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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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  2. S3Alex
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    S3Alex Rarely neutral

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    [Aug 16, 2014]
    A little bit of black hole shock....

    A few months ago,the inlet looked like this.....

    [​IMG]


    Then it got cleaned and looked like this......

    [​IMG]


    Well....back to normal.....


    [​IMG]


    And thats after only 5 months,with a catch can etc.

    Clearly not as bad as the last time round,but still impressive.
  3. Doogie...
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    Doogie... Active Member

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    [Aug 17, 2014]
    Doesn't take long to coke back up eh. I thought it was a steady/long process to coke the engine. I had mine cleaned around 4 months ago so mine should be in a similar state to yours. And i'm without a catch can. Nightmare
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  4. S3Alex
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    S3Alex Rarely neutral

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    [Aug 17, 2014]
    I think it probably reaches a point where air flow means it doesn't get much worse but along the way you do lose a good bit of performance.

    I'm hoping the breather system I've found will get this cured.
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  5. S3Alex
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    S3Alex Rarely neutral

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    [Aug 18, 2014]
    :scared2:Progressing well.

    Head's off,and being stripped down,with only the bolt for the hydraulic tensioner giving some serious resistance,so that's holding things up a bit.

    New ARP bolts on the way,and obviously cam belt and chain being changed as well.


    Something along these lines....

    [​IMG]


    Then the fun can begin for Steve to put the valves in and make it all work.
    Last edited: Aug 18, 2014
  6. s3_trev
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    s3_trev 3 door or no door!

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    [Aug 18, 2014]
    Wow....is that catch can doing the slightest bit of good do you think?
  7. S3Alex
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    S3Alex Rarely neutral

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    [Aug 18, 2014]
    The current one......not much I think.

    The VTA system from Integrated Engineering should be a whole different ball game.
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  8. S3Alex
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    S3Alex Rarely neutral

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    [Aug 19, 2014]
    Steve has managed to sort that hydraulic tensioner bolt.......head off,and in bits now.

    Good news is that the head,pistons,and stock valves are all in good condition,and no signs of any problems there,even after 500+bhp and 66 000 miles on the engine in total,with 30 000 since since the bottom end rebuild.

    Apologies for the phone pic quality,but there are some better ones to follow from AMD.

    [​IMG]


    [​IMG]

    Also seems that various companies (and I think APR included) have looked at porting the S3 head,and all came away thinking it to be of little benefit,although Integrated Engineering WILL do it,if you ask,but even they advised me that it wasn't needed or likely to help.
    veeeight and sliced like this.
  9. S3Alex
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    S3Alex Rarely neutral

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    [Aug 22, 2014]
    So nearly ready but a few connectors I missed from the breather kit.

    Cams in and timed.
    Nearly ready to run.
  10. S3_Mat
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    S3_Mat Active Member

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    [Aug 22, 2014]
    You getting a dyno run in Alex this time?
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  11. perazzi
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    perazzi Member

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    [Aug 22, 2014]
    I'm pretty sure I'm not the only quiet one who enjoys your build threads, and sage advice...

    P
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  12. S3Alex
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    S3Alex Rarely neutral

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    [Aug 22, 2014]
    Hopefully.

    It needs the timing and fuelling plus boost settings sorting out with the new cams so it may just need a little run.

    The timing is going to be pushed a bit with the WMI and the maximum boost setting raised to 2.2bar.
  13. S3Alex
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    S3Alex Rarely neutral

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    [Aug 23, 2014]
    The missing bits of the breather are circled in red......ignore the PCV plate,which isn't relevant.


    [​IMG]
  14. S3Alex
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    S3Alex Rarely neutral

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    [Aug 23, 2014]
    I'm surprised AMD have me back each time....


    This.....


    [​IMG]


    Wants to go here....

    [​IMG]


    But it's current occupant is the EVAP can.

    More work for Steve.
  15. S3Alex
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    S3Alex Rarely neutral

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  16. Dean_T
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    Dean_T Active Member

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    [Aug 23, 2014]
    AMD certainly have their work cut out with you fella :audibash:
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  17. S.
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    S. Well-Known Member

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    [Aug 23, 2014]
    and the shiny cover :D
  18. S3Alex
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    S3Alex Rarely neutral

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    [Aug 23, 2014]
    I think they had enough trouble a couple of weeks ago with an APR turbo build that didnt quite fit,but nothing on mine has ever been easy!

    The ATP turbo kit wasn't exactly RHD as billed,and needed a lot of work.
    The ITG CAI didn't easily fit the turbo downpipe.
    The Boulekos manifold needed a little trip to the grinder.
    And so on.....:keule:

    I have to hand it to Steve at AMD who never seems phased by all the little(or large )problems,and between the guys there,it just gets fixed every time.

    If it was my place,I'd probably shut the doors every time the thing appears!
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  19. S3Alex
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    S3Alex Rarely neutral

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    [Aug 23, 2014]
    That should look nice....and do a useful job if we're right.

    If not,it'll just look good....LOL
  20. Dean_T
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    Dean_T Active Member

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    [Aug 23, 2014]
    To be fair though, a good workshop would welcome the challenge and they certainly have stepped up to the plate :)

    Many, many times :jump::icon thumright:
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  21. S3Alex
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    S3Alex Rarely neutral

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    [Aug 23, 2014]


    I don't think they've shied away from anything that's actually practical.

