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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. Sevv

    Sevv Pushing the limits..

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    i know right such a hypocrite i am :p .. but please its not my fault its my retarded workshops' undignified shameless being
     
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  3. S3Alex

    S3Alex Rarely neutral
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    I've got nothing to shout about either. Lol.

    There are quite a few of us on here responsible for leading others down the road to ruin.
     
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  4. Sevv

    Sevv Pushing the limits..

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    oh dear yes i think both of us top that list.. and its quite unfortunate and sad that if some one said would you do it again in australia id say HELL NO! maybe in the US or UK i would though more clued up diligent people compared to Australia...

    on the other hand im hoping to receive the curse this friday but ill be you $100 it wouldn't be huh..
     
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  5. S3Alex

    S3Alex Rarely neutral
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    True.

    However I have a couple of European friends to blame/thank for my current obsession,and their ability to find new and shiny parts is nothing short of amazing.

    If someone had suggested to me last year that I'd have bought a billet aluminium manifold from a custom builder in Greece,followed by a Dutch ECU etc,I'd have doubted it.....but there you go.
     
  6. Sevv

    Sevv Pushing the limits..

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    oh well i guess guilty people always point the finger... i point the finger at this forum started on the 8L forum :p but hey its always good to apportion fault with others... i think if you can financially and its within reason then why not but thats my rationale and test i failed :p
     
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  7. S3Alex

    S3Alex Rarely neutral
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    Well....you've heard of repossession.....here's proof of possession....demonic that is.

    The number of the beast finally came up.


    [​IMG]


    And if that isn't enough,there's more in the shape of 32mpg ....... that's unnatural....


    [​IMG]
     
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  8. NHN

    NHN Retrofitter - Audi - VW - Skoda - Seat
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    Take it easy lol
     
  9. S3Alex

    S3Alex Rarely neutral
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    Thought there was the smell of brimstone this morning....
     
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  10. warren_S5

    warren_S5 Moderator
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    Less than 70k and you've had ............2(?) head decokes! Can you imagine what powere might have been robbed if you hadn't bothered. Makes you wonder what some short journeyed, mediocre maintenance cars must look like.

    How does the car feel, good as ever given everything you've had done. Mega MPG considering.
     
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  11. S3Alex

    S3Alex Rarely neutral
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    To be fair to the old beast,it's been in bits a couple of times,which made that work easier and more obvious.

    I know what power was missing though,as we've gone from 2bar,to 1.87bar,and it feels a lot quicker despite the drop in boost,so there were definitely a few horses gained along the way,from around 495 before.

    It honestly gets better every time something gets done,so I'm looking forwards to it's next set of mods.
     
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  12. S3Alex

    S3Alex Rarely neutral
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    Well,as always when you ask more people,or find more parts for a car,you get more answers and more potential issues.

    What I wanted to do was get the top end of the engine sorted....

    So,the cam cover and VTA breather kit is sorted and waiting to go,and that left the time for getting the valves etc done.
    Now the idea of getting the cams done entered the mix,and Cat Cams do some very nice products for the TFSi so I've had some advice and a good look at those.

    [​IMG]


    Look good,dont they....and compatible with VVT etc.

    But not entirely compatible with the valves I'd chosen as the lift max for the Ferreas is quoted as 11mm and these lift a bit more,so that's another one to research.

    If the worst comes to the worst,then it may be better to keep the stock valve train,and go with these cams,as the power and torque gains are substantial.

    More phone calls........
     
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  13. warren_S5

    warren_S5 Moderator
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    Wow, last time I saw a set of cams out and about was back in the early 90's when I had some Schrick cams put in my Mk2 GTi 16v. To be fair the 16v wasn't a bad engine, but you had to wring its neck to get the power out of it as it was a torque less beast. The cams gave more top end and with filter an exhaust I tipped 150bhp (dyno lottery at the original AmD in Lower Oddington run by Geoff and Mike). In those days it felt like motoring utopia, today I'm sure anything 'warm' would thrash it.

    Interested to see what route you go. Surprised the Ferreas only quoted to 11mm.. has anyone ascertained what the limitation is?

    Look nice cams though so you ought to really ;-)
     
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  14. Ron burgundy

    Ron burgundy Active Member

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    I miss my mk2 gti 16v small bumper ...don't know if you ever heard of them but mine was Gti RE1900 16v ? It come with the 2 tone leather and different suspension and bored out engine..
     
