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TQS progress thread, From STD-Scroll-Eliminator.

Broken Byzan Nov 14, 2009

  1. Bradderz_1988

    Bradderz_1988 Dont replace it, Upgrade it !!

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    Hope the turbo survived this, what you planning on doing now then VR6 Turbo :p

    Vulture mode engaged :- if you decide to bin the block and go for a 06A block give us first dibs on the crank and IM shaft :)
     
  2. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    It's possible she'll be broken atm. Cost is a huge problem.
     
  3. Bradderz_1988

    Bradderz_1988 Dont replace it, Upgrade it !!

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    Well in that case i want dibs on the ME7 setup aswell if the price is right lol just make sure its after my hols in august ha

    Be a shame to break it with all the hard invested cash and time youve put in and with the hicups along the way but if its the sensible option its got to be done. Im seriously thinking of changing my daily to a small/cheap runaround as mines showing its age and needs some well needed tlc lol
     
  4. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    Just keep it simple and you'll have it back on the road for not much money at all.

    You dont need a fancy stroked out built engine to make power, welly and paul have proven that with serious figures on stock motors.

    AEB's are cheap, you know this as you've bought them before, just buy a motor and get it installed.


    Sell the crank and IM shaft to someone wanting a stroker build and you've paid for a stock motor.

    Sell those fancy cams which can fund any remaining bits, and if the turbo has survived you'll have an engine making more or less the same power as before for very little.


    If you start down the path of trying to build another "fancy" engine or converting to 06b, it WILL become a money pit and it'll end up unaffordable.
     
  5. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Brad
    How much is crank and shaft worth to you? It's the forged abf
     
  6. Bradderz_1988

    Bradderz_1988 Dont replace it, Upgrade it !!

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    Well the cranks normally go for less than £100 when ive been watching them on ebay ive seen one go for £50 !! for both i think my top end would be £150 posted but its down to you on price mate and im not in the position to buy it yet as got the mother in laws wedding this month and holiday next month.

    PM me if you want with a price you have in mind.
     
  7. Sulli79

    Sulli79 Active Member

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    Ah man gutted for you. Hope she is back up and running in some form soonish!
     
  8. INA

    INA http://www.inaengineering.com

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    Not really Doh...infact , not even a merit in this discussion.
    This is user GolfRS on vwvortex which if anyone took a few minutes to read his thread , there is no reasoning.
    Cliff notes:
    - Connecting rods are supplied and installed
    - 35,000 km's (THIRTY-FIVE THOUSAND) after Dimitris sorts out his tune for his 287369 revision , he develops a "rod knock".
    - He emails us on a saturday requesting assistance.
    - After consulting with numerous people looking @ his logs , it is clear that he was running lean which will hammer the wrist pins out of any connecting rod.
    - He is told the soonest we could have a set of rods sent to him would be the following Thursday (4 business days later) and no cost to him as Greg (owner of DM) did not want to be associated with bad press so early in his business.
    - We (him and I) get into an argument where I tell him , even if we send him a replacement sent , he needs to sort his tune out.
    - He chooses to not listen and subsequently purchase a set of connecting rods from a competitor.

    All the power to him but that video does not paint the full picture.
    We can take this up offline Mark.
    Issam
     
  9. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    Why would running lean damage wrist pins?

    Stock tune on ME7 cars typically runs the engine at or very close to stoich until EGT enrichment kicks in does it not?
     
  10. INA

    INA http://www.inaengineering.com

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    This was not on ME7 , it was on ME9.
    Common knowledge
    Tappered wrist pins + high power request + lean condition = failure.
    Mark has straight wrist pins so chalk vs cheese comparison.
     
  11. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    I dont know much about ME9, but i'd imagine it uses the same lean running strategys that ME7 does for emissions reasons?

    Just wondering what it is about lean running that causes the failures? Is it something specific to DI engines perhaps? I could see how pre-ignition or det could cause it, maybe running lean on a DI engine has similar results?
     
  12. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Seems I have done a little bit of work on the motor.After dome assistance from my young helper at removing the old unit. Never too young to start..lol uploadfromtaptalk1405887511816.jpg
     

    Attached Files:

    <tuffty/> and slepy like this.
  13. PaulJC84

    PaulJC84 Owner

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    Did you ever get this rebuilt? What are the plans now, standard engine with rods and the TFSI turbo?
     
  14. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Got lots done. She's running and run in now . I have pictures and stuff I've just been lazy
     
    <tuffty/> likes this.
  15. PaulJC84

    PaulJC84 Owner

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    Cool, did you build another stroker engine?
     
  16. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Yeah stroker on je pistons at 83mm.[​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG]
     
    ScottD3 likes this.
  17. Bradderz_1988

    Bradderz_1988 Dont replace it, Upgrade it !!

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    Are those rifle drilled DM rods ??
     
  18. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Yup and rebushed to remove the play and the stupid oil groove
     
  19. Bradderz_1988

    Bradderz_1988 Dont replace it, Upgrade it !!

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    Cool, are all DM rods rifle drilled ??

    And if i bought a set would they need re-bushing or have they sorted the issue now ?? If not how much it cost for rebushing and oil groove removal ??
     