    And they know there's more after this......somewhere along the way,this thing needs it's extra injector rail hooking up....

    [​IMG]
  22. Sevv
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    Sevv Pushing the limits..

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    [Aug 24, 2014]
    looking Good Alex, as usual amazing progress.. cant wait to see dyno figures you really need them extra injectors as the car has more potential beyond that 550hp @ the crank mark... i think the porsche 911 injectors are a viable way forward for people without your manifold...
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  23. S3Alex
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    S3Alex Rarely neutral

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    [Aug 24, 2014]
    Hi Sevv,

    As always,it's being done incrementally....get the cams and cam cover plus breather done and running first,then back later for the extra injectors.

    We want to see how far we can get on the RS4 injectors before hooking up the extra rail.
  24. Sevv
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    Sevv Pushing the limits..

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    [Aug 24, 2014]
    would be wise im being told 550 is the most ill make with them injectors so ill be sourcing different injectors down the track.. tuning will always be an issue to be honest.., 8 injectors sounds complicated and you'll have more parts means more things prone to break... id hate to see the tuning side of things will be a challenge for sure....
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  25. s3_sid
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    s3_sid Active Member

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    [Aug 24, 2014]
    Tuning should not be to bad , has anyone thought of using the latest mk7 r ecu config if the current one cannt handle port injection as I know they come port and direct injection standard could be a oem way to get round it all
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  26. S3Alex
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    S3Alex Rarely neutral

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    [Aug 24, 2014]
    I think trying to fit a later model ECU is asking for trouble probably but thanks for the heads up on that.

    What we will do is to use a standalone ECU mapped for boost,rpm,and temp as used by a friend of mine on his 700+bhp Golf.

    That solution works and is relatively easy to implement without rewriting software and of course the Revo software would be incompatible.
  27. S3Alex
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    S3Alex Rarely neutral

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    [Aug 24, 2014]
    That seems to be what some say.

    Mine seems fine fuel wise at 500bhp and as we turn the boost up to 2.2bar or beyond AMD will be able to look at the AFR and there should be a bit to gain from the timing and cams.
  28. jackj
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    jackj Member

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    [Aug 24, 2014]
    Really good read this mate - car's looking awesome
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  29. S3Alex
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    S3Alex Rarely neutral

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    [Aug 24, 2014]
    Thanks very much!

    It's turning into a bit of a marathon read but everything that's been done,gone right or turned into a battle is all there.

    If it encourages anyone or saves a few wrong turns along the way for someone then it's worthwhile and it's been a blast for me.
  30. jackj
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    jackj Member

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    [Aug 24, 2014]
    It made for a good read with my cuppa this morning mate so keep it up!
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  31. S3Alex
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    S3Alex Rarely neutral

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    [Aug 24, 2014]
    Lol

    Maybe a whole coffee pot.

    Plenty more to follow after this round.

    Also hoping to get a working diffuser and splitter if that project holds together.
  32. S3Alex
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    S3Alex Rarely neutral

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    [Aug 24, 2014]
    This is looking like the most probable candidate for the injector ECU.

    [​IMG]

    Comes with it's own software,allows mapping for load(TPS and MAP),rpm,temp,and battery voltage,plus it will only cut in when required,so it won't interfere,with the software already running,whereas any other solution requires a complete new software install,and neither Revo,nor APR would help(and indeed APR would only support their own hardware,i.e. the GTX2867,and I'm way beyond that).
  33. P40ULW
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    P40ULW Deep VAG lover :) Regional Rep

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    [Aug 25, 2014]
    Great build thread here sir! :)
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  34. S3Alex
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    S3Alex Rarely neutral

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    [Aug 25, 2014]
    A whole smorgasbord of ways to empty your wallet.
  35. S3Alex
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    S3Alex Rarely neutral

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  36. S3Alex
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    S3Alex Rarely neutral

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    [Aug 28, 2014]
    It's alive once more.

    Waiting now for the timing and software setup,and reprogramming the boost controller.
  37. Mesa
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    Mesa Member

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    [Aug 28, 2014]
    Seriously, seriously impressed and inspired by this thread. Tons of massive info, should be pinned for anyone looking to get big power out their 8P.

    I've not even read it properly yet but I'll be reading this start to end as it's so useful if you're looking at getting more than 360ish.

    Top work.
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  38. S3Alex
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    S3Alex Rarely neutral

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    [Aug 28, 2014]
    Thank you....lots more to come,I hope!

    It's due to guys here,and over on the sadly soon to close VAGOC,that I've been able to do this,plus the endless patience and technical abilities of AMDTuning.

    I wanted to try and put back something into the forum,and maybe help a few of us put their money into the right places as we go.

    The car is running again now after the latest pile of bits,and I'm waiting to see how it runs.
  39. Mesa
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    Mesa Member

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    [Aug 28, 2014]
    Gotta love these communities.

    I've been guilty of using audi-sport as a reference for info without putting anything back. On of the reasons for starting my own thread. And whilst I won't get to the same levels as you it all adds to the richness of info for people to chew on and digest.

    Good stuff....subbed.
  40. S3Alex
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    S3Alex Rarely neutral

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    [Aug 28, 2014]

    That's what I said to someone a few yrs ago......LOL

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