! It'll be we'll worth it Stacey! Bill that exhaust sounds damn amazing! This is going to be a beast!
Some of you already may know but car was on the dyno friday and done a couple of pulls managing 410bhp peak at 24psi but Bill believes theres some work to be done with the cams yet dialing them in as car was performing in a strange manner with regards to timing advance and when vvt is used, so theres more to be done there
Once fans etc were switched off for the night it was apparent that the turbo was sounding a bit odd....
Bill recognised this sound as possible bearing failure of the turbo so it was shut off straight away and from what can be seen at the moment all the blades appear to be intact
Main suspect is that the bearing cage has broken down which is supprisingly plastic? Couple of options at the moment stand as (providing only bearings are damaged)
1. Take a risk and send it back to ATP in USA and hope they will honour the warrenty even though it was purchased a year and a half ago
2. Theres two options for possible bearing replacement in the UK one being metal caged bearing but costing around 500 or a plastic and ceramic option for about 1/2 - 2/3s of the cost
Or if shaft blades etc are damaged I will need a complete chra on service exchange but that gets ££££
Anyone want to donate a turbo to a good cause lol
If you didn't have bad luck you wouldn't have any, gutted for you mate....
Can you talk to ATP and see if they contribute towards getting the bearings replaced in UK to save shipping it back to them?
Is there any idea of what could have caused the bearings to break?
What a ****.
Your luck with cars is very similar to mine
Pah. You poor *******.
Sorry to hear this man, come so far to have news like this
Been keeping up with this as it progressed and was really happy to hear it had started etc and am gutted for you that another hurdle has been thrown in your way.
Hoping it can be sorted without having to wait too long and without costing you an arm leg and any other apendage
Gutted for you mate.
But as I said to you at inters. No good getting down on it. Choose your option and keep moving forward bud ð
Sorry to hear Stacey not. The best news but that's cars for you ey! Nothing is ever 100%! Best thing is to move on with it and get it sorted. I'd get a metal bearing case thingy, saves it from going again?
Imo it just sholdnt happen, not on a brand new turbo, regardless of how long its not been used.
I mean i know theyre somewhat sensitive to conditions, but theyre an assembly spinning at mach10 and therefore should be built to a high standard from the get go. These turbos are 1200+ quid without a fooking exhaust housing, there is no excuses and i certainly hope garrett honour their responsibility as the industries leading turbo manufacturer to replace this and say 'this should not happen, ever. Were sorry'.
Best of luck with the repair/warranty replacement. Keep us updated. If this were to happen with mine someone will get raped.
P.s. Whats bills opinion of the whole situation?
That is proper ****. Like Karl says, they should just send you out a new one. They're pretty active on Facebook. Shoot them a message, bit harder to ignore it in public view.
Have you had the housings off yet?
Cheers for comments guys appreciate the kind words
Have been firing a few emails back and forth with atp and think will send it bavk to them and wait and see what they can do?
Been lots and lots of thoughts running through my head at the moment and going to wait and see the outcome of the inspection before making a decision
Bill will have to comment himself im affraid as dont want to quote and get it wrong as my memory is appalling
He did have a couple of graphs and info with relation to how it was running with and without vvt so will hopefully post them up as was quite intriguing
graphs of progress as it was last friday before turbo made its horroble bearing noise on shutdown.
vvt effect on spool seen below as an example..
Actual emulator live mapping with winols
Playing with vvt on rpm setpoints to see why torque would just fall away like a mofo in "normal" mode of operation.
The car istself is not wanting to accept much ign timing at all... which is not normal.. I suspect cam to cam timing is a little off somehow, as the vvt effects seen above are not normal... Inlet I think wants to be more advanced than it currently is (retarded 2 deg)
Turbo beatings doing what they did is more than a little dissapointing for everyone. Oil feed is fine, very healthy supply, water flow to chra checked and also healthy... only 27psi max boost run twice, and only on 24psi sustained whilst I figure out why it wants no ign timing.. (10deg vs 20deg on a normal GT30 car and it still pulls CF). EGTs have been logged and only got to 700deg, but whilst the timing wont stick this is why I have had to keep a lid on boost and correct the cam issues.. Turbo bearing noise caused end of play however.
Its a sh1t sandwich all round. Hopefully ATP will replace it.. There is no reason for it to have gone so noisy so soon. Less than 4 hours engine run time. It has oil, water.... and looks as new on its CHRA
Note for folks.... GT garretts come with plastic bearing cages.. yes plastic.. and they are known to melt and distort, causing bearing failures. Had the very same myself on my hybrid gt35.. Caught it in time, and had Owen Developments replace its shyte garrett bearing pack with their own metal caged version. Given how hot 1.8t engines run, this would be a good upgrade for anyone considering garrett GT.