  20. olethalb

    olethalb Active Member

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    just read all of this, what a journey. just bought a b5 1.8tqs myself and looking into more power. i'm now scared haha
     
  21. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    After the DM rod small end failure causing contact I somehow leaft an 1/8th of a valve in the intake system requiring a new piston on the already full JE rebuild.

    Also 3 x TFSI 064's have been on and off, hopefully the last one it'll ever have is sat on my desk now
     
  22. olethalb

    olethalb Active Member

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    ahh balls, whats been up with 064's?
     
  23. olethalb

    olethalb Active Member

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    how did it tune with the JE pistons, did you calculate compression ratio or go with what was on the box?
     
  24. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Je pistons are fine. I haven't measured the cr tbh no worse knock detection than std bore/stroke cr. I am tempted to rebuild to a tighter clearence to lose the cold je rattle. Makes my car sound on deaths door when first started. Lol.

    I have been testing various setups and combinations for the manufacturer and have been unlucky. Hoping this new one is the one
     
  25. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Mine were 9.2 but are now closer 8.5 as I had to have the damage removed to match the pistons to one another on my valve section episode on the dyno. It deffo dumbs down the drive on a daily car to reduce cr but it made no noticeable odds to allowed timing in the tune as it was reserved anyway.
     
  26. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    its something that has always put me off aftermarket pistons....

    Doesnt anyone make OEM type pistons from the factory grade alloy that doesnt have this huge expansion rate etc?
     
  27. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    Seems after some research that 4032 pistons are what you want!
     
  28. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    I had those in my woosners but they are not readily available. I knew it's be a bit noisier but I feel perhaps they machinist that did mine has set mine up on the loose side. Gops car and tufftys are fine for instance
     
  29. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Around 2000 miles after that build, we thought, she's run in, lets stuff her on the dyno. First run, she dropped a cylinder.
    This somehow stayed around, after intake and IC being washed etc
    [​IMG]
    Causing this
    [​IMG]

    [​IMG]
    [​IMG]

    [​IMG]

    [​IMG]

    2000 mile old turbo and piston shot to bits

    I acquired a used piston from JP that was 8.5-1 instead of 9.5-1 as these were, but thought, it would be a good time to machine a bit off to match the new piston CR and also remove the marks from them.

    This ran for a year like this, only consuming 2 experimental turbos due to heat shield issues

    She was a bit rattly in the mornings, maybe it was the oversize done by the engine company as they changed hands and the work wasn't found to be as good by the new owner, or my honing to remove as many marks i felt was safe/
    I thought i'd acquire another block and start again before it casued any harm

    Another rebuild, this time it was to rid myself of the over bored (45thou) block before i exploded it again to find i was lucky it survived this long.
    OUT you come
    [​IMG]

    That got hot, has the injector failed or the machining left it too thin??

    [​IMG]

    Im sure the gaps were better than this when they went in.
    [​IMG]

    So now she has another set of 8.5-1 JE pistons "donated" by Bill in there with new rings and the bores machined to 30thou over the size of each piston to ensure the bores match the pistons

    [​IMG]

    A replacement turbo with a proper heat shield in place
    [​IMG]

    Ported to match the gaskets, the adapter and the ports

    Also a tweak to the output side of the comp cover
    [​IMG]

    Some added gayness to keep my chav hand in.

    [​IMG]


    I chose to put the supertech inlet valves back in too, so bought the 3 missing ones destroyed last time, to find i had 2 bent exhaust valves too, so have also replaced those. I assume the bend was heat over FOD as there was no witness marks at all. Oddly the car still ran on 4 and pulled fine. just proves you have no idea whats occuring till you look.
    Hoping to find time to get her in and running this week, time will tell

    [​IMG]
     
    <tuffty/> likes this.
  30. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    None of these builds would have been possible if it wer not for @badger5 and @<tuffty/> or the mrs
     
    <tuffty/> likes this.
  31. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    Welcome great mate

    <tuffty/>
     
  32. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    Looking good, fingers crossed this time it stays in one piece! You need some luck with this build!
     
    Broken Byzan likes this.
  33. docurley

    docurley Moderator Staff Member Moderator

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    You are not having much luck with this, hope you get it sorted.
     
    Broken Byzan likes this.
  34. slepy

    slepy Extremely smart and handsome person. VCDS Map User

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    Reading this makes me think I should not even think about touching my engine myself.


    Sent from my iPhone using Tapatalk
     
  35. gmx

    gmx Member

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    What modifications needed to the K04-064 turbo itself? 'tweak on the compressor side'
    Do you have pics of your discharge pipe?
    Do these use metic banjo bolts for coolant/oil?
     
  36. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    I had to shave the bottom mounting lug off and reduce a dp mounting lug length. I'll look for pics on my dB and update. Currently she's dead after I smashed the sump out of her.

    Sent from my SM-G935F using Tapatalk
     
  37. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Std m14 for water. The a4 oil line pretty much works too

    Sent from my SM-G935F using Tapatalk
     
  38. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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  39. EvilSnow

    EvilSnow Active Member

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    What downpipe you gonna use aswell?

    Sent from my SM-G920F using Tapatalk
     
  40. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    mine is a custom 3 inch turbo back to miltek single 3 inch system
     

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