Stacey's Belated Yo Yo Build Thread

Interesting about the intank and swirl pot issue....

I have plans for a swirl pot at some point but was going to put the filter between the intank and the swirl pot.... I wonder if that would be enough...

There is also the TFSI filters that have FPR's built in... don't know if that would be a solution at all...

Wonder if this is just related to a third party pump rather than a std OE intank... a DW65V seems a little over kill for a lift pump tbh... IIRC Bill once calculated he would have 45 ish secs of fuel on full chat in his Ibiza using a 2ltr swirl pot and an S3 intank pump...

<tuffty/>
 
<tuffty/> said:
Interesting about the intank and swirl pot issue....

I have plans for a swirl pot at some point but was going to put the filter between the intank and the swirl pot.... I wonder if that would be enough...

There is also the TFSI filters that have FPR's built in... don't know if that would be a solution at all...

Wonder if this is just related to a third party pump rather than a std OE intank... a DW65V seems a little over kill for a lift pump tbh... IIRC Bill once calculated he would have 45 ish secs of fuel on full chat in his Ibiza using a 2ltr swirl pot and an S3 intank pump...

<tuffty/>
Click to expand...

Interesting one on the tfsi filter, that would work, on the DW loop it's currently got OEM lines to filter, OEM filter, -6an to cooler, cooler to surge tank and then back to main tank via -6an and OEM line. Whilst should flow well it would have liked to have thought would provide enough resistance, doesn't pick up though unless clamped :(

TBH this pump was chosen for its compatibilities with other fuels like ethanol etc, I had started to wonder also wether OEM would flow enough for the turbo and injectors? Think will have to change the whole system tbh if do go e85 and 8 injectors to see full potential with this turbo
 
badger5 said:
3.3ltr/min no load from std S3 pump (with the extra outlet blanked off) at 13.4volts
Click to expand...

May well just switch back to OEM to keep me going for now, shame old ones seized solid and need new basket now lol

Stock pump shouldn't have issues picking up from other side?
 
StaceyS3 said:
Interesting one on the tfsi filter, that would work, on the DW loop it's currently got OEM lines to filter, OEM filter, -6an to cooler, cooler to surge tank and then back to main tank via -6an and OEM line. Whilst should flow well it would have liked to have thought would provide enough resistance, doesn't pick up though unless clamped :(

TBH this pump was chosen for its compatibilities with other fuels like ethanol etc, I had started to wonder also wether OEM would flow enough for the turbo and injectors? Think will have to change the whole system tbh if do go e85 and 8 injectors to see full potential with this turbo
Click to expand...

tbh mate if using that kinda fuel you almost want to go fuel cell... seals etc will be the issue with those fuels... OE stuff is designed for normal fuels realistically...

I planned to run -8 from the inline to an IE rail when I do mine... intank using -6 to the swirl pot through a filter and OE return....

Thats the plan at least anyway...

<tuffty/>
 
How have you piped up the swirl pot? where does the return from the rail go?

<tuffty/>
 
<tuffty/> said:
tbh mate if using that kinda fuel you almost want to go fuel cell... seals etc will be the issue with those fuels... OE stuff is designed for normal fuels realistically...

I planned to run -8 from the inline to an IE rail when I do mine... intank using -6 to the swirl pot through a filter and OE return....

Thats the plan at least anyway...

<tuffty/>
Click to expand...

TBH that's my long term plan, in drawing and research stages at the moment as well as so many other plans/dreams. May well raise up the priority list quicker now though lol

Currently on mine the two loops as such run like following

Intank pump, OEM lines to filter location, OEM filter, -6an there on to cooler, top of surge tank, top of surge tank back to main tank with -6an and OEM line.

Rail feed is, 2x 044's with IE manifold, -8an to front of car, filter on fuel rail, rail and 2200cc injectors, -6an to FPR, -6an back to top of surge tank.

Few emails going back and forth between me and DW, hopefully find a solution or just drop a fresh OEM one in with new basket.
 
So return from rail goes to the surge tank? do you have a return off the surge tank back to the actual tank?

<tuffty/>
 
<tuffty/> said:
So return from rail goes to the surge tank? do you have a return off the surge tank back to the actual tank?

<tuffty/>
Click to expand...

Yeah rail back to one of the three ports on the top of the surge tank, and one of them ports is also the return to main tank, with the last of the 3 ports on the top being feed from the main tank.
Fuel should only return to main tank once it's pretty much full.
 
fill to surge tank at bottom, return to tank at top? (so it can vent air) - yea?
main pump sucks off bottom, returns where?
 
do a check of just in tank pump recirculating through siwrl pot tank... See if that works ok.
then do same test on 044's and see if that also keeps going...
checks both circuits work ok.
 
badger5 said:
fill to surge tank at bottom, return to tank at top? (so it can vent air) - yea?
main pump sucks off bottom, returns where?
Click to expand...