  15. warren_S5

    warren_S5 Moderator
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    I remember TSR doing an 1900 overbore as I had that block put into a Mk2 Jetta (which was my last Mk2). I think it's product name was 'The Donington'. There was then a 2000 and 2100 overbore but I never saw / head of many that went this route.

    The 1900 gave a touch more grunt, and the unit I purchased came out of a write off so it was lift in / lift out. In fact I'll have a dig in my files. I think I have a photo of me doing the engine transplant in my student digs back in '96!
     
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  16. Ron burgundy

    Ron burgundy Active Member

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    Ah nice

    Not heard of ' the donington' I'll look it up..

    From what I remember I'm sure the work was done at the silverstone track then given to its first owner but I think it still only had around 160bhp , maybe 170 bhp but it had a good bit of torque and was fun to drive..

    It was red and absolutely mint..
     
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  17. S3Alex

    S3Alex Rarely neutral
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    The Cosworths I owned both had a few sets of cams thrown in.

    The Sierra went from stock cams to BD16's which were along with all the other parts,a huge change.
    My old Escort arrived with a set of really knobbly so-called scatter cams and on those was a real B**tard to drive around town so we swapped them for BD14s and removed the GpN restrictor toe make it a lot easier to use.

    The problem with TFSi cams has been firstly the variable timing(which apparently isn't a big thing for comapnies like Cat) and also the trapezoidal fuel pump lobes that are required.

    Cat Cams have produced custom made cams for a friend of mine running a very high power TFSi engine,and also produce a number of cams from mild to wild for the sort of use I have in mind.
    What I don't want to be doing is tearing down the bottom end again for different pistons,and they do make cams that will accomadate my lower compression pistons.

    I'm still waiting to find out about the Ferrea valve compatibility with them.
     
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  18. S3Alex

    S3Alex Rarely neutral
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    My brain's properly on fire now.

    I've been chasing through Ferrea and Supertech's sites to find maximum lift values,then trying to run down any information relevant to the stock valve set,which may be the best way of getting this lot to work.

    Cat have been extremely helpful,along with Co-ordsport,but still need more figures......
     
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  19. Ron burgundy

    Ron burgundy Active Member

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    Ha I really wish I could get some patients back in to my system for modding cars properly like yours...

    The problem I have now is if the car isn't running right even if it's a minor thing, it literally keeps me awake at night...
     
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  20. S3Alex

    S3Alex Rarely neutral
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    LOL....and thanks!

    I've learnt to be a very patient man over the years!

    And that's not just the cars.....

    I do like it running just right but for the most part I leave that to AMD.
     
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  21. superkarl

    superkarl MAN OF STEEL

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    contact IE. Pete@IE posted on Vortex just the other day some info on lift and 1.8t vs tfsi heads. I know for a fact he mentioned the lift of stock heads and what you can take them too. With that sort of knowledge he would surely be able to answer your question.
    :icon_thumright:
     
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  23. KevZA

    KevZA New Member

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    Forbzeeee, Compkiler, minty86 and 2 others like this.
  24. S3Alex

    S3Alex Rarely neutral
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    Cheers Karl,much appreciated.

    Cassidy at I.E. got through to me yesterday,and recommended their spring and retainer set for the TFSi head,which is good for nearly 12mm lift,and I'm just waiting now on compatibility with the stock valves,as this may be the best way to go after all of this rooting around.
     
  25. S3Alex

    S3Alex Rarely neutral
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    So.....do I have this worked out now?

    1.Going back a bit,polishing/porting the head seemed to be a good idea,until the various opinions started drifting in,and some feedback from people in the know,and that got binned.

    2.Then doing the valves alone looked good,until I found that there are now a decent selection of uprated cams avilable at last for the TFSi,and I must thank my friends in Europe for that!

    3.Then the issue of how much lift a given set of valves/retainers and springs will support.

    4.Back to the drawing board for a while,until IE came up with their own valve springs and retainers,good for nrly 13mm lift.

    5.Now,waiting to find out whether the Ferrea valves,with IE springs etc are a runner,or Supertech.


    At least the cam cover is all sorted.
     
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  26. S3Alex

    S3Alex Rarely neutral
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    Car blog continues....

    I think I'm beginning to get the hang of all this valve lift malarkey,but I could be very wrong.

    Cassidy at IE in the States has been immensely helpful and patient,and I have nothing but praise for their operation.

