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**TTRS** Project 750hp

Discussion in 'The Project Room' started by poverty, Jun 9, 2012.

  1. poverty
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    poverty Member

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    [Jun 9, 2012]
    Hi just thought Id share my project.

    The story start in autumn 2010.

    All my life I had wanted a UrQuattro or a turbocharged 5 cylinder audi, so when they announced the TTRS my prayers where answered.

    So I went ahead and traded in my stage 2 plus, 360hp, 2.0TFSI Cupra K1.

    [​IMG]

    Great car, practical, cheap to run, and looked the part for a young man! Loved the car, hated the dealer after support!

    I then picked up this beauty, Ibis white, delivery miles, so happy! Dream come true.

    First thing I did was to remove the license plate off the front. Looks much better!

    [​IMG]

    [​IMG]
    #1
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  3. poverty
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    poverty Member

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    [Jun 9, 2012]
    First mod obviously is a remap.

    I got this done by Revo, and it bumped the car up to 400hp on stage 1.

    I then added a full turbo back race exhaust from milltek.

    Stock

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    Milltek vs oem


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    Next I looked at the brakes. The OEM pads were very dusty and didnt last long at all.

    I bought some brembo blues for the car.

    [​IMG]


    In hindsight these werent a very good addition as the soon killed the admittely not very good stock rotors.

    Next I changed the panel filter.

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    I then looked at the intercooler. The stock intercooler is tiny so I fitted a forge motorsport unit. I got it fitted at Forge HQ, got a chance to meet the big boss Peter who is a really nice guy and really enthusiastic about his products which was nice to see.

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    #2
  4. poverty
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    poverty Member

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    [Jun 9, 2012]
    At this point I will introduce my buddies roadster. We mod our cars together, so he also got the forge intercooler fitted at HQ the same day.

    His spec then being identical to mine up at that point.

    [​IMG]


    Both of us not being happy with our brakes, we turned our attention to calipers.

    We both settled on a set of rs4/rs5/r8/gallardo 8 pot calipers.

    [​IMG]

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    We also bought some new braided brake lines, castrol SRF brake fluid and I bought mintex 1155 pads. A friend machined the "revo" plate for us so the pads would sit on the oem disc properly.

    [​IMG]

    [​IMG]

    Next up I attended a 30-130 and top speed event at a runway.

    This was my best result. 30-130 in 14 secs, and 170mph top speed. Basically the same results as stock GTR on the day. Not bad for a manual 400hp TTRS.

    [​IMG]

    [​IMG]


    After that it was show season, and the two TTRS attended a few! The TTRS also won a auto X, handling challenge type event at one of the shows, which surprised many as we thought the track would be more suited to a N.A super mini type car. As soon as the TT was on boost it was time to brake again, so a good and shock result.

    [​IMG]


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    #3
  5. poverty
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    poverty Member

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    [Jun 9, 2012]
    I then replaced the stock intercooler hoses for some uprated forge ones. Another great forge product!

    [​IMG]

    However we then came across a THS intercooler for free, and we were wondering what we could do with it. So, we decided to cram it behind the roadsters engine bay somehow!

    And so this is what we came up with. Removed the air conditioning rad, attempted to remove the A/C pump aswell, but thats required due to the way the belts run on the engine. For it to fit we also had to cut the crash bar.

    [​IMG]

    Then we painted the intercooler black for the stealth look.

    [​IMG]

    [​IMG]

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    End results via logging shows that temps are even cooler, and will peak at a certain temp and not increase anymore, but if you ask me whether its worth massacaring your TTRS for the small gain over the forge unit, I would say no. Therefore the coupe wont be going this route, and it did highlight actually how well the forge unit is actually designed, as the temps differences were minimal!
    #4
  6. poverty
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    poverty Member

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    [Jun 9, 2012]
    [​IMG]

    The roadster then got some new wheels, whilst the coupe got race plugs.

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    New vs old

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    [​IMG]

    Full polybush set for both cars

    [​IMG]
    #5
  7. poverty
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    poverty Member

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    [Jun 9, 2012]
    [​IMG]

    Then I decided to ditch the milltek in favour of a scorpion turbo back titanium exhaust.
    This exhaust is the most beautiful piece of engineering I have ever got to touch I must say. Work of art!

