SERIOUS UPGRADE QUESTION

S3 GEORGE said:

Hi
does any one know a good kit for my audi s3 225 I wanted a GT3071RWG or GT28RS (I think) need a equal length manifold, ported inlet manifold, 475cc Injectors( I think), 4 BAR Fuel Pump and Fuel Pressure Regulator, and any other bits you can fink of that mite help?
i want to run 350-400bhp

this is my 1st post btw
thanks

Click to expand...

Here we have a 2001 Audi S3 approximately 50,000 miles with the following modifications:

Green Cotton Panel Filter
Forge TIP
Milltek Cat-Back System
Custom-Code Phase One

Every other component is standard.

The car has now been fitted with the hybrid JBS 05 turbo, 4 bar fuel pressure regulator and Custom-Code Phase Three.

Please note standard downpipe, cats, manifold and intercoolers!

For the stage one, we decided to run a maximum boost of 1.8bar spike, tailing to a constant 1.4bar to the redline. Please see VAG COM log below.

Engine Speed Load Cmd Pressure Press @ Intercool
TIME
STAMP /min % mbar mbar
24.64 1920 106.8 1840 1330
24.95 1920 109 1860 1340
25.24 1960 111.3 1870 1350
25.55 2000 112.8 1900 1370
25.85 2040 115.8 1950 1390
26.16 2080 118.8 1990 1420
26.45 2120 121.8 2020 1440
26.76 2160 125.6 2040 1470
27.06 2200 130.1 2040 1490
27.37 2280 134.6 2060 1550
27.67 2360 141.4 2080 1610
27.97 2440 149.6 2100 1680
28.26 2520 160.2 2130 1780
28.57 2600 175.2 2150 1930
28.87 2720 191.7 2160 2110
29.18 2840 191.7 2180 2350
29.48 3040 191.7 2220 2540
29.78 3280 191.7 2290 2540
30.07 3440 191.7 2380 2540
30.38 3720 191.7 2390 2540
30.69 3960 191.7 2400 2540
30.99 4240 191.7 2390 2540
31.29 4440 191.7 2390 2540
31.59 4680 191.7 2380 2540
31.89 4880 191.7 2360 2540
32.19 5040 191.7 2370 2510
32.49 5240 191.7 2360 2460
32.8 5400 191.7 2380 2480
33.1 5520 191.7 2390 2460
33.4 5680 191.7 2410 2440
33.7 5800 191.7 2400 2420
34 5920 191.7 2330 2440
34.31 6000 191.7 2290 2390
34.61 6080 191.7 2240 2380
34.91 6200 191.7 2210 2470
35.21 6280 184.2 2170 2500
35.52 6360 181.2 2150 2450
35.82 6440 171.4 2110 2540
36.12 6520 166.2 2100 2510
36.42 6560 151.1 2080 2420

As you can see, the turbo is quite capable of holding over 1.4bar at the redline and is fully controlled via the N75 valve. The offset you see between actual and requested is due to the 10psi wastegate actuator. A few tricks were needed in the Custom-Code Phase Three mapping to achieve this. We fuelled it at around 0.79 on spike tailing to 0.81 at redline. Maximum EGT recorded was 700˚C, this means no glowing manifolds or turbine housings!

The results speak for themselves.

As you can see from the dyno and logs, we now have near factory spool and a massive increase in both BHP and torque. Not to mention up to 1.5bar at 6.5k plus.

We then decided to see just how far we could push this turbo on the standard manifold, downpipe and cats. The limiting factor became a combination of these three components. We managed to hold just over 1.5bar at 7k with a maximum EGT of 850˚C which is as high as we would ever want to go, but just shows what is possible. We were also very near to total saturation of the MAF element at 240g/s. We also increased ignition timing by approximately 8˚ below spool which can be clearly seen on the dyno graph in the form of extra torque low down.

Please see the dyno graph below.

We firmly believe that with just a high flow down pipe and de-cat a totally reliable 300-310BHP as well as 330-340lb ft is readily available. With the addition of our JBS Tubular Collected High Flow Manifold, up to 340BHP and 360lb ft will be on tap. We have now officially put this turbo into production and we are taking orders on our first batch of 10 as of now.

