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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. NHN
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    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

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    [Oct 3, 2013]
    Yes I agree, only when a part is at the extreme's, will it show the slightest tiny defect that will cause an issue.
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  2. S3Alex
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    S3Alex Rarely neutral

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    [Oct 3, 2013]
    Thats the problem I think......what myself and a few others have done is to push the TFSi a bit and it's after Stg2+ that you start finding the issues that you won't otherwise find,with everything up to that level being so well researched and sorted that you can practically guarantee the thing will work.

    So far,I've been surprised by how well it's all come together and how reliable the car has been overall,but there is still an element of discovery to a lot of this.
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  3. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 3, 2013]
    I have been experimenting with WMI & found so many way's to play with. Most folk use 50/50 mixes but not alway's the best & people are to afraid to experiment seeing its still very "new" to the UK market.

    To get the most out from the WMI system you could try & set it by starting of at 0.7bar and on full boost at 1.2bar through to 2bar. Setting the WMI at 0.5 is not really that important as there's not mutch heat or engine load at this lower boost levels. ( 0.7 will be a better starting poin't)

    15% meth if you use Tesco 99 has the potential to give you 102-105 fuel octane! You can set your timing at 6-7 27 degrees a nice agresive setting if you prepared to play you'er self.

    if you mix a 5L bottle you could mix 70% water 25% Meth 5% screen wash.
    Last edited: Oct 3, 2013
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  4. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 3, 2013]
    How does the ATP manifold hold up? I know its very early stages.
  5. S3Alex
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    S3Alex Rarely neutral

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    [Oct 3, 2013]
    My kit is an ATP kit......it's been on the car for around 3 years now,and there's been no problems with any part of it,although the exhaust downpipe and turbo inelt pipes did need to be modified to fit a RHD car.

    The inlet manifold is a different matter and is a work in progress.....it will be fun when it's done though.
  6. S3Alex
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    S3Alex Rarely neutral

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    [Oct 4, 2013]
    A few more words on this little beauty....

    [​IMG]


    Not a cheap addition to the car,but by comparison with something like say the Haldex controller,which costs about the same sort of money,the value in terms of grip and handling is way better.

    Yes,the 2 compliment each other,and I suppose ideally you'd have both(I already had the controller and waited until Quaife produced a diff for the 4WD gearbox),but this thing really does do the job.

    On a wet road,like today,traction is better,and more secure under acceleration,and the car doesn't feel like it's fighting you every inch of the way.
    It's therefore smoother and easier to drive,less of a handful,and more predictable,but as I said earlier,it doesn't seem as snappy as previous Quaife ATB diffs I've used a while ago.

    It does show up how bad a decision it was for Audi to stick a simple open diff in the car.

    I mean...this thing is just not the same....


    [​IMG]
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  7. KentKid
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    KentKid Active Member

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    [Oct 4, 2013]
    ^^^^^ *adds to wish list*
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  8. S3Alex
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    S3Alex Rarely neutral

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    [Oct 4, 2013]
    My wish list continues to grow as well.

    Found a few more bits that I absolutely "need".
  9. S3Alex
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    S3Alex Rarely neutral

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    [Oct 5, 2013]
    Getting used to driving the car again,and having substantially more power.

    At risk of prattling on about the diff,it's seriously impressed me.
    The car corners and accelerates with a lot less fuss than before,and no scrabbling around,even when the inevitable happens and enough torque to overcome grip occurs.
    Previously at that point,the car was a bit of a handful and would tend to snake around but now it simply goes where it's been pointed,which is great.

    The brakes are much improved too.....AMD fitted a set of ZeroSixty discs and Mintex 1155 pads at the rear,as the old discs were pretty much shot,and now,with the fronts adjusted,it pulls up straight,and the rear doesn't go light either.

    Just a few things that added together make for a real improvement.

    Now...got to get the carbon front wings,and then lower the car a little,not much,just a couple of cms,and then onto the next few projects.
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  10. S3Alex
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    S3Alex Rarely neutral

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    [Oct 6, 2013]
    Car got the seal of approval from my son today,which is pretty good considering he also liked the old Escort.


