Time for a build thread....big turbo

A4_DTM · Mar 12, 2015

S3Alex said:
This probably shows things a bit better.

Coming in to the right of this pic is the cam breather,and to the other side is the crank breather.

bearing I couldn't tell you,but they are uprated bearings and shells.

Tnx, that helped me a lot!

S3Alex · Mar 12, 2015

I think as a system it works very well,and it really is beautifully turned out parts you get from IE,but it fills up pretty quickly,and the stuff is nasty.

When you consider that all of it would go through the intake and into the engine otherwise,it makes it worthwhile.

I think mayonnaise isn't the right word.....

Mario8P · Mar 12, 2015

More of a expired mayonnaise

Every time you post a pic that has to do with the valve cover and catch can, I get itchy to start buying it bit by bit!

Waiting for IE as they might have a solution for cars fitted with the carbon canister!

sheridan94 · Mar 12, 2015

Alex

I'm pretty much new to your thread and haven't found time to have a look through it all yet!
one thing for certain is that this build is epic and the attention to detail is second to none :applaus:

I'd love to see some footage of this when its on the road

S3Alex · Mar 12, 2015

Mario8P said:
More of a expired mayonnaise

Every time you post a pic that has to do with the valve cover and catch can, I get itchy to start buying it bit by bit!

Waiting for IE as they might have a solution for cars fitted with the carbon canister!

On mine,AMD relocated the carbon canister to the left front bumper area,so it's there,you just can't see it.

S3Alex · Mar 12, 2015

sheridan94 said:
Alex

I'm pretty much new to your thread and haven't found time to have a look through it all yet!
one thing for certain is that this build is epic and the attention to detail is second to none

I'd love to see some footage of this when its on the road

Thank you!

Good luck for making it through the entire thread before you get bored,or the S3 has become a vintage car in the meantime,as it is a bit lengthy.

I've had a lot of help,good advice,and the input of many friends doing similar things to their cars,as well as the good fortune to find some really good hands-on people such as Steve at AMDTuning,Alan and James at Nortech,and Andy at Storm.

Without those people,this project would be nowhere.

S3Alex · Mar 16, 2015

Waiting for updates on the brain....

In the meantime it's going to have an infusion of Motul 300V 5W-40 race oil....one I've not tried before.

Mario8P · Mar 16, 2015

S3Alex said:
Waiting for updates on the brain....

In the meantime it's going to have an infusion of Motul 300V 5W-40 race oil....one I've not tried before.

I've ran it in my previous car. Its a sick oil! But costy, and need to be drained on short intervals. This oil doesn't like to sit doing nothing in oil pans

S3Alex · Mar 16, 2015

Mario8P said:
I've ran it in my previous car. Its a sick oil! But costy, and need to be drained on short intervals. This oil doesn't like to sit doing nothing in oil pans

Cheers Mario.....I don't mind the cost or the change intervals,as it spends much of it's time in bit anyway,but if it works,and it does provide a few extra BHP as claimed,I can't complain.

Mario8P · Mar 16, 2015

S3Alex said:
Cheers Mario.....I don't mind the cost or the change intervals,as it spends much of it's time in bit anyway,but if it works,and it does provide a few extra BHP as claimed,I can't complain.

To be honest Alex I did feel a difference in power. Not sure if my butt dyno was out of wack

Oil temps are much better than any other oil i tried too.

S3Alex · Mar 16, 2015

Mario8P said:
To be honest Alex I did feel a difference in power. Not sure if my butt dyno was out of wack

Oil temps are much better than any other oil i tried too.

Sounds useful all round.

I do remember trying a well known race oil a few yrs back on one of the Cosworths......it was a very low viscosity oil,and made the engine sound like a bag of nails,so it went.

S3Alex · Mar 19, 2015

Quick update but no piccies or results.

It's alive.....

Brain is fitted and working,extra injectors have been plugged into the brain in case we need them,oil changed,plugs on the way,and it actually runs and drives.

The real setup work hasn't begun so this was like a test run,before the timing,fuelling,boost and so on are set up,and the car can be put on the dyno.

Once that's under way,Storm can decide how the Syvecs is set to manage the car,and if we either need the extra injectors,or simply ramp up the HP rail pressure to achieve the bhp figures.

