2.0T FSI Forged Engine Build Has Started, Big Turbo Build.
- Thread starter Craig Cull
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Looking good.
Nortech have done a superb job for me on the exhaust manifold and fittings,including turbo inlet piping,and you fortunately have a bit more space in some areas.
The turbo on mine is a very tight fit indeed.
Your intake manifold has a familiar look to it!
Nortech have done a superb job for me on the exhaust manifold and fittings,including turbo inlet piping,and you fortunately have a bit more space in some areas.
The turbo on mine is a very tight fit indeed.
Your intake manifold has a familiar look to it!
I couldn't get in at Nortech unfortunately but this andy seems to be doing a good job so far. I could have left it next to the chassis leg but I just couldn't risk it, plus I want that turbo to smash you in the face when you open the bonnet
F tech inlet manifold I believe mate, had abit more welding done on it when the head went for port and polish.
Over to peron on Monday for the fmic and we're ready for mapping.
I actually can't wait now, still loads left to do with very little time to do it, but it's looking good. If it comes back today then I've got tonight, Saturday and Sunday to finish everything off. Then a steady drive over Sunday afternoon/Monday morning. Then I pick it up next Friday or Saturday, need to do another 250 miles on the second run in and I think we should be ready to drop it off with rick.
Cheers chaps!
Yeah I wanted to use Nortech but he couldn't get me in until next month, which is just a tad too late for me.
The manifold is F tech, but we've added some more welds in the places that are tiny bit thin after porting to the inlet.
But I'm really looking forward to firing it up this weekend. Aslong as its back today I've got a fighting chance of getting it up and running for Sunday. Then over to Birmingham Monday. Fingers crossed
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Got it....they've helped me out immensely with the exhaust manifold on mine.
I thought I recognnised the intake manifold as it looks a bit like mine,which is a Boulekos,but you've found another,which is also useful for everyone else,to have a few sources to choose from.
Good luck getting yours running....mine is in bits and waiting for a new ECU!
Totally agree, it's great to have a few options.
I'm currently working on a range of more cost affective tuning products for the B7 as there's just nothing around. Especially for power freaks like me lol.
I think if parts were more readily available then we would have seen more big turbo B7's floating around, like in the states.
Next shout is to get a B8 - B8.5 in to see what we can do with one of them.
What's happened to your ecu?
I've just sold an ecu for an S3
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Hi Craig,
I agree.....the more options and manufacturers around,the better.
The problem I have is that the current ECU and software really have reached their limits.
I was looking around anyway,and it was Nortech who put me onto the newest option around,from Syvecs.
This ECU looks amazing,and Storm Developments have been working on it,so I think I'm the guinea pig!.....spec list below.
Fuelling Control
Ignition Control
Boost Control – Open Loop or Closed Loop
Gear Shift Set-up – Auto or Manual
Gear Cut – Open Loop or Closed loop
Gear Blip – Open loop or Closed loop
Throttle Jacker Control
Throttle Bypass Value control
Limp Switch Setup
Anti Lag System
Nitrous Control – Wet or Dry Control
Traction Control – Based on Lateral G or Steering angle
Flex Fuel
Basic Knock Control – ****** only
Full Knock Control – Advance and ******, Fully adjustable
Starting
Idle Control – Closed or Open Loop
Idle stepper control
Limiters
Launch Control – Open Loop or Closed loop
Drive by wire
Variable Valve timing – Closed or Open Loop
GDI Control
Supercharger Bypass Valve control
Differential Control
Cruise Control
Torque Estimation and Limiation – DCT Control
Output Functions
Fuel Consumption monitoring
Engine Use Restriction
Output Testing
Adjustable Pin Assignments
Datastreams – Configurable Custom CAN or Custom RS232
Map Switching – Live and up to 24 options
Onboard Datalogging
GPS Receiver Support
RJ45 Ethernet Connection
Could I control a separate set of injectors alongside everything else with it?
I may have to look into this next year.
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The answer is up to 8 injectors.
It will run 4 TFSi injectors and 4 port injectors
That may not be necessary as there are a few high flow injectors around now and the Syvecs may support higher fuel pressures as well.
Let's see how we get on with mine and I'll feed it all back to you.
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Excellent mate, sounds great.
I'm reluctant to run higher fuel pressure due to the excess pressure on the camshaft etc. I wanting to run a higher rpm range with lower fuel pressure and add the port injection further up the Rev range.
But it's all talk at the moment.
Looks like we're going to miss out on the Intercooler fitment due to me not getting the car back until tomorrow afternoon which is a paint, but we've done well to meet every other deadline. Looks like we're keeping the old Intercooler for now, then re booking after mapping. Not ideal but I can always drop it back to rick for a tweak if the cooler proves a hinderance.