    And the weight saving is awesome too, i could lift the backbox with my two little fingers!

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    It turns blue after getting hot!

    [​IMG]
    #6
  8. poverty
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    poverty Member

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    [Jun 9, 2012]
    The roadster then got this prototype ITG intake! Made nice gains!

    [​IMG]

    And we decided the roadster needed a louder exhaust that the milltek race back box.

    So we fitted a single exit rear can! Now its really loud, sounds super!

    [​IMG]
    #7
  9. poverty
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    poverty Member

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    [Jun 9, 2012]
    At this point it was decided that we would move away from Revo software, and paid a visit to APR.

    They wrote a stage 2 map for the car, we were hoping for great things and we werent dissapointed. The power holding that the map provided vs the revo stage 2 map was just crazy. Its pulls and pulls all the way to the redline. The way the power doesnt drop off and it keeps on just pulling leaves you smiling from ear to ear.

    Now after the forge intercooler was installed, the car was dynoed at 420hp at stage 2 and between 380-400lbft of torque, I cant remember the exact figure.

    I decided I wanted to dyno this new map to see what the car was making now.

    [​IMG]



    The APR map gave me a nice gain, 430hp and 450lbft! The power curve is just beautiful aswell!

    So now we are at 430hp and just about reaching the limits of the stock turbo.

    We still need more power.

    To do this the car requires:

    Uprated clutch
    Uprated fuelling
    Bigger turbo
    Internals, because we are going over the 600/650hp threshold


    So all of the above is in the works now.

    Clutch spec has been decided on, it will be a twin plate, and the engine build will be starting very soon, so expect a massive update soon!
    #8
  10. slade777
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    slade777 Member

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    [Jun 9, 2012]
    I like this thread!! Great work!
    #9
  11. Bean5
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    Bean5 kidney bean

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    [Jun 9, 2012]
    nice work!!! would love to spend this sort of money on my a4!!!
    #10
  12. boost-addict
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    boost-addict Member

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    [Jun 9, 2012]
    nice, loverly car and shame the tt still retains that hair dresser look. but with that much power who cares. really like that scorpion system
    #11
  13. Cozza McA
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    Cozza McA Crunching The Gears VCDS Map User

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    [Jun 9, 2012]
    wow amazing write up.. look forward to the rest of this build
    at 170 no one would question your work motives:undwech:
    #12
  14. superkarl
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    superkarl MAN OF STEEL

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    [Jun 10, 2012]
    have you been in touch with storm developments?
    they built a 2.5t 5pot 8l s3, it was around 700hp, gt35 turbo i think.
    #13
  15. poverty
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    poverty Member

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    [Jun 10, 2012]
    Yeah I've spoke to them, their 2.5 5pot was from the states, a non Tfsi version with a turbo kit conversion so not quite the same engine.
    #14
  16. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 10, 2012]
    Crackin project so far mate, they do look & sound awesome these TTRS's. I also agree that Ti exhaust is a work of art, I would hate to guess what it cost you though. Out of interest how are you planning to squeeze 750 horses from your car? Which turbo, internals, fuel system etc are you planning on using? don't keep us in the dark dude :thumbsup:
    #15
  17. poverty
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    poverty Member

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    [Jun 10, 2012]
    The scorpion Ti exhaust is actually nowehere near as expensive as people think. When compared to price of a steel milltek system its actually a bargain.

    Well the engine is out and in bits at race developments, same guys who built the skoda bonneville engine. Pistons and rods are custom, and will be running valvetrain. Its a full on race engine build, I'll dilvuge the full spec once completed, in about a week or two.

    The car will be running a APR turbo kit, with probably a GTX35 turbo when finished. Fuelling will also be a APR solution.
    #16
  18. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 10, 2012]
    Awesome, can't wait to see this one unfold, looking forward to see the dyno plot once she's running.
    #17
  19. poverty
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    poverty Member

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    [Jun 11, 2012]
    And so the engine build has begun!