    I need a couple of new projects now,and I think I need some carbon.

    The Osir carbon wings would do nicely,at 20mm wider,and allow me to drop the car a little as well.
    Osir used to do a carbon bonnet,but it looks like it's down to Seibon for that now,plus some nice flush mounted bonnet catches.

    Then I still have a hankering for a replacement splitter and rear wing,and I think I know just the place to go,but I'm going to need AMD to get going on a bit of fitting expertise.

    More to come.....
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  11. KentKid
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    KentKid Active Member

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    [Oct 7, 2013]
    It won't be too long until your S3 starts to look like a full-on road going Rally car!

    Can't wait to see the pictures when you get round to having all these bits fitted - any thoughts as to what colour carbon panels you will use on your white S3?
  12. S3Alex
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    S3Alex Rarely neutral

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    [Oct 7, 2013]
    Lol.

    Back to what I used to drive.

    The panels come unpainted and I'd have them sprayed white.

    The bonnet catches are a bit of a pain to fit but that will be AMDs problem!
  13. S3Alex
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    S3Alex Rarely neutral

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    [Oct 7, 2013]
    May be in for a bit of a laugh or not tomorrow.

    Not only an MOT,but perhaps a run on the dyno to see what's changed,if anything!

    Last time it really didn't like the dyno and kept pulling back,which it never does on the road,and made around 480bhp while it was busy doing all of that,so it's back for a return bout tomorrow.

    I don't think any of us expect it to like the dyno any better than last time,but since it goes like a b*st*rd on the real road,it seems only fair to give it a whirl.

    If there's anything worth seeing,I'll post it up,and if it explodes,I'll just stay quiet.....
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  14. turbonutz
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    turbonutz Active Member

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    [Oct 7, 2013]
    you coming up to scotland with this thing some day so a can get a we sit in it going vrooooom!!!!? lol
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  15. S3Alex
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    S3Alex Rarely neutral

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    [Oct 7, 2013]
    Got to say I would love that.

    Haven't been to Scotland for a loonnnng time,but the last trip was great fun in one of my Cosworths.....went up to Arbroath and Edzell,and had a great drive.
  16. turbonutz
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    turbonutz Active Member

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    [Oct 7, 2013]
    yeh man some lovely roads here, AMDshould be funding ya to do it to promote there brand up here lol, only revo a can think of that has any tuning hand up here really?
  17. S3Alex
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    S3Alex Rarely neutral

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    [Oct 7, 2013]
    Some wonderful roads and fantastic scenery,which we just don't have down here.

    I'll put it to AMD tomorrow that they should fund a road trip,but then my car is a real hybrid.....AMD engineering,parts from all over the world,and Revo software.
  18. turbonutz
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    turbonutz Active Member

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    [Oct 7, 2013]
    yeh alot of that here, just pishing down alot tho lol :p

    ahhh no amd parts? but ya used there expertise lol. and thought they woulda done yer custom mapping by that stage ha
  19. S3Alex
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    S3Alex Rarely neutral

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    [Oct 7, 2013]
    Well....I've got half an AMD intake!

    The rest of it is pretty much a custom build of ITG and ATP parts adapted to fit my car.

    [​IMG]


    [​IMG]


    [​IMG]



    Otherwise,a lot of very neat and clever work installing my WMI system and the Haldex controller....


    [​IMG]


    [​IMG]



    The work is always very neat and goes the extra mile for neatness and placement...


    Boost controller and solenoid...

    [​IMG]


    [​IMG]


    And....almost forgot I had a custom exhaust from them,which my neighbours complained about....!


    [​IMG]
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  20. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 8, 2013]
    Not true! There are other tuners like SWMotorsport who do Unitronic in Edinburgh!
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  21. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 8, 2013]
    What figures are you thinking it will make Alex? I think i'm more exited then you are to know. LOL
  22. S3Alex
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    S3Alex Rarely neutral

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    [Oct 8, 2013]
    If it makes more than 480bhp I'd be happy as there were problems getting it to run on the dyno before.

