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Audi S3 "Punisher" 2.1L stroker build, image heavy

Warsuperior Jan 30, 2019

  1. hydro s3

    hydro s3 S3 amk

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    Do the arp head bolts not take more strain over the oem one's? If so with you putting more torque threw the engine would the arp ones not be best.
     
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  3. Warsuperior

    Warsuperior Registered User

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    I went nuts and ordered head stud and main bearing stud kit. At least now they should not fail
     
  4. ADs3

    ADs3 Active Member Silver Supporter

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    Have you seen any measurements recorded of how the x-parts manifold flows......total flow, equal distribution of the ports?
     
  5. Warsuperior

    Warsuperior Registered User

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    Nope. only that its identical to one that had 1000hp flow and equal distribution and when I measured this, it seems to be 100% match, excetp I have to polish insides.
     
    ADs3 likes this.
  6. ADs3

    ADs3 Active Member Silver Supporter

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    Sounds interesting. I did check there site out but couldn't find any data on it & looked online also for any info on how it performs against other similar manifolds but couldn't find anything either. Looks like a nice piece of kit but would like to see some hard evidence on it before I pull the trigger.
     
  7. Warsuperior

    Warsuperior Registered User

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    I have seen picture of flow and Number were
    • Runner 1 - 290.424839 CFM
    • Runner 2 - 289.215817 CFM
    • Runner 3 - 288.897168 CFM
    • Runner 4 - 289.169699 CFM
    average per cylinder.
    https://store.034motorsport.com/034...take-manifold-transverse-1-8t-large-port.html
    Its 100% copy of that.

    Here where I live is now two 2litre stroker both producing over 850hp and same intake. 2nd Audi put out 853hp on oem throttle body! Think about that :D
     
    ADs3 likes this.
  8. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    if X-Parts one is copy of 034 which is based on Grams Honda one, we ran a test on it vs IE vs SEM... On a 550bhp car the IE was 15bhp more and SEM was 25bhp more than the 034 one. All on 80mm Throttle body
    fyi
     
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  9. ADs3

    ADs3 Active Member Silver Supporter

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    Cant beat back to back testing like that, thanks Bill
     
  10. Warsuperior

    Warsuperior Registered User

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    hmm ok my comment didnt post here but thanks badger5! I was aware of that too, that there is differences. Friend has the 034 one and he had problems too but he modified it and now has over 850hp on that intake.

    Friend who has the drag racer had some problems with knocking etc. he tightened the ARP bolts to 110Nm and almost all problems disappeared.
    Of course Im not going to do this since I dont have over 200hp/cyl :)

    Some more stuff appeared btw.
    2L surge tank for dual AEM pumps
    Tial wastegate 44mm by trix
     

    Attached Files:

  11. Warsuperior

    Warsuperior Registered User

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    Polishing inside of intake.
    Before:
    [​IMG]

    Soon there:
    61084214_10211329549673309_1595949640342044672_n.jpg
    61175724_10211329549113295_1098310823639515136_n.jpg

    Fluidampr arrived:
    61263876_10211329549393302_6576279401934094336_n.jpg
     

    Attached Files:

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  13. Warsuperior

    Warsuperior Registered User

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    Engine, crank and head are on machine shop.
    Deck+head are smimmed, crank inspected and dual pinned crank gear incoming. They machine valves too since I cannot be ***** :D
    Too lot to do anyways :)
    I really cannot wait to see how lot torque this thing can push on lower rpm. Driving in city should be easier too. Im just now settling in with 6speed box, Im so used to drive in 2nd with 5speed and now 3rd is the way to go.
    IDK should I remove the gear shortener, I have now twice put it in 3rd instead of 5 and on high rpm damn! Well not so high that over 7k but near it..
    Any tips on elevated shifter or something?
    I was thinking of keeping car OEM look but I ordered plastic fender flares and I kinda liked the look. I like bit "race" look and in end its my car so dont really care how others look it(mostly they see it from behind :p) but open for opinions as usual :)

    Still pondering do I put in SMF and Sachs SRE stuff or keep the LUK DMF with Sachs 4paddle and sachs pressure plate(not sre). Tuffty has pushed this to 440lbft without problem but launching I dont really think is wise with this... Alltho I can always break it, then renew :D
     