After that,it's where the boost comes in,and whether or not the car needs some degree of ALS running to keep the turbo spooled between gear changes or not.

crazylegscrane · Mar 20, 2015

Good news Alex bet you can't wait to drive it again :drool:

Compkiler · Mar 20, 2015

I think its still gona take a fair bit of time and fine tuning to get her the way you want her.
Also i would be dubious about putting my foot down and breaking something lol.

Im still a bit nervous now when flooring my car at stage 2+. Duno why as the maps have been proven and tested but i just think one day my engines gona go bang or something lol?

S3Alex · Mar 20, 2015

Compkiler said:
I think its still gona take a fair bit of time and fine tuning to get her the way you want her.
Also i would be dubious about putting my foot down and breaking something lol.

Im still a bit nervous now when flooring my car at stage 2+. Duno why as the maps have been proven and tested but i just think one day my engines gona go bang or something lol?

There's certainly time to do a lot with the ECU.

The initial plan is to get it running and go for the potential of the current injectors as that's well within what the turbo is capable of.

After that there are more aggressive strategies like ALS,gear cut and blip and flat shifting to be considered plus the extra injectors.

The real killer is torque and all of the internals have been specced for what's intended but of course you never know what will happen until you try but their approach and mine is incremental.

S3Alex · Mar 23, 2015

Cold running now fixed.

Previously Run flap delete resulted in poor cold running with misfiring under load so that's been sorted.

Can't wait to get it on the RR.

Also getting a Toucan. Lol

leshkin · Mar 23, 2015

Are you saying that it may be ready in time for the RR day then? Looking forward to seeing in the flesh!

S3Alex · Mar 23, 2015

leshkin said:
Are you saying that it may be ready in time for the RR day then? Looking forward to seeing in the flesh!

Me too!

I do hope so but there's a lot of work to be done before then.
Storm's main man has been unwell so he hasn't been able to get it going as much as he'd hoped but this week may change that.

S3Alex · Mar 23, 2015

How about this....

Mario8P · Mar 23, 2015

And another pornography content by you Mr Alex!

S3Alex · Mar 23, 2015

Mario8P said:
And another pornography content by you Mr Alex!

Why have one can when you can have Toucan ....

Mario8P · Mar 23, 2015

S3Alex said:
Why have one can when you can have Toucan ....

Hahahahah lovely quote

S3Alex · Mar 25, 2015

CAN-BUS software now complete so everything in the car talks to the ECU.

That sounded like a really complicated part of the job to me and there should be more soon.

Toucan flying in soon.

Alex_Wil · Mar 25, 2015

Just in time for the RR day at amd

S3Alex · Mar 25, 2015

Alex_Wil said:
Just in time for the RR day at amd

Fingers crossed.

There's a LOT of work still to be done,but Andy at Storm is hopeful that it will be completed next week.

The car needs to be set up on the RR,and functions such as traction control,diff control,+/- things like ALS and the various shifting options such as flat shift and gear blip etc need to be worked on.

It was running as early as last week,but really only for a systems check,and to make sure it would actually run before the real work begins.

The Toucan was included as it allows touchscreen control of most of the engine settings on the fly,and allows you to enable/disable things like TC and ALS if you aren't actively using them.
TC on this can run via steering angle or lateral G.

S3Alex · Mar 25, 2015

More smut....awful,awful naughtiness.....

Dean_T · Mar 26, 2015

Storm developments... I know that name - didnt they do a supercharger for the VR6 back in the mid 90s?

And back on topic... looks like things are coming along nicely alex :thumbs up:

S3Alex · Mar 26, 2015

Dean_T said:
Storm developments... I know that name - didnt they do a supercharger for the VR6 back in the mid 90s?

And back on topic... looks like things are coming along nicely alex

Might have done,and I know they've done a lot of other VAG projects,and I've seen a few of their cars at shows and so on.

What impressed me was that Nortech had recommended them to me,and mentioned that they were doing the development work with Syvecs for this ECU on VAG TFSi engines.

When I spoke to Andy at Storm,his knowledge and enthusiasm really came through,plus his attitude to tuning which was close to mine,i.e. get it working first,and then increase power and add options,not just to chuck everything on and cross your fingers.

So far,he's taken things carefully and had already got the car running,but needed the time to log everything and get all of the sensors talking to the ECU.

He'd also taken the time to hook the additional injectors into the ECU,which wasn't in the original plan,but showed a lot of foresight for what we might do later.

S3Alex · Mar 27, 2015

Just had a nice chat with Andy.

True to form,the car is fighting back.....

At idle,the lambda is full rich,as it would be at full throttle,and the figures from the stock ECU were even worse.

