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Time for a build thread....big turbo

Discussion in 'A3/S3/Sportback (8P Chassis)' started by S3Alex, Oct 19, 2010.

  1. snowy
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    snowy Crunching Gears

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    [Aug 3, 2013]
    I've got both the front axle and rear axle Peloquin LSD's

    Been fitted for 2yrs now and been used on pretty much every type of surface

    Slowly making my way through your thread - epic stuff

    Been hatching a plot to convert my GT to GTX (want more hp without sacrificing spool, so not as much hp than you're going for)
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  2. NHN
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    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

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    [Aug 3, 2013]
    Welcome to the site.

    Woah bet that's fun :)
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  3. snowy
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    snowy Crunching Gears

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    [Aug 3, 2013]
    Thanks

    Been a lurker for a while

    The diffs where worth every single penny

    I'm currently on a Blue haldex, but have concluded the HPA will work much better with a rear axle LSD
    due to diff unload on release of drive to rear axle when braking with the blue

    tbh Surprise Gary Peloquin hasn't released a version for later haldex units yet
    Last edited: Aug 3, 2013
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  4. S3Alex
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    S3Alex Rarely neutral

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    [Aug 3, 2013]
    Welcome to the site,and thank you!

    One of the things I've found here is you always learn something new,and thanks to your first post,I have.

    I didn't know Peloquin did a rear diff as well,so I'll keep that in mind for another time.

    What turbo are you currently running?

    I've got a GT3071,with 0.5A/r compressor housing,and 0.64A/r turbine.....there isn't any more lag really,than with the stock turbo,unless you're way below the boost,and that comes in around 500rpm higher than the K04.

    Now.....what I've been told is the GTX3076 will come in a bit higher,and with a billet wheel,lag should be minimised,although I've gone for a bigger A/r turbine housing this time,so we'll see what happens.
  5. snowy
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    snowy Crunching Gears

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    [Aug 5, 2013]
    I'm current on a .64 GT2860RS

    Owens have given a whole range of options for converting to GTX2863R or GTX2867R, with a 400 - 450 hp power range between the options

    My first thoughts had been to go with a .64 GTX2863R being the direct replacement


    But I'm also upgrading to a braced 2L block with billet crank, so thinking the faster spin up might allow for a bigger turbo

    I want to maintain the supercharger like response of my current setup
  6. S3Alex
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    S3Alex Rarely neutral

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    [Aug 5, 2013]
    Those should give you decent response and a good bit more flow.

    I think of the two you mention,the 2867 would offer the best compromise.

    I started with a GT3071 and now feel that it's a bit wrung out so a GTX3076 would deliver more flow at a similar level of lag and thus much better performance overall.

    That's the plan anyway.
  7. snowy
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    snowy Crunching Gears

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    [Aug 5, 2013]
    I suspect your gearbox is going to need counselling ;)
  8. S3Alex
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    S3Alex Rarely neutral

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    [Aug 5, 2013]
    It's been counselled and received some support a couple of yrs ago. Lol

    Since then,its behaved and managed to stay out of trouble.

    It had uprated bearings and new synchros and selector forks.

    Also a new transfer case.
  9. S3Alex
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    S3Alex Rarely neutral

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    [Aug 8, 2013]
    Bit of a delay......another car has been holding work on mine back,so hopefully next week now.
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  10. 15Degrees
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    15Degrees Active Member

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    [Aug 9, 2013]
    Who did that work?
  11. S3Alex
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    S3Alex Rarely neutral

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    [Aug 9, 2013]
    I don't know the name,but it's a gearbox company based in Kent,and AMD would have the name and address.

    So far,it's been good,but clearly I don't beat the thing around too much,as I see it as a bit of a weak spot on the S3,given that it was designed with far less power in mind.

    Had you considered a dog box kit for yours?
  12. S3_Jacko
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    S3_Jacko Well-Known Member

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    [Aug 12, 2013]
    Amazing mate..... I'm a newbie and reading this has made me wanna chuck my standard s3 in the bin ha...