  14. Warsuperior

    Warsuperior Registered User

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    So update topic.
    Ive had lots of problems with build. Head had to be skimmed again, since the was scratch between 2&3 cylinder.
    [​IMG]
    Pistons had to be cut down to get oil squirters to fit
    [​IMG]
    One piston ring cracked(own fault) had to get new one.
    [​IMG]
    Crankshaft trigger wheel had to be welded(actually melted with TIG) to make sure it wont move
    [​IMG][​IMG]
    Oil pan needed to be grinded to fit ARP main bearing studs

    I chose Sach SRE SMF kit to be clutch of choise
    [​IMG][​IMG][​IMG]

    I coated pistons with slick ceracoate on sides, heat dissipating below and top
     
    Last edited: Oct 8, 2019
  15. Warsuperior

    Warsuperior Registered User

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    Silver-Project rear trail arms
    69241050_10211839167933447_1766563355000045568_n.jpg
    Titanium vs oem retainers
    67494902_10211689860080844_2051249098937335808_n.jpg
    Installing valves with 15€ lawnmover tool
    67403106_10211680460405858_2839971971142254592_n.jpg
    Coated parts
    67879054_10211728544367927_7761892436661501952_n.jpg
    ACL race bearings
    67814919_10211728543647909_3294329607834042368_n.jpg
    Millers drive-in oil 10w-40
    67688758_10211722674901194_1256214407218724864_n.jpg
    Balancing report after tig weld plus flywheel plus clutch plate plus camgear
    69896233_10211824700091760_5212528363767332864_n.jpg
    Dual AEM 400lph
    70303453_10211899707166890_4853546896859332608_n.jpg
    ND to EV6 adapters and 11mm->14mm injector adapters
    70063853_10211899712727029_730589828428595200_n.jpg 70242771_10211899714767080_2798817671821393920_n.jpg

    Waiting for head to be installed
    71063865_10211953966803347_2837989362698813440_o.jpg
    Athena 83,8mm and 1,4mm thich race MLS head gasket. CR is now about 9,24:1 or bit more
    71477246_10212025399949131_2096432253675503616_n.jpg
    Head painted
    67595262_10211680467326031_8497245976526848000_n.jpg
    67367381_10211680470326106_6805716533411577856_n.jpg
    Block painted with acid black
    67824352_10211680463845944_5275838526762516480_n.jpg
    Valves all in with dual sprins+titanium retainers. Guides changed to exhaust side and Inconel supertech exhaust valves
    67247419_10211675205434487_9217120484322181120_n.jpg

    Filing piston rings
    67585189_10211722452895644_807400662773006336_n.jpg
    Making adaptor from old cambelt gear to fit the timing wheel
    71497124_10212038161748168_2317954104023842816_n.jpg 72165452_10212038162348183_2399946889425321984_n.jpg

    Engine and head assembled together and starting to set Cat cams 3658 timing
    72949064_10212038236510037_3540490916760387584_o.jpg
     
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  16. Warsuperior

    Warsuperior Registered User

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    Reason why the trigger wheel is melted is because using old one, the bolts go too deep. Picture here to explain
    [​IMG]
     

    Attached Files:

  17. Warsuperior

    Warsuperior Registered User

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    I decided to run E85 with engine since I am soon in city where E85 is available. We shall see what kind of figures we can push out :)
    Most likely, I will drop some hp in favor for reliability and as daily driver, I dont need full power nonstop but more torque on low to mid is best :)

    Going to take S3 apart this week or weekend.
     
  18. Warsuperior

    Warsuperior Registered User

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    Car is now running and under tuning! Lots have happened and I didnt post here lot but I have a facebook link where is tons of pics, info etc.
    Bill from badger5 helped me A LOT and I cant ever thank him enough for not losing nerves with my endless questions!

    Alltho my understanding of english did make things worse and I had to ask until I understood but never the less, Bill was amazing help. Also Balasz from Ignitron and so many others.