    So anything more would be a sort of bonus.
  23. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 8, 2013]
    You should easily run 530bhp and then if you play around with the WMI you can ad another 40hp! I would start playing with you'er sps switch and start getting use to playing wit it. It's risky but you got to start somewhere. I think you should try and play with you'er SPS switch. LOL
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  24. NHN
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    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

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    [Oct 8, 2013]
    :sign_plug:
  25. S3Alex
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    S3Alex Rarely neutral

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    [Oct 8, 2013]
    I'm not sure about playing with anything!

    May get the timing adjusted for the WMI though but need the head work done.
    Almost time to see how it's done.

    Also would have been an MOT fail today.
    LOL

    Left rear brake light
  26. S3Alex
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    S3Alex Rarely neutral

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    [Oct 8, 2013]
    I hate this bit....

    Hearing the car from the outside at full chat.

    Always expect it to be followed by the sound of pistons and rods exiting stage left.
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  27. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 8, 2013]
    I presume you have personal BAD experience with this :sign_plug: including SWMotorsport?
  28. S3Alex
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    S3Alex Rarely neutral

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    [Oct 8, 2013]
    All done.

    Made a little more but rolled off at around 6000rpm.

    Need a stronger wastegate spring !

    Holds boost better on the road but still limiting the top end.

    Graph shows it quite nicely.

    Pic to follow.
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  29. S3_Mat
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    S3_Mat Active Member

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    [Oct 8, 2013]
    Whats the boost set to currently Alex? Looking forward to the graphs!
  30. NHN
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    [Oct 8, 2013]
    Are you the tuner Unitronic?
  31. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 8, 2013]
  32. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 8, 2013]
    Yes I am but im not advertissing or trying to poach! Just letting people know that Revo is not just the only tuning compony out there! I :beerchug:
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  33. superkarl
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    superkarl MAN OF STEEL

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    [Oct 8, 2013]
    This.
    Gotta be 550hp in there, turbo wont be working too hard for that.
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  34. Unitronic
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    Unitronic Fear is just a word!

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    [Oct 8, 2013]
    In theory yes! It all depends on the map & setup! You will gain more with a custom map.
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  35. S3Alex
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    S3Alex Rarely neutral

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    [Oct 8, 2013]
    So......here's what happened.


    [​IMG]

    Topped out at just short of 490bhp,and torque is also being limited.


    You can easily see that as soon as it hits 2bar boost at around 5500-6000 rpm,it stops gaining both power and torque,and on the logging,AMD could clearly see the wastegate wasn't holding onto the boost.

    I can actually see this on the boost gauge myself,as it flutters at around the same point on the road,and flattens everything off.

    In retrospect it's to be expected as the wastegate is running a 1bar spring,which is sufficient to allow it to control up to 2bar of boost and no more.

    So...the next thing is a 1.5bar spring.
    Last edited: Oct 8, 2013
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  36. voorhees
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    voorhees Moderator Staff Member Moderator

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    [Oct 8, 2013]
    Not bad :hubbahubba:
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  37. S3_Mat
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    S3_Mat Active Member

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    [Oct 8, 2013]
    That is a monstrous power graph.. Nearly 600nm! Not a great deal more than last time though probably due to the waste gate. Any estimations to power output when you have the stronger spring?
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  38. S3Alex
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    S3Alex Rarely neutral

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    [Oct 8, 2013]
    The thing is just hitting it's stride as the wastegate begins to bleed off the boost unfortunately,although we did get the WMI system adjusted,and previously got the boost controller gain sorted out.
  39. S3Alex
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    S3Alex Rarely neutral

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  40. S3Alex
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    S3Alex Rarely neutral

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    [Oct 8, 2013]
    At a guess,running 10% more boost,and allowing for losses etc etc,should top 500bhp even on the dyno.

    It actually runs better on the road,in that the dyno doesn't load it up the way a nice dry road does,but the limiting factor is still the wastegate.

    Actually got it to over 480lbs or 650Nm on the old 3071,at full boost,so this one isn't even near to being fully loaded.
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