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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. S3Alex
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    S3Alex Rarely neutral

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    The next thing has to be a sort of parts and suppliers list....

    First and foremost,somewhere to get the work done....AMD Tuning

    undefined

    Turbo kit....ATP Turbo

    GT3071R Turbo kit for FWD 2.0T FSI, MKV VW Golf/GTI/Jetta and Audi A3 (500HP) : atpturbo.com

    Auxiliary fuel pump(over 440bhp)...USP Motorsports.

    http://uspmotorsports.com

    Intercooler....ProAlloy.

    Pro Alloy Motorsport - Specialist alloy components - Audi S3 (2.0TFSI) front mount intercooler kit

    Water injection...I chose AEM.

    AEM Water/Methanol Injection Kits - Water-Meth Injection Systems for Turbo/Super - Wideband O2 UEGO, Water/Methanol, Stand Alone Engine Management, Piggyback F/IC, Tru Boost Controller, Gauges, Automotive Performance Electronics

    Bought from Advanced Motorsport and Engineering

    http://www.advancedme.co.uk/

    Engine mounts and brakes....Volkswagen Racing.

    Volkswagen Racing

    Induction system....ITG.

    ITG Air Filters - performance air filters for road and race vehicles | Maxogen Airflow Systems

    BSH steel throttle body pipe plumbed for WMI.

    BSH FSI Integrated Throttle Pipe - BSH Speedshop

    Exhaust...Milltek.

    Milltek Sport Performance Exhausts and Sports Cats

    Spec clutch....Stg3+ monster.

    www.specclutch.com

    All other parts and bits sourced via AMD Tuning

    That includes:

    Uprated Haldex controller.

    kW v3 suspension.

    H&R anti roll bars.

    Gizzmo boost controller

    RS4 injectors and fuel pressure regulator.
    And no doubt a pile of other bits I've forgotten.
    Last edited: Apr 19, 2012
    #81
    pinterovski likes this.
  2. quattro81
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    quattro81 All the gear.. No idea

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    Alex.. you don't even need a pen15 with a spec liked that, dude!:rockwoot:
    #82
  3. S.
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    S. Active Member

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    lovely build alex, and ofcourse thanks for the parts list :D
    #83
  4. S3Alex
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    S3Alex Rarely neutral

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    Who said I had one....!
    #84
  5. quattro81
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    quattro81 All the gear.. No idea

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    :lmfao: I spose you could be female? my cousin's called alex.. have i just made a big chauvinist feck-up? are you really a gorgeous babe with a 500bhp+ s3??? If so, marriage proposal on its way!
    #85
  6. S3Alex
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    S3Alex Rarely neutral

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    No....just meant no willy....LOL
    #86
  7. S3Alex
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    S3Alex Rarely neutral

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    A pleasure,and thank you....I went through a lot of looking around to do this,and also got a lot of help along the way,so it's good to put some back.
    #87
  8. S3Alex
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    S3Alex Rarely neutral

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    Anyway....with that being most of the work until now,there's still a few things to go.

    The dyno runs didn't work terribly well,with some problem on the RR causing the ECU to cut load at over 480bhp,which it doesn't do on the real road.

    There are basically 2 types of RR,one uses inertia built up and calculates BHP and torque from that,and the other type uses eddy current braking to provide load,and that's what we need to try.

    Basically what we got proves the car has rather more than 480bhp,but not how much more.

    That's item No1....

    The other things I can't let out right now,but they will be fun,and hopefully in time for the Inters.
    #88
  9. quattro81
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    quattro81 All the gear.. No idea

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    All joking aside, I think this is a wicked build, mate.. Full credit to you for doing your research and taking the time to go about things the right way round.. The result is starting to look like a very faaaast competent beast of an s3. Though it sounds like there's a little more to come yet.....:icon_thumright:
    #89
  10. S3Alex
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    S3Alex Rarely neutral

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    Thanks again!

    It's around 330-350bhp/tonne right now,which isn't bad for a shopping trolley,and will certainly give Carreras and so on a nasty surprise.

    The other parts will be interesting,but I can't go into them right now other than to say it's going to be worthwhile.

    I have some mates over on the other forum who have been immensely helpful and generous,and the quality of AMD Tuning's work has been outstanding.