Specification and prices below.

Modified compressor housing inlet
C.N.C re-profiled compressor cover for high flow
350bhp capable “billet” custom compressor wheel
Modified seal plate
360 degree performance thrust bearing
Hybrid K04 large trim left hand thread turbine wheel
Lightening and balancing of turbine wheel for faster ‘spool up’
Modified turbine housing
Up-rated twin turbine seals
Cryogenically treated components
10psi wategate actuator set up with the option to upgrade

BRAND NEW JBS05 turbo unit (not exchange) £1150.00+VAT

Exchange basis JBS05 (as long as the old unit is in useable condition) £850+VAT

JBS Tubular Collected manifold (not equal length) £450+VAT

Custom-Code Phase 3 mapping £550+VAT (reduced from £650)

Fitting of the manifold and turbo can be done for an extra £279.45+VAT - This includes labour, gaskets, oil, oil filter and coolant.

Customers who already have a Custom-Code remap will receive a 33% discount on their phase three price. The JBS 05 hardware and software package is also available from Custom-Code agents.

Many thanks for all the interest in the development of this product.

Click to expand...

I've compiled the theoretical HP numbers that common sized injectors can support. There are 4 variables:

Injector flow rating: amount of fuel an injector can flow at 100% duty cycle (wide open) at a specified pressure (3 bar is assumed)
Relative fuel pressure at injector: The fuel pressure the system is set to minus any effects from boost or vacuum.
Duty cycle: the percentage time the ecu signals the injector to be open. Depending on which injectors and who you ask, maximum should be less than 80 or 90%.
Brake Specific Fuel Consumption: the amount of fuel the engine burns to make one (crank)horsepower for 1 hour in pounds/hour. This is the "unknown" variable. I have included values form .45 (really, really excellent) to .60 (mediocre). I don't believe any value lower than .45 for a 1.8T, BUT some people would disagree with that. There is no question that the equation from which these values are calculated is accurate. (HP= Injector Flow*Duty Cycle*# injectors/BSFC) What can be questioned are the variables- what is actual fuel pressure? Do the injectors really flow at their rating? What is the actual BSFC? The only one we can be completely sure of is the number of injectors. Fuel pressure is pretty certain.
Injector flow is less so: people may be surprised how much injectors can vary from rated flow.
BSFC: the only guide here is we have here is similar engines where this is actually measured on an engine dyno. In my OPINION, the farther you get from stock (the more HP), the higher this number is likely to be.


Injector size: 380cc (36lb Hr)

Fuel Pressure 3 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 256 HP
85% 272 HP
90% 288 HP
95% 304 HP
100% 320 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 230.4 HP
85% 244.8 HP
90% 259.2 HP
95% 273.6 HP
100% 288 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 209.45 HP
85% 222.55 HP
90% 235.64 HP
95% 248.73 HP
100% 261.82 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 192 HP
85% 204 HP
90% 216 HP
95% 228 HP
100% 240 HP
Injector size: 380cc (36lb Hr)
Fuel Pressure 4 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 296.53 HP
85% 315.07 HP
90% 333.6 HP
95% 352.13 HP
100% 370.67 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 266.88 HP
85% 283.56 HP
90% 300.24 HP
95% 316.92 HP
100% 333.6 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 242.62 HP
85% 257.78 HP
90% 272.95 HP
95% 288.11 HP
100% 303.27 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 222.4 HP
85% 236.3 HP
90% 250.2 HP
95% 264.1 HP
100% 278 HP

Injector size: 440cc (42lb Hr)
Fuel Pressure 3 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 298.67 HP
85% 317.33 HP
90% 336 HP
95% 354.67 HP
100% 373.33 HP
Fuel Pressure 3 Bar
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 268.8 HP
85% 285.6 HP
90% 302.4 HP
95% 319.2 HP
100% 336 HP
Fuel Pressure 3 Bar
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 244.36 HP
85% 259.64 HP
90% 274.91 HP
95% 290.18 HP
100% 305.45 HP
Fuel Pressure 3 Bar
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 224 HP
85% 238 HP
90% 252 HP
95% 266 HP
100% 280 HP