I'm using the IE dual surge tank, all 3 of the ports are near the top in a line, should get 90% of the air out of there but suppose it can't run completely empty using whole capacity as pump inlets won't be right at the bottom.

badger5 said:
do a check of just in tank pump recirculating through siwrl pot tank... See if that works ok.
then do same test on 044's and see if that also keeps going...
checks both circuits work ok.
Click to expand...

I've done tonnes of circulating with the main in tank loop, was testing to try and get it to pick up from the other saddle but not done anything much on the fuel rail supply side. Pumps are a bit noisy and wondering if leaving them on the shelf all winter has done some damage and they've got a bit tight?
The OEM intank i removed and put on the shelf siezed solid and won't turn at all.
 
badger5 said:
water in your system?
Click to expand...

Shouldn't be, would it take a lot to cause issues and effect fuel pressure much being a liquid?

This vid can see an ever so slight flicker on the fuel gauge at the end which caused a misfire, this was the DW intank not keeping up and must have been a pocket of air.



This was the intank flow with the unseated o rings



Flow with intank working correctly



This was with a working in tank but don't think surge pumps were keeping up as at this point we had no misfires like with the air just had pressure dropping

 
Can't speak for the IE surge tank thingies... this shouldn't be an issue on a separate swirl pot setup... the 044's pull fuel from a third of the way up the tank IIRC... just wonder if its a tad on the small side for the volume of fuel....

<tuffty/>
 
possibly.. Mines a different setup being a seperate 2ltr rectangular tank, out of which there are 2 lower feeds which feed my 2 x 044's via hose connections. Much bigger volume in mine.
Whether this is the issue tho.. quote how much fuel is being consumed? 2200cc/inj at what duty cycles?
 
<tuffty/> said:
Can't speak for the IE surge tank thingies... this shouldn't be an issue on a separate swirl pot setup... the 044's pull fuel from a third of the way up the tank IIRC... just wonder if its a tad on the small side for the volume of fuel....

<tuffty/>
Click to expand...

I got to admit it is possibly a bit on the small side to which a traditional surge tank would give more in the bag, or even mounting the tank with all the outlets/inlets at the top. Strange thing is it all worked faultlessly for the first couple of weeks and AFR's were in check, even when i accidentally saw 3.5bar boost :D

I do suspect that the tank wasn't emptying on the later issue where pressure wasn't dropping as symptoms before always had a misfire or sputtered where as this wasn't it was just dropping pressure.

badger5 said:
possibly.. Mines a different setup being a seperate 2ltr rectangular tank, out of which there are 2 lower feeds which feed my 2 x 044's via hose connections. Much bigger volume in mine.
Whether this is the issue tho.. quote how much fuel is being consumed? 2200cc/inj at what duty cycles?
Click to expand...

We were seeing 50/60s on the dyno but had more than 1000rpm to go and don't think was pushing the turbo to near its potential yet, generally max boost was 1.5bar and mainly lower.

Just checked my logs from santa pod and was seeing mid 30's IDC at 8000 but this was only at 0.65 bar boost and 12.4afr at that point
 
audi upgrades
Been getting the car ready for a big weekend ahead at bugjam!

First off swapped out my early proto subframe with heavily altered geo mounts for a newer revised one as is to much for a 4wd car with prop clearance. Would perfectly suit a fwd based car though



New



Old ( nice and light at 7kg iirc)


Took the car for some finalised alignment, big thanks to the guys at Tyre-Smart in witham, if your local give these guys a go, Martin on the alignmnet side really knows his stuff!



Got to eventually see these in the flesh as completed sets and am well chuffed with the results. :)







The car because of the help of a close friend has had its first "proper" clean in 6 or so years! Am so chuffed with he has done, although he wasn't still happy with it at all and wants more time. We had a total of 4 hours on it and i was schooled and learnt so much on the way. I'm now proud to say the paint doesn't feel like sand paper any more!! The clay bar turned a rusty orange colour which can only assume is from the metal fillings embeded in the paint form the years of fabrication.

Before pics





After







I was well chuffed but the OCD and perfectionist ion Gary said it need double the amount of time it had

Last but not least during some road mapping i done some testing! This was at 1.6-1.7bar and was short shifting 1000-1500 rpm, at Santa Pod and with more mapping time it will be >2.5bar and lots more revs which is where the car really feels like it comes alive. Launch will also be raised and mor aggressive but was trying my best not to break it days before the event.



If your at BugJam this weekend don't hesitate to come over and say hello or maybe even for a beer depending on time of day ;)
 
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