    His advice is a set of their springs and retainers as before,and he also recommends my original choice of Ferrea valves,the difference being that IE's spring/retainer set will allow a lot more lift than Ferrea's will,and that's what makes the difference.

    I'm also slowly getting my head around maximum cam duration,duration at 1mm,maximum lift,and lift at TDC.

    Matt at Cat Cams is another very helpful and patient man,and I'd recommend both Cat and IE to anyone looking to do this to their TFSi.
     
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  27. S3Alex

    S3Alex Rarely neutral
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    Well Karl,

    Your advice,and Cassidy from IE's was on the nail.

    He took a look at my requirements,gave me a parts list,and checked mine,and also was of the opinion that the head doesn't need porting etc.

    That was in contrast to my software supplier whose reply was that it isn't worth it as the turbo will flow far more than the head will,although to be honest I don't recall them ever publishing flow results on a TFSi head,so I don't really know where that came from.
     
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  28. S3Alex

    S3Alex Rarely neutral
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    Plunge taken....


    Entire valvetrain plus oil seals and springs plus retainers.


    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]


    If it's anything like the last order I'd expect this lot in a couple of days.


    Now got to get the cams on order.
     
  29. thetrashcanman

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    Awesome build thread this mate, just love how you keep adding more and more to it :D
     
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  30. S3Alex

    S3Alex Rarely neutral
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    Thank you.

    Lots more to come I think!
     
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  31. thetrashcanman

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    Splendid, shall be following with keen interest mate :D
     
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  32. S3Alex

    S3Alex Rarely neutral
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    Have to get AMD to assemble the jigsaw now......parts ordered last night are already in transit.

    Also got instant checking and confirmation from Integrated Engineering last night....thats real customer focussed service.
     
  33. S3Alex

    S3Alex Rarely neutral
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    Final part on order.....the cams.

    Every time I do this sort of thing even though I've checked it about 20 times,I still worry about whether it's all going to fit together or end up very messily.

    It SHOULD be ok,and the cams should add around 30bhp or so,which would be a decent gain,plus we can turn the boost up a bit after this lot,and raise the rpm limit as well.
    All of that should add up to a bit more grunt.
     
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  34. S3Alex

    S3Alex Rarely neutral
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    I was having a bit of a think about the head porting issue today...maybe that's not such a good idea coming from me but anyway.....

    Revo were very dismissive of fitting the valves and cams,saying it won't make any difference,whereas,IE said that it doesn't need porting,and that got me thinking about all of the **** in the inlet from the breathers.

    Clearing all of that out made a huge difference,and I'd be willing to bet that much of the gains from porting,such as they may be,would be gone quite soon thanks to the carbon build-up,so I'll be happy to get that issue behind me with the new breather system,and then I can compare figures from before the valvetrain and cams,with some from after,and maybe lay the debate to rest.
     
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  35. warren_S5

    warren_S5 Moderator
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    Intriguing that there can be such a mx of views from within the industry. I know Revo (dealers) have done a fair bit of work on the various engines), so must have a view, but even if there was no extra power gains you have to assume it would be far more robust and should run freer. I'm fascinated to see where this all ends up, brave man!
     
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  36. S3Alex

    S3Alex Rarely neutral
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    The thing is that all I got in reply to my questions about mapping for the new cams was a sort of blanket "it's not worth it",without any supporting data.

    IE have put this engine and a number of other VAG engines on a Superflow dyno and airflow test bench and based their reply on that,so I at least have some answers there,but I'm still waiting on Revo's reply about mapping or support.
     
  37. Dan-Jnr

    Dan-Jnr Well-Known Member

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    Speak with Loba Motorsport don't they offer CNC port and polishing?
     
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  38. S3Alex

    S3Alex Rarely neutral
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    They do,and I have already spoken to them in the past.

    I can't really add anything to that,but it only added to the debate.
     
  39. S3Alex

    S3Alex Rarely neutral
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    Also just dug an old thread on VAGOC re Schrik cams for the S3.

    The cams I'm getting have greater lift and duration than Schrik's most "aggressive" profile,and they're rated as fairly mild by Cat....LOL
     
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  40. Ron burgundy

    Ron burgundy Active Member

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  41. S3Alex

    S3Alex Rarely neutral
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    That's a pretty decent spec,and not far from what mine was at the time.

    Someone could get an absolute hoot of a car.
     
  42. Ron burgundy

    Ron burgundy Active Member

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    Yeah looks decent.

    Would love a go of one on the gravel.

    Bet they drive superb .
     
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