    Keep up the good work! :)
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  13. S3Alex
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    S3Alex Rarely neutral

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    [Aug 12, 2013]
    Many thanks.

    I'll keep finding ways to "invest" in this project,but right now I want to get it back and get driving again.

    Due to another customer's car occupying the space mine needs to be in,work on mine has been delayed.
  14. Unitronic
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    Unitronic Fear is just a word!

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    [Aug 12, 2013]

    Oh man,,,,I know the feeling bro! I can't wait to get mines out & about!
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  15. S3Alex
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    S3Alex Rarely neutral

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    [Aug 12, 2013]
    Me too.....hoping for an update today when Ben gets back,and the estimate previously was maybe end of the week.

    Diesels are great in some ways.....wife's DS3 does 60mpg without trying too hard,but it's just not the same.
  16. S3Alex
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    S3Alex Rarely neutral

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    [Aug 13, 2013]
    Time for a quick update.

    Went down to AMDTuning after paying all of my current bills(!),and had a look around.

    Got a good look around the Honda BTCC car,and went to automotive heaven....the quality of the workmanship on that car is stunning.
    Every fitting,linkage,upright and even the interior is just pure race porn,and altogether,the thick end of £500k.

    So now,back to something a bit more affordable.

    Car is going up on the ramps today,after a horde of other cars come down,and then it gets pulled to bits.

    Subframe comes off,and the gearbox,clutch and diff come out,to swap the diffs,and get a look at how the clutch is getting on,plus change the release bearing.

    Turbo,downpipe and exhaust system off,to swap the GT for the GTX(and I do have some pics to come later today),and to find the leak.

    New boost gauge ordered.....One of these....


    [​IMG]


    Not the prettiest maybe,but it does fit the existing holder,AND it runs to 2.5bar,and it's quite difficult to find analogue gauges running to anywhere over 2bar.
    Since the car currently runs 2 bar,and we should get more flow,lower EGTs,and better power from the GTX,I don't see that we'd go beyond what this can measure.

    Rear brake pads arrived today....Mintex 1155s,so that should restore some balance.


    After it all gets put back together comes the difficult part......mapping and running.

    The Revo Stg4 map will stay on,and it's then a matter of getting the car running,checking the boost,fuelling,and timing,and seeing how the WMI system gets on with the new turbo......we're changing to a bigger injector as well.


    Fingers crossed as progress begins.
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  17. Unitronic
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    Unitronic Fear is just a word!

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    [Aug 13, 2013]
    Did you do any head work Alex? This's where you achieve the most power from you'er TFSI? I have picked the same gauges you have, oil pressure & temperature in one gauge with boost gauge. I'm thinking of installing it in the 2 air vents on the dashboard.

    Can't wait to see you'er pics!!
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  18. S3Alex
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    S3Alex Rarely neutral

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    [Aug 13, 2013]
    Cheers!

    No head work as yet,and I know there's some gains to be had there,judging by what you've already done on yours,and I have to say you've done a superb job.

    I've gone about the build on mine in a sort of sequence of planned projects,as I still use the car every day,and have to fit it into both work and holidays,but the head is another plan altogether.
    It's going to come off for a few jobs,when the new intake manifold is ready.......that's being developed currently,and when it's ready,we can get the head off,get it opened a bit,remove the intake runner flaps,and also maybe change the exhaust manifold as well.

    I don't think there are any specific problems with the ATP cast manifold,as others have got more power from it than I have,but a tubular manifold and flowed head would be better.

    Right now however,the inlet manifold isn't ready,so there's no real point us taking the head to bits until it arrives.
  19. Dean_T
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    Dean_T Active Member

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    [Aug 13, 2013]
    I bet the bill payment was painful but just think of all those stampeding, wild horses that are going under the bonnet :)

    Where are you putting the boost guage, A pillar or somewhere else?