    Along the way I ran out of time and had to make some changes. Last specs are

    AGU head refurbished
    OEM intake valves and OEM old guides just machined old valves to seats
    Supertech Inconel 1-Groove exhaust valves machined to seats
    Rosten-Performance double springs with titanium retainers
    CatCams 3658 set with adjustable wheels
    Rosten-Performance adjustable cam wheel
    Athena 1.4mm and 83,8mm MLS gasket. CR is now 9.2:1
    VVT with Ignitron control
    AGU base engine bored to 83mm
    83mm 9.5:1 CR Je-Pistons with better flame travel profile
    FCP 144mm X-Rods (should handle more torque than H)
    ACL Race/King race bearings, OEM pressure bearings
    ALH 1.9TDI 95.5mm stroke balanced and polished crank with 1.8t modified cam belt wheel+2 extra pins on crankshaft for cam belt wheel
    Melded(yes melted with TIG so no balance change) trigger wheel to camshaft
    GTX2860R genII with T25 cast manifold
    Rennsport HRT intake(smallport) with spacer from small to big
    OEM TB
    3" Downpipe with 3" SS exhaust with 3 magnaflows
    600x300x76mm FMIC
    K&N RC-5112 air filter
    Intank OEM pump new
    AEM 400LPH in-line pump under car
    Ignitron Ecu
    1200cc EV14 Injectors
    OEM fuel rail OEM style adjustable FPR
    Sachs race engineering 7.2kg SMF and full clutch kit with 4-paddle disk
    SSQV dumb valve

    I also now have flexfuel sensor fitted ready, LCR fuel filter moved where active charcoal chamber was.

    Also hilarious image when I got my wastegate control fcked and on 4000rpm it pushed 2.24bar like for second, I know it doesnt reflect real life but I gotta say, car was insanely fast on that drive, even I didnt rev it much. boost was almost instat cus the pressure pushed wastegate close :D

    78614275_10212405713656736_4585008383119065088_o.jpg

    here is FB link
    Code:
    https://www.facebook.com/groups/203244473354322/permalink/949480938730668/
     
  19. Warsuperior

    Warsuperior Registered User

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    Perhaps not prettiest S3 out there but next summer I polish and paint etc.
    Car is now in "winter" mood also. Dont like the rear and the sideview rear is bit too low vs front.
     

    Attached Files:

  20. Warsuperior

    Warsuperior Registered User

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    First drive and boost pipe BLOW cus it was loose and well the WG problem was still there.
     
  21. Warsuperior

    Warsuperior Registered User

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    Longer drive, sorry for music etc :D
    and camera on head not optimal
     
  22. Warsuperior

    Warsuperior Registered User

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    Please dont say about my AFR meter place, its horrible and is now moving to dual pod where boost meter is.

    Happy new year all!
     
  23. hydro s3

    hydro s3 S3 amk

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    Happy new year to you aswell mate.
    You seem to be hammering on there rightly in the snow. I know your more used to it than what we would be but still going quickly.
     
  24. Warsuperior

    Warsuperior Registered User

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    Thank you Hydro s3 :)
    Only good thing about winter is that you can powerslide everywhere :D With ignitron haldex control the car is quite nice when 50/50 power delivery.
    On drives I have it on OEM mode but still it tries to push rear to side :)

    I bought this yesterday 034 big port intake, heavily modified with 1litre spacer (approx 3.3litres volume now) polished and improved flow.
    Been on 900hp drag racer stroker here.
    I can use now my 80mm Hemi TB and finally get more out of big port head.
    81021048_10157254590933167_504112397569490944_o.jpg

    Also last year I got very very very cheap Golf R 2011 DSG box that has been only sen approx 90 000km
    It leaks between seals but fixable. Only leaks when its running.
    its DQ250 MTX box but it will be strong enough for my use. Can handle 600Nm and even heard that someone has with 650Nm daily driver this box.
    If I would want it more strong, I could upgrade the packs inside of it but Im sure this will handle my power/torque anytime.
    Now I only need rest parts for DSG swap :)
    78686741_10212341692536248_8911753691170603008_n.jpg

    Interesting year going to be this 2020
    G25-660
    Better intake
    DSG!!!! controllered by Ignitron
    :)
     
    hydro s3 likes this.
  25. hydro s3

    hydro s3 S3 amk

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    This car is going to be extremely quick when you get this all on. Good work mate.
     