    I need the car to be reliable,and as I've said before,if you can find a tuner that can build and run a proper race car and team,then you have a good chance of getting that.

    The BTCC is one of the most competitive forms of tin-top racing out there,with the top 10 qualifying cars separated by well under 1s,and getting results there is immensely difficult even for the big teams......to score points there,AMD are doing well.
    Last edited: Apr 19, 2012
    #90
  11. S3Alex
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    S3Alex Rarely neutral

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    Another thing......how often do other members have the tracking and geometry on their cars checked?
    Mine is checked every 6 months or so,when I swap the tyres over,and it's always out,sometimes comically so,and I'll post the latest set up later when i get a chance,but it really does make a difference,and it's always out of spec.
    #91
  12. S3Alex
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    S3Alex Rarely neutral

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    Now,as promised,here's why it's always a good idea to get the geometry checked every 6 months...

    Before.....

    [​IMG]

    Fighting itself back and front,but basically trying to turn left.

    And after....

    [​IMG]

    All nice and straight again,plus more rear camber,and noticeably better handling.
    #92
  13. NHN
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    NHN Modmetractor Site Sponsor

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    I have to say Alex, I like you & your whole approach to a build thread, absolute pleaure to keep an eye on this thread mate, watching every step, not seen this iirc ever on ASN, keep it up fella :)
    #93
  14. S3Alex
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    S3Alex Rarely neutral

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  15. quattro81
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    quattro81 All the gear.. No idea

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    Full 4 wheel alignment makes soo much difference! Did you need ajustable tie-bars at the back? I did on my TT with coils as couldnt get the camber right without'em iirc... and adjustable rear toe bushes!?:think: It's a while ago, and a mk1tt chassis though!
    #95
  16. S3Alex
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    S3Alex Rarely neutral

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    Thanks again.....It makes a huge difference,and I have it done twice a year usually,but I do have a few plans for the suspension...
    #96
  17. Farhan
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    Farhan Active Member

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    Excellent build alex, How comes the alignment always falls out though? I fully understand the importance of getting alignment done often but is it more a case of alot of torque steer or vibrations through the chassis from power that kicks the alignment out over time?
    #97
  18. NHN
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    NHN Modmetractor Site Sponsor

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    Thats because there will be a tolerance in design to allow adjustment to correct the alignment that manufacturing cant be perfect on, so that relies on a bolt/nut which unless it has a locator lug for a fixed position, will allow movement when pressure of a said amount is applied to the joint, hence potholes & kerbs can cause linkages to get knocked out of alignment.
    #98
  19. S3Alex
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    S3Alex Rarely neutral

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    It's exactly as NHN says....

    The suspension members are tightened up with bolts and the alignment will get knocked out by potholes etc in daily use.

    It's a pain but worth checking regularly to make sure the car isn't trying to steer itself!
    #99
  20. S3Alex
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    S3Alex Rarely neutral

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    Car driving really well right now(rain aside).
    Also begun pricing up some options on the turbo side,as the GT3071 is pretty much at it's limits,and a GTX3076 would fit the bill quite nicely.
    I'd need that,plus a bigger TIAL wastegate,and also the metal bearing cage,as the stock item has a plastic retainer for the ball bearings,and is prone to getting cooked.
  21. S3Alex
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    S3Alex Rarely neutral

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    Slight issue last week with one of the pre-intercooler boost hoses blowing off at 2+bar....LOL.
    All sorted within a couple of days thanks to AMDTuning,and having an adustable boost controller on board made setting it for virtually zero boost(to protect the turbo from overspeed)a piece of cake.
    Back to it's usual rude health now,and awaiting the next series of bits......more later.
  22. z1mma
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    z1mma Member

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    oh wow, no way am i gunna be able to achieve a stage 3+ :drag: too much stuff to change, plus with a baby coming along dont think ill be able to afford it!
  23. S3Alex
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    S3Alex Rarely neutral

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    Hi there.....I've replied to your thread on VAGOC.....it is a shame as you've said,but I don't think this is a baby-friendly thing to do!
    My advice would be to uprate the suspension and brakes and then you'll get more out of the car as it is,without having to spend a huge amount more.
    Last edited: Jun 14, 2012
  24. MartayMcFly
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    MartayMcFly Active Member Regional Rep

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    Does that mean you'll be selling the V3s?
  25. Adamantium
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    Adamantium Member

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    Very impressive build!