But I'm very happy with this -
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Mmmmm nice and shiny!
I think the Syvecs can run up to 200bar,so that would significantly increase flow through the RS4 injectors,but the current plan is just to get the car running and see what we can get from it as is.
I think the Syvecs can run up to 200bar,so that would significantly increase flow through the RS4 injectors,but the current plan is just to get the car running and see what we can get from it as is.
200bar!!!! That's a lot of load on the cam, definitely need the roller conversion on the Hpfp. But I like what im hearing! Looking forward to the feedback
Where abouts are you based Alex? Maybe we could meet up when the builds finished? Would like to see your car and go for Abit of turbo talk. It's not always easy on here, especially when your busy etc. Using Nortech I'm guessing your not too far away?
That is a nice looking exhaust manifold Craig, how much did it cost you if you don't mind me asking? (PM if you don't want to say on here lol!)
Thanks mate, I got a good deal tbh, I'll pm you the price as I intend on a offering a full package for the B7 owners very soon. Which could open aloy of doors for the big turbo builds of the future. Naturally a forum members discount always applies
SDHA4SLine
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Hate to be a bit boring but that manifold is a great looking piece of engineering, pipe bending and welding guys obviously very talented 
Shame you can't get stuff like this for dirty diesels as I would have one on mine just to look at it
Shame you can't get stuff like this for dirty diesels as I would have one on mine just to look at it
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Hate to be a bit boring but that manifold is a great looking piece of engineering, pipe bending and welding guys obviously very talented
Shame you can't get stuff like this for dirty diesels as I would have one on mine just to look at it
I'll bet you can if you ask Nortech,or the guys who did Craig's exhaust.
You can have anything mate. The one thing I have learned through this build is anything is possible. Speak to Andy @ Zorstech in Shipley and tell him I put you in touch. He will give you discount.Hate to be a bit boring but that manifold is a great looking piece of engineering, pipe bending and welding guys obviously very talented
Shame you can't get stuff like this for dirty diesels as I would have one on mine just to look at it
This is the finished product from Andy. It's a squeeze in every way and yes we're going to have to modify the headlight but it's all in the name of POWER!! 
SDHA4SLine
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This is the finished product from Andy. It's a squeeze in every way and yes we're going to have to modify the headlight but it's all in the name of POWER!!
Sad old me again, I'm just admiring how clean and shiny things look in that engine bay. I'm just a little weird like that
Can't wait to find out how things turn out.
That's what it's all about mate. It was the envy of ollys DTM that brought this side out in me. Now I've made a business out of it.Sad old me again, I'm just admiring how clean and shiny things look in that engine bay. I'm just a little weird like that
Can't wait to find out how things turn out.
All for people like your self. The A4 from the the B7 onwards has nothing in the way of bolt on mods performance wise. Unless you go to APR and spend a years wage in one blast.
Hope you enjoy the build
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This is the finished product from Andy. It's a squeeze in every way and yes we're going to have to modify the headlight but it's all in the name of POWER!!
That really has come together well.
Having the extra room to the side of the engine with a longitudinal engine does give you a lot more flexibility to both fabricate the manifold,and then to hang a big turbo on it.
With the S3,things are so tight around the back of the engine bay,that it takes a magician to make it all fit.
Anyhow...who needs headlights....!
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Haha yes traveling at the speed of lights does render headlights useless
Craig and I have had a similar joke running about the possibilities of loud bangs in the next few weeks.....it will either be mine exceeding the sound barrier,or the pistons doing it on their own.....
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Around 500bhp at 2bar on the old turbo.....Storm think that on the new ECU it should be a lot more.
Forged internals,WMI,Ferrea valves etc etc.
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Not me.
That pump has been in my car from Stg2+ until now so it's managed to somehow get through over 50 000 miles.
It's not the pump but how it's put together.
glad someone talks sense, all i ever hear is people slating them for what i can see no real reason, maybe just apr now loba snobbery. i've ran mine hard for a fair few miles and different camshafts no issues as yet
no issues as yet
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glad someone talks sense, all i ever hear is people slating them for what i can see no real reason, maybe just apr now loba snobbery. i've ran mine hard for a fair few miles and different camshafts
Same.
I think the problem comes when they're made up on the kitchen floor.
I never had an issue with mine either, apart from running out of fuel, but that was a combination of my lpfp and what looked like the early signs of camshaft wear, due to the non revised camshaft.glad someone talks sense, all i ever hear is people slating them for what i can see no real reason, maybe just apr now loba snobbery. i've ran mine hard for a fair few miles and different camshafts
Other than that seemed like it did the job. Anything will seize if it's not installed properly
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