Injector size: 440cc (42lb Hr)
Fuel Pressure 4 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 345.6 HP
85% 367.2 HP
90% 388.8 HP
95% 410.4 HP
100% 432 HP
Fuel Pressure 4 Bar
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 311.04 HP
85% 330.48 HP
90% 349.92 HP
95% 369.36 HP
100% 388.8 HP
Fuel Pressure 4 Bar
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 282.76 HP
85% 300.44 HP
90% 318.11 HP
95% 335.78 HP
100% 353.45 HP
Fuel Pressure 4 Bar
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 259.2 HP
85% 275.4 HP
90% 291.6 HP
95% 307.8 HP
100% 324 HP
Injector size: 580cc (55lb Hr)
Fuel Pressure 3 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 391.11 HP
85% 415.56 HP
90% 440 HP
95% 464.44 HP
100% 488.89 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 352 HP
85% 374 HP
90% 396 HP
95% 418 HP
100% 440 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 320 HP
85% 340 HP
90% 360 HP
95% 380 HP
100% 400 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 293.33 HP
85% 311.67 HP
90% 330 HP
95% 348.33 HP
100% 366.67 HP
Injector size: 580cc (55lb Hr)
Fuel Pressure 4 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 452.98 HP
85% 481.29 HP
90% 509.6 HP
95% 537.91 HP
100% 566.22 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 407.68 HP
85% 433.16 HP
90% 458.64 HP
95% 484.12 HP
100% 509.6 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 370.62 HP
85% 393.78 HP
90% 416.95 HP
95% 440.11 HP
100% 463.27 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 339.73 HP
85% 360.97 HP
90% 382.2 HP
95% 403.43 HP
100% 424.67 HP

60 lb/hr
3bar FP
.45 BSFC
Duty Cyle Max HP @ Duty Cycle
80% 426.67 HP
85% 453.33 HP
90% 480 HP
95% 506.67 HP
100% 533.33 HP
.50 BSFC
Duty Cyle Max HP @ Duty Cycle
80% 384 HP
85% 408 HP
90% 432 HP
95% 456 HP
100% 480 HP
.55 BSFC
Duty Cyle Max HP @ Duty Cycle
80% 349.09 HP
85% 370.91 HP
90% 392.73 HP
95% 414.55 HP
100% 436.36 HP
.6 BSFC
Duty Cyle Max HP @ Duty Cycle
80% 320 HP
85% 340 HP
90% 360 HP
95% 380 HP
100% 400 HP
4 bar
.45 BSFC
Duty Cyle Max HP @ Duty Cycle
80% 498.49 HP
85% 529.64 HP
90% 560.8 HP
95% 591.96 HP
100% 623.11 HP

.50 BSFC
Duty Cyle Max HP @ Duty Cycle
80% 448.64 HP
85% 476.68 HP
90% 504.72 HP
95% 532.76 HP
100% 560.8 HP
.55 BSFC
Duty Cyle Max HP @ Duty Cycle
80% 407.85 HP
85% 433.35 HP
90% 458.84 HP
95% 484.33 HP
100% 509.82 HP
.60 BSFC Duty Cyle Max HP @ Duty Cycle
80% 373.87 HP
85% 397.23 HP
90% 420.6 HP
95% 443.97 HP
100% 467.33 HP

Injector size: 755cc (72lb Hr)

Fuel Pressure 3 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 512 HP
85% 544 HP
90% 576 HP
95% 608 HP
100% 640 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 460.8 HP
85% 489.6 HP
90% 518.4 HP
95% 547.2 HP
100% 576 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 418.91 HP
85% 445.09 HP
90% 471.27 HP
95% 497.45 HP
100% 523.64 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 384 HP
85% 408 HP
90% 432 HP
95% 456 HP
100% 480 HP
Injector size: 755cc (72lb Hr)
Fuel Pressure 4 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 593.07 HP
85% 630.13 HP
90% 667.2 HP
95% 704.27 HP
100% 741.33 HP

BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 533.76 HP
85% 567.12 HP
90% 600.48 HP
95% 633.84 HP
100% 667.2 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 485.24 HP
85% 515.56 HP
90% 545.89 HP
95% 576.22 HP
100% 606.55 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 444.8 HP
85% 472.6 HP
90% 500.4 HP
95% 528.2 HP
100% 556 HP
Injector size: 880cc (83lb Hr)
Fuel Pressure 3 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 590.22 HP
85% 627.11 HP
90% 664 HP
95% 700.89 HP
100% 737.78 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 531.2 HP
85% 564.4 HP
90% 597.6 HP
95% 630.8 HP
100% 664 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 482.91 HP
85% 513.09 HP
90% 543.27 HP
95% 573.45 HP
100% 603.64 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 442.67 HP
85% 470.33 HP
90% 498 HP
95% 525.67 HP
100% 553.33 HP

Injector size: 880cc (83lb Hr)
Fuel Pressure 4 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 683.38 HP
85% 726.09 HP
90% 768.8 HP
95% 811.51 HP
100% 854.22 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 615.04 HP
85% 653.48 HP
90% 691.92 HP
95% 730.36 HP
100% 768.8 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 559.13 HP
85% 594.07 HP
90% 629.02 HP
95% 663.96 HP
100% 698.91 HP

BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 512.53 HP
85% 544.57 HP
90% 576.6 HP
95% 608.63 HP
100% 640.67 HP
Injector size: 1008cc (96lb Hr)
Fuel Pressure 3 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 682.67 HP
85% 725.33 HP
90% 768 HP
95% 810.67 HP
100% 853.33 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 614.4 HP
85% 652.8 HP
90% 691.2 HP
95% 729.6 HP
100% 768 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 558.55 HP
85% 593.45 HP
90% 628.36 HP
95% 663.27 HP
100% 698.18 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 512 HP
85% 544 HP
90% 576 HP
95% 608 HP
100% 640 HP

Injector size: 1008cc (96lb Hr)
Fuel Pressure 4 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 790.76 HP
85% 840.18 HP
90% 889.6 HP
95% 939.02 HP
100% 988.44 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 711.68 HP
85% 756.16 HP
90% 800.64 HP
95% 845.12 HP
100% 889.6 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 646.98 HP
85% 687.42 HP
90% 727.85 HP
95% 768.29 HP
100% 808.73 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 593.07 HP
85% 630.13 HP
90% 667.2 HP
95% 704.27 HP
100% 741.33 HP

Injector size: 1680cc (160lb Hr)
Fuel Pressure 3 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 1137.78 HP
85% 1208.89 HP
90% 1280 HP
95% 1351.11 HP
100% 1422.22 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 1024 HP
85% 1088 HP
90% 1152 HP
95% 1216 HP
100% 1280 HP

BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 930.91 HP
85% 989.09 HP
90% 1047.27 HP
95% 1105.45 HP
100% 1163.64 HP
BSFC .60
Duty Cyle Max HP @ Duty Cycle
80% 853.33 HP
85% 906.67 HP
90% 960 HP
95% 1013.33 HP
100% 1066.67 HP
Injector size: 1680cc (160lb Hr)
Fuel Pressure 4 Bar
BSFC .45
Duty Cyle Max HP @ Duty Cycle
80% 1317.69 HP
85% 1400.04 HP
90% 1482.4 HP
95% 1564.76 HP
100% 1647.11 HP
BSFC .50
Duty Cyle Max HP @ Duty Cycle
80% 1185.92 HP
85% 1260.04 HP
90% 1334.16 HP
95% 1408.28 HP
100% 1482.4 HP
BSFC .55
Duty Cyle Max HP @ Duty Cycle
80% 1078.11 HP
85% 1145.49 HP
90% 1212.87 HP
95% 1280.25 HP
100% 1347.64 HP
BSFC .60 Duty Cyle Max HP @ Duty Cycle
80% 988.27 HP
85% 1050.03 HP
90% 1111.8 HP
95% 1173.57 HP
100% 1235.33 HP

Click to expand...