    I wouldnt mind a couple of guages, oil temp mainly but also boost guage too!
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  20. S3Alex
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    S3Alex Rarely neutral

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    [Aug 13, 2013]
    Hi Dean,

    The current gauge is mounted on a NewSouth pod and looks like this.....



    [​IMG]





    NewSouth Performance

    The new gauge will fit straight into the pod.


    I think if I go for more,I'll either get an OBD interface and link to the iPhone,or maybe an AEM wideband lambda sensor.
  21. S3Alex
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    S3Alex Rarely neutral

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    [Aug 13, 2013]

    OK...finally.

    This was sitting on the desk down at AMDTuning today.....



    [​IMG]


    4" inlet,with anti-surge housing.


    The current GT3071 has a 4" inlet,but no anti-surge housing,and surge has been a bit of an issue on part throttle openings.



    Shown here for comparison....

    [​IMG]
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  22. S3Alex
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    S3Alex Rarely neutral

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    [Aug 13, 2013]
    So....a few more from now,and the vaults....

    Old turbo hot side....

    [​IMG]



    And the new one.....



    [​IMG]
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  23. S3Alex
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    S3Alex Rarely neutral

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    [Aug 14, 2013]
    And one more...


    [​IMG]


    The hot side of the turbo above has one of these from my previous turbo.....


    [​IMG]


    The worry with these is that they retain heat and confine it to the turbo,so you do have to be sensible and allow it some time to cool after a hard run,or go to Owen Developments,and have them build you a turbo with a metal cage for the bearings....which this one has.

    On the plus side,less radiated heat which is another issue,given how close the propshaft runs to all this,and hotter gas equals better flow.
    Last edited: Aug 14, 2013
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  24. Rhyso
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    Rhyso Active Member VCDS Map User

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    [Aug 14, 2013]
    Think you need to put NSFW in the thread title!! Thats pure porn right there :wub:
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  25. S3Alex
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    S3Alex Rarely neutral

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    [Aug 14, 2013]
    Maybe I should put one of these at the top.


    [​IMG]


    Anyway.....As you'd expect,I have more.
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  26. S3Alex
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    S3Alex Rarely neutral

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    [Aug 14, 2013]
    I forgot I'd had these fitted when the engine was being built....turns out they were a very good choice.


    [​IMG]



    [​IMG]


    The stock CR on the S3 engine is 10.5:1,and it turns out that these are 9.2:1,so raising the boost isn't going to raise the roof on the engine.
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  27. Sevv
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    Sevv Pushing the limits..

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    [Aug 15, 2013]
    hey mate where your pistons head treated with tuff coatings ? still dabbling with what pistons to get leaning towards the wossners though..

    P.S this is real car pron its amazing.. how much HP will she putting out btw are you doing more engine work for the 3076 or have you already put a girder kit on it?
  28. Dean_T
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    Dean_T Active Member

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    [Aug 15, 2013]
    Those turbo pictures :wub:
  29. leeds2592
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    leeds2592 When I grow up, I want a 964!

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    [Aug 15, 2013]
    I don't know what that silver thing is, or what it does, but it looks good and I like it :laugh:
  30. S3Alex
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    S3Alex Rarely neutral

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    [Aug 15, 2013]
    If you mean the jacket on the turbo it's a heat jacket.

    Keeps heat in the turbo and not in parts around it so gas flow is improved as well.

    Very useful with the propshafts and transfer case so close.
  31. S3Alex
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    S3Alex Rarely neutral

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    [Aug 15, 2013]
    Thanks as always !

    Just stock Wossners. Nothing unusual other than the low CR.
    The block isn't girdled but it doesn't seem an absolute from all the others running this sort of power.

    It runs around 500bhp now so should get a bit more at the same boost on this big mutha.
  32. leeds2592
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    leeds2592 When I grow up, I want a 964!