I know the car has always been pretty smoky since the RS4 injectors were put in,so this looks to be the cause,and the Syvecs can only pull it back to 0.83,when it should be 1.0 at idle.

So......thankfully the extra injectors are wired in,and the cure is to go back to S3 injectors,and use the other rail above 400bhp,to get the fuelling and lambda correct.

Strike 1 again to the car.....

S3Alex · Mar 31, 2015

So....the list goes on,and the worksheet gets bigger,but I kind of expected that.

The plan for this week is:

1. Remove and replace the RS4 injectors with S3's(and I can't find my old S3 injectors so that's another for the parts list).

2.Trace and sort a small water leak.

3.Deal with the cold start fuelling(as that has to be calibrated again for the smaller injectors)

4.Install the Toucan and diagnostic port.

5.The good bit.....power runs planned for next week.

Price wise about what I expected....Eeek.

S3Alex · Apr 6, 2015

Hopefully,all being well,tomorrow is RR day.

Seems like an age since I've driven the car,and I'm getting pretty used to the DS3's economy to be honest.

That said,I can't wait to see what the car feels like when it does come home......it's had quite a life so far,from being the first recent car I said I wouldn't modify,the Revo Stg1 through to Stg4,a pile of parts,4 turbos,2 complete suspension upgrades,a new ECU and now back to Stg 0 in a sense....

Fingers and toes crossed.

Compkiler · Apr 6, 2015

Good luck then bud!

S3Alex · Apr 6, 2015

Compkiler said:
Good luck then bud!

If it does explode,at the sort of power they expect then everyone should be able to pick up a piece outside their front door.

Everyone who's been to an AMD RR day knows how I hate hearing the car on a dyno so I should be grateful it's a fair distance away.

S3Alex · Apr 7, 2015

On the dyno as we speak.

No results yet but Andy from Storm and Ryan from Syvecs both hard at work mapping the engine and transmission.

Compkiler · Apr 7, 2015

Awesome any news yet? Is it still in one peace?

S3Alex · Apr 7, 2015

Compkiler said:
Awesome any news yet? Is it still in one peace?

Pending pics etc later.

It's been mapped and wound back to around 550bhp and 540lbs.

It made over 600bhp which was certainly what I'd hoped for but runs better with less boost.

S3_Mat · Apr 7, 2015

What was the limiting factor to stop you achieving 600hp Alex? I take it you have all 8 injectors running?

S3Alex · Apr 7, 2015

S3_Mat said:
What was the limiting factor to stop you achieving 600hp Alex? I take it you have all 8 injectors running?

It was running over 600bhp on the dyno but Andy at Storm felt in terms of driveability there was little to gain by running 2.3bar as opposed to a more relaxed 2 bar and not having to wring it out to peak rpm to get the bar room rights.

Compkiler · Apr 7, 2015

Main thing is that it's running and safe! You've gained 50bhp more which is a lot but was it worth the money in the end do you think? Or is there even more fine tuning to get her running to that 600bhp mark safely and consistently?

S3Alex · Apr 7, 2015

Compkiler said:
Main thing is that it's running and safe! You've gained 50bhp more which is a lot but was it worth the money in the end do you think? Or is there even more fine tuning to get her running to that 600bhp mark safely and consistently?

Andy's view was that this being the first TFSi to run the Syvecs ECU in combination with a turbo this size,the best thing was to set it up to be able to run more,but to then run it conservatively.

That means there is the potential for a lot more(and it's worth pointing out that whilst the turbo will flow enough for 750bhp,that doesn't mean it's either good or safe to actually do that).

It's also been set up to run TC via the Syvecs,which runs much quicker and less intrusively than VAG's form of TC,but works better with the engine as it is.....he said they'd managed to get the TC coming in on 3rd gear on a dry road,also taking into account the way the ECU manages the Haldex.

The really big gains are:

OK...."only" 60bhp more,but no more hesitation,as with the old turbo and Revo software.

100 ft/lbs more torque,and no huge drop off towards peak rpm.

Fully integrated TC and diff control.

6 stage ALS.....Andy's description of the lag to me actually sounded awful at first,but once he'd described the turbo coming in at 4000rpm,I realised it's actually no worse than the outgoing 3076,but the ALS will reduce that.
Point is,it runs from 4000 rpm right out to the revised rpm limit of 7500rpm without tailing off.

Time for a build thread....big turbo

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