Audi S3 - Stroker Big Turbo build.

interesting. I have the normal fixed vband type on my turbo outlet and the gasket they supply just falls apart every time clamped up. Does'nt leak as the 'O' ring element of it seems to seal but the moulded flat portions of it just squeaze out and get extruded out.. effectively cutting them off.
 
badger5 said:
interesting. I have the normal fixed vband type on my turbo outlet and the gasket they supply just falls apart every time clamped up. Does'nt leak as the 'O' ring element of it seems to seal but the moulded flat portions of it just squeaze out and get extruded out.. effectively cutting them off.
Click to expand...

I noticed the same thing with my vband clamp. Every time I opened the clamp, the o-ring was destroyed. I don't think the o-ring can take the heat from the turbo. I was thinking about trying a different type of o-ring.
 
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Turbo oil drain and wastegate discharge vband left to do.

123
 
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Picked up the head yesterday and started lapping in the new valves.

3 angle valve seats


Back cut valves


the petrolheads jigsaw puzzle
 
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aaaaand BumbleBiatch is rolling again with the new wheels and tyres. Not the most exciting picture but its proof it left the garage :)



Had some boost issues. Wastegate pressure went from 13psi on the old setup to 23psi on the new setup. After a night drive out to the mountains the wastegate pressure settled on 17psi. After a week the steep slippery road to big turbo arrived.......



The second blanking nipple decided it no longer wanted to be friends with the wastegate, it left and took the threads with it, resulting in uncontrollable boost :(
I decided the wastegate need to be re-engineered and got the damaged port welded up. Also changed out the wastegate springs to a lower setup while the wastegate was out and apart.
Its all back together now and wastegate pressure is 15psi.

Overall the work on the head and the larger 4.0" / 3.5" exhaust DP/midpipe has made a huge difference in off boost driving. The car feels way more responsive and spool happens a fair bit sooner. Guess that's what an exhaust system that doesn't restrict exhaust gasses will do :)
 
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How bumble beast sits on the coilovers and Team Dynamics

S3 123
 
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FYI - DON'T launch your S3 with semi slicks on. I tried this, it didn't end well.

The car shot forward for a few meters then BANG and lots of front wheel spinning.

20151130 191717


20151128 182620


Sheared off the 3 bolts that secure the propshaft to the transfer box.
I thought this was going to be a nightmare to get the broken bolts out as I used loctite when I put them in.
But it was a quick job, used the drill and a 3mm drill bit. Once the bit had bitten into the bolt, the bolt threaded out on the transfer box side of the output flange. Happy days :)
Picked up new bolts and coupler from Audi today, should be back on the road for Thursdays morning club drive and maybe a little autocross event on Friday.
There will be NO more launch attempts while on semi slicks. These things are sticky!!!
 
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Good work D-Dog.... launching is a killer regardless but I guess its safer to have these 'weak' points in so that more expensive/awkward items don't let go...

The joys of high power in peoples car platform huh :)

<tuffty/>
 
I have never launched it using LC, always launched it the old fashion way so it wasn't making boost at launch.
This time I launched it at about 10psi.
I need everything to be made from unobtainium :)
 
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I've done that six times now. Snapped four drive shafts, wisted two and done a few cv joints.

Looked into carbon shafts and props but the costs are high.
 
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Andrew@A.L.D said:
I've done that six times now. Snapped four drive shafts, wisted two and done a few cv joints.

Looked into carbon shafts and props but the costs are high.
Click to expand...

Once is enough for me :)

There's a guy in SA that is making drive shafts, he has them in his S3 and says he runs 11.4 on the 1/4 mile.
Shaft
 
Since my drama with the dodgy internal braided flexi joint, I have always been suspicious that there was some part of the braid stuck in one of the mufflers.
So my inner boy went and bought one stupid *** fart can and I built another rear section of the exhaust system.
This new setup will not be the daily setup but more for track days and club drives.

I present to you the Apexi N1 fart canon - 4.5" tip :blink:

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This was the work in progress shot

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All welded up

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Naturally the exhaust is the loudest thing on the planet but it sounds awesome at 8k rpm through the mountains.
It also has added bonus of small flames

Flame on


I have been told that NLS flames are longer - someday I will need to gopro this as proof

Some petrolhead music -


And lastly I would like to say a massive THANK YOU to Bill @badger5 for helping be with the tune on my car.
Its probably been the longest running tuning session in the history of the world, but my S3 is finally at the target HP level that I set out to achieve.

We did a club dyno day today and Bumblebitch managed to put down 442 awhp, so that's easily over the 500bhp mark.

So maybe its time to get some badger cams :rock:
 
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My clutch has finally given up.

Not sure what has happened but the clutch is not disengaging when the peddle is pushed down. The peddle still returns to the top but it does feel a lot softer.
I have visions that the slave cylinder has punched through the pressure plate.

So I went ahead and bought the FX850, Mike from Stevebilt offered it to me at a very good price.

123


BumbleBiatch will be off the road once again.
Going to do all the necessary gearbox upgrades, steel shifters, reinforcement plate, 4th gear input shaft support and just maybe one of those SQS jobbies that Andrew is flashing around.
 
Bought a spare gearbox to rebuild with some goodies. After cleaning the casing I found out that the code is DRP, which according to the interweb, its the box to have.

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the fancy parts to be fitted over the summer.....

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Quaife LSD, Steel shifter forks, 4th gear support, gearbox casing support, solid shifter cable bushes and billet input shaft.
Waiting for the gaskets, seals and new bearings to arrive from ECS.

OEM diff is at the machine shop to get the rivets drilled out.
 
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Where did you get the billet shaft from? And what are the little brass bushes for?

Is the DRP the earlier box?
 
Sam_ said:
Where did you get the billet shaft from? And what are the little brass bushes for?

Is the DRP the earlier box?
Click to expand...

Yeah, as Andrew said, billet shaft is from DonkeyTec, their website is in German so takes a bit of time with google translate to process your order if you don't understand German. When I placed my order, it said no stock was available and would take 3-4 days but the order was shipped the same day. Was impressed with their service, also bought the shifter cable bushes from them.

The brass things are upgraded sliders for the shifter forks, I got these from Darkside Developments along with all the other stuff. Great service from them too.

This box was still attached to a 2.8 v6 4 motion motor.
The scrapyards here in Dubai buy container loads of low mileage half cars from Japan. So they still in pretty good condition.
 
Decided to get the gearbox off and check what was going on with the old setup.
Took the whole engine out too :)

Asn 4


Got the box off and found the problem, 3 year old stage 4 clutch net setup that's seen a lot of abuse ( LC and NLS )

Asn 1



and this would be the reason I couldn't engage gears

Asn 3
 
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Zakir883 said:
EDIT.... no spamming other peoples threads with your advertising!...
Click to expand...

Not really polite putting your advert on someone's build thread!!


Sent from my iPhone using Tapatalk
 
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Just getting it out there mate didn't it would hit a soft spot

Sent from my SM-G925F using Tapatalk
 
Put it on a classified page.
Not even a 8L so completely off topic


Sent from my iPhone using Tapatalk
 
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Zakir883 said:
I'm selling my Audi S3 2011 reg with stage 1 map pushing 290bhp and 325lbs

EDIT.... no spamming other peoples threads with your advertising!...

Sent from my SM-G925F using Tapatalk
Click to expand...

WHOA!!! 290hp, that's cute
 
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