    Reminds me of my subaru/evo days, especially ATP turbos, although we used to have a problem with the manifolds they supplied on the evo cracking.

    All in the past now. That kind of power must feel amazing in the S3. Want a race?
  26. S3Alex
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    S3Alex Rarely neutral

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    Thank you!

    The ATP manifold seems absolutely fine on mine although I have heard the same problem that you had.

    It's around 340-350 bhp/tonne currently so it is pretty brisk but we do have a few things in the pipeline right now which may improve on that a bit.

    Off boost it drives like the stock model but the power on boost is quite something and I think both Revo and AMDTuning have done amazing things to get that sort of grunt but retain the drivability.

    My Escort wasn't as fast in a straight line and never had the civilised nature of this car even if the suspension was in another league( and that includes price as it needed revalving at least yearly).
  27. S3Alex
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    S3Alex Rarely neutral

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    Not sure right now....it's possible, I need to look into both kW(Clubsport) and possibly AST,but with the other things we're looking at right now,I have neither the time nor inclination to start going on something else as well,so it's on the back burner.
  28. DJ_Troopa
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    DJ_Troopa K1 Driver

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    Just read through this build thread and i like... alot! :)

    I'm defo getting an 8P S3 in a few years after my current TDI. I had an 8L S3 before and i miss that 270bhp and quattro fun sometimes! Good luck mate, looks great so far.
  29. S3Alex
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    S3Alex Rarely neutral

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    Thanks as well!
    Should be a few nice little extras on the way soon from AMDTuning.
    Last edited: Jun 15, 2012
  30. leach76
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    Nice build thread Alex,its interesting to read whats needed when trying to push a few boundries,are you planning on taking it to the inters still if all is well ?
  31. PaulAr
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    PaulAr S3 (8P)

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    Would love to see this on the strip at Inters but Alex is having none of it....:(
  32. leach76
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    Is he shy ? is he backwards coming forwards?
  33. PaulAr
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    PaulAr S3 (8P)

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    Clutch caution
  34. S3Alex
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    S3Alex Rarely neutral

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    Not at all....it's going to the Inters,but I won't be doing any standing start drag runs.

    The reason is very simple.....rebuilding the gearbox isn't something I want to do again....it was rebuilt when the car was having the engine rebuild,as 5th gear had been pretty noisy.

    Turned out the selector forks were worn,plus a few bearings,and the transfer case was pretty shabby as well.
    Now the box had been noisy from new,which I'd assumed was OK coming from a really noisy car before,but in retrospect,there may have been a problem from new which we missed.

    Anyway...I'm happy to do 30-130 runs,but not drag starts.
  35. S3Alex
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    S3Alex Rarely neutral

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    LOL...more like transmission caution.....the clutch will take nearly 600lbs.

    I'm just not sure the transmission will take full power standing starts too often.
    Unitronic likes this.
  36. PaulAr
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    PaulAr S3 (8P)

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    Might give mine a shot on the strip, see what launch control is all about:racer:

    Some of the quicker cars I saw last time where DSG so it should be a laugh to see what this glass roof S3 wagon can do!
  37. S3Alex
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    S3Alex Rarely neutral

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    Should be good fun.

    I think for me the thing is that it's easy to trash a gearbox or driveshafts with that sort of thing,and it's not indicative of real on-road performance anyway.
  38. leach76
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    I wanted to go this year but selfish mate is having a stag night,was supposed to be going down with Statller because helped them on Steves porsche and that should be amazing if all goes well and then there might be a few tricks up the sleeve of his golf (again if all goes well).
    Kelza likes this.
  39. S3Alex
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    S3Alex Rarely neutral

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    Enjoy the stag night!

    It looks like some heavy showers are forecast for Saturday,so it might put a dampener on things.
  40. S3Alex
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    S3Alex Rarely neutral

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    Apart from the awful accident which resulted in 3 casualties,the Inters was a good event and well worth the journey.
    I met up with both Revo/Stasis and Milltek,and apart from a good chat with each,came away with good news for software developments,and also some encouraging news on the hardware fronts.

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