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    [Aug 15, 2013]
    Ah right, I see. Tbh, I don't know what a lot of things are in this thread as I'm not technically minded, although I am slowly learning more and more. I still check this thread everytime you put an update though as it's epic!
  33. sje00
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    sje00 Member

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    [Aug 15, 2013]
    Have none of you big turbo guys thought about the HTA turbos from Owen Developments?
    I run a GT2868HTA on my 106 Rallye and its an extremely impressive turbo!! Makes a GTX2867 look pony! Only down side is the price, but then again you get what you pay for!
  34. S3Alex
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    S3Alex Rarely neutral

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    [Aug 15, 2013]
    I took advice from both Owen and Revo on the specifics.

    Revo's software was developed on Garrett turbos,and it came down to a choice between a GTX3076 and GTX3576.
    The trade off between lag and topend flow,and what I could sensibly hope to do with the 2.0TFSi meant that the 3076 was the best choice overall.

    On yours,you'd be running a bigger turbine than on the GTX if I'm correct,so that would account for the difference,but this is larger again.

    The HTA3082 which would have been an option has a larger turbine than my 3076,but mine has all of the other options and extras that the HTA has.
    Inc the choice of aspect ratios etc and motorsport ball bearing cage,billet compressor,antisurge inlet but it doesn't have the choice of colours.

    The price after mine was built up is about the same as the 3082,so I guess I got what I paid for!


    BTW...your car must be an absolute hoot!......less than 1 tonne?

    Brilliant!
    Last edited: Aug 15, 2013
  35. sje00
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    sje00 Member

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    [Aug 15, 2013]
    Ah fair enough mate! if Owen's suggest what you got then who's to argue lol!
    I just dont know of too many people using the HTA's and it'd be nice to hear there experiences.

    What sort of figures you looking at once its finished?

    Yea probs sub 900kg. previously it was 385bhp @23psi & 345ft/lb. It had a full interior, but now its stripped and caged with a swirl pot, so should be able to up the boost as i maxed out the Walbro 255 before.

    It's a scary drive EVERYTIME you drive lol.
  36. S3Alex
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    S3Alex Rarely neutral

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    [Aug 15, 2013]
    I think that's just brilliant....one scary little car for you,and anyone who's daft enough to try outrunning it.....really seriously good fun.

    I know a couple of people who've used either Precision Turbo,or HTAs and not heard anything bad,so I think in this world,that translates to good overall!

    One guy I know was getting around 600bhp from his TFSi,so that's more than good enough I guess.

    I got a huge amount of advice from Owen's on this turbo,and I couldn't give anything but praise,from the moment I started asking for advice,without being sure I was even going to buy,until it was bought,built,and paid for.
    Absolutely superb throughout.

    I'd be hoping for a start at around the 500bhp mark,which is where we are right now,on the 3071,which is pretty well maxed out,and also producing a bit of part- throttle surge which I try to avoid at all costs.
    This thing should do at least the same power,at maybe 1.8bar,instead of the 2bar I currently run,with lower temps,and no surge thanks to the housing.

    After that,I need to get the head done,but I have a new inlet manifold coming sometime,so the head will come off then,and the inlet and exhaust manifolds can also be changed.

    My car weighs about 1450kgs,so it needs to go on a diet as well(like me)...I can easily lose the rear seats sometime,and then get the carbon wings and bonnet,so that would lose another 90kgs or so,and I think that would be about enough.
  37. superkarl
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    superkarl MAN OF STEEL

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    [Aug 16, 2013]
    LOL
  38. S3Alex
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    S3Alex Rarely neutral

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    [Aug 16, 2013]
    I tell you,that power in that car would make me LOL or maybe worse!
  39. superkarl
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    superkarl MAN OF STEEL

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    [Aug 16, 2013]
    i was originally lol'ing at the last comment, but yeh, would be crazy fun.
    I've a friend who was building a gt30 duratec 106, its been about 3 years in the making now and i think he might have given up :(
  40. S3Alex
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    S3Alex Rarely neutral

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    [Aug 16, 2013]
    I love the idea of a reasonably stock looking car that goes like hell ....I've tried to keep near that with mine but I'm running out of ways to do that.
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