    This is how its started:

    [​IMG]

    [​IMG]



    And this is where we are at now:


    Stripped down head

    [​IMG]

    Port moulds and the ferrea valevtrain

    [​IMG]

    [​IMG]
    #18
  20. boost-addict
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    boost-addict Member

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    [Jun 11, 2012]
    whats the port moulds all about?
    #19
  21. k1ano
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    k1ano Member

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    [Jun 11, 2012]
    Excellent read :)
    #20
  22. poverty
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    poverty Member

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    [Jun 11, 2012]
    helps to aid the redesign of the cylinder head port and flow
    #21
  23. boost-addict
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    boost-addict Member

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    [Jun 11, 2012]
    thought it had something to do with flow, wasnt sure. like the idea tho
    #22
  24. Brodster
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    Brodster Shark Performance In Scotland Regional Rep Site Sponsor VCDS Map User

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    [Jun 12, 2012]
    This is going to be impressive when its finished. 750bhp......very nice!!!
    #23
  25. poverty
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    poverty Member

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    [Jun 26, 2012]
    ]Rings gapped, parts balanced, ready for assembly. High temp, low friction thermal coating.

    [​IMG]

    Old VS new

    [​IMG]
    #24
  26. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 27, 2012]
    [​IMG]

    Im surprised to see two bolt main caps in one of Audi's RS model engines! I have to say there new age RS, high price tag motors aren't what they use to be! In light of this are you planning on adding a girdle / crank ladder considering the grunt your shooting for? Out of interest do you know the thickness of the low friction coating on those pistons and what it is? Port shapes don't look to bad either :thumbsup: keep the pic's coming :o.k:
    #25
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  27. N8
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    N8 Kowalski Details VCDS Map User

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    [Jun 27, 2012]
    This is serious!
    #26
  28. poverty
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    poverty Member

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    [Jun 27, 2012]
    Pass on all of those question. Race developments are doing the build and I have left everything in their capable hands to spec. They have built two 700hp 2.0TFSI motors so im sure anything it would need they would have specced.

    Not bad looking for OEM shapes, shame we wont get to see port moulds once the heads been port and polished!
    #27
  29. osiris
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    osiris Member

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    [Jun 28, 2012]
    Impressive stuff :)
    #28
  30. jb0o
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    jb0o North East Forum Moderator Regional Rep Site Sponsor VCDS Map User

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    [Jun 28, 2012]
    Awesome!!
    #29
  31. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jun 28, 2012]
    Don't get me wrong fella, I certainly don't doubt Race Developments credentials, I was just surprised to see the big ends laid out in that fashion and wonder weather they / you planned to do anything about it. Regards the port moulds, it wasn't so much the port shapes that caught my eye but it appears the included valve angle looks quite nice :icon_thumright:
    #30
  32. poverty
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    poverty Member

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    [Jun 28, 2012]
    Ahhh ok. Those valves have been deleted now!
    #31
  33. poverty
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    poverty Member

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    [Jul 1, 2012]
    Progress shot on the cylinder head

    [​IMG]
    #32
  34. JtotheD
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    JtotheD Events Moderator

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    [Jul 1, 2012]
    this build looks the dogs fella, bet you can't wait to get it back from Race Developments!
    #33
  35. poverty
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    poverty Member

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    [Jul 18, 2012]
    #34
  36. boost-addict
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    boost-addict Member

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    [Jul 18, 2012]
    gah my go ped is quicker lol

    how far are you in to it now?
    #35
  37. IN 2 Deep
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    IN 2 Deep Hoonigan

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    [Jul 19, 2012]
    Can I see deck cooling channels milled in there?

    Come on, lets see some progress pics from your car, not arsed about APR's development car ;)
    #36
  38. boost-addict
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    boost-addict Member

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    [Jul 19, 2012]
    Don't get me wrong power is good and lots of it makes you smile but do you not feel 430hp isn't enough for a stock turbo that's doing well?
    #37
  39. bowen
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    bowen Member

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    [Jul 19, 2012]
    credit for doing this to such a new and beautiful car!
    #38
  40. poverty
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    poverty Member

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    [Jul 20, 2012]
    Powerwise its never enough. If it ever gets to the point where it scares me when I drive it, then yeah, but with 430hp, whilst the car is really quick, the chassis can easily handle some more power.


    No updates as such, but the fuelling side of things has now been sorted courtesy of APR.

    HPFP and Injectors ready to go!

    [​IMG]
    #39
    Kelza likes this.
  41. boost-addict
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    boost-addict Member

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    [Jul 20, 2012]
    Oh yer decently.. What mpg do you expect with 750? 0 lol
    #40

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