  26. Warsuperior

    Warsuperior Registered User

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    I started to rip the DSG apart and fix the leak issue.good but the 2nd lock ring I cannot get off so I had to order special pliers and I get them tomorrow. After I I can rip the DSG in 2 halves, check the leak and fix it and hopefully it can be fixed.

    Also my roofliner was hanging so I took the lining off and added some Ground zero noise killer mat, also there comes another layer of soft mat to absorb sounds.
    Only problem is that I dont know for sure how to fix the hanging liner. Any tips appreciated!

    Can anyone remember seat LCR fuel filter code? I cannot and I would like to order new.

    I have video of taking DSG apart but I have not edited them yet.
     
  27. Warsuperior

    Warsuperior Registered User

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    Car ran for few secs with DSG and horrible grinding noise. I think its the middle metal sheet between gearbox and engine and I really really hope it is not hard to fix and I have a clue where it came from, possibly the rear small cover is bend inwards and makes contact to flywheel.
    Positive was that at least now it didnt leak so far, I hope it wont start when I get more pressure to it.
    BTW the CR is 9.8:1 I had wrong figures on one spot whe I calculated it, so no wonder it started to knock with 98 fuel on 1.2bar boost, now its E85 and car worked really well with it.

    Then I noticed the ECU wont talk to DSG and of course it wont if you forget to connect +12v acc wire D'oh!
    I have run into problem after problem after problem and making things worse, my hands are overworked, they hurt day and night so I have had to push this project forward and forward.

    New parts or changed:
    1300cc EV14 matched set https://finjector.com/eng/ev14_1300_cc_12_ohm_c_jetronic_liitin_keskipitka_o_o_49_mm-p-486741-0 I really suggest this place, they ship worldwide too. Fast&Great customer service, fast shipping and delivery in total, make account if you order(the more you buy, they give you personal discount that applies to prices when you login) These have very great spray!
    Turbosmart - GenV HyperGate 45 14psi External Wastegate

    Now I am missing downpipe+wastegate pipe+some breather lines. So close but so far away still...

    Not much I know but I am not good with making downpipes or the pipe for wastegate. Now the downpipe has to be put in below with twisting it many times to it goes to place. I have to weld 2"v-band close to the pipe for connection to wastegate and then I hope it still will fit.
    All this on ground too witch is pain in *** to do.
    119206409_419576312351505_5016686133424783718_n.jpg

    List what you need:(at least on my build)
    - DSG, I have MTX Gearbox from Golf R 2011 (its been said it can handle 650Nm on stock clutch pack so I kept it, I will limit torque)
    - ECU what can control it, I prefer and suggest Ignitron, it is the best there is [​IMG]
    - Electrical connector round for DSG box 1J0927320
    - Electrical connector for DSG shifter 1k0972776, doesnt come with connectors so get them elsewhere, on VW they cost 15€/pcs and that price is a gunless robbery! Dont waste money on the VW fix wires which are 15€/pc here at least! You can use the small amp square connectors that cost less than euro, sorry I forgot the number for them. Get 5 of them but I usually buy more cus i **** them up regulary. I suggest buying good crimping pliers example aliexpress.
    - Right side driveshaft flange from 02M gearbox, the one with MTX and seems with others too, dont fit
    - Driveshafts: Left fits just like that, right you have to cut 40mm. I cut mine with lathe and TIG welded. I could not find ones that would fit without modding and I tested 9 different driveshafts. TT 3.2 ones dont fit with this one
    - Flywheel 06F105266L or Sachs 2295 000 541
    - Bigot bearing middle of flywheel Sachs 1863 869 047 <-DO NOT forget to put this in
    - Starter motor 02E911023L
    - 2 coolant hoses 8N0121096H coolant hose from DSG cooler to waterpump. 8N0121073A, coolant hose from interior heat exchanger to DSG cooler.
    OR DIY hoses, i used 16mm 90degree ones 2 of them, warmed the hose so I could push it to one way valve
    -One-way valve 1J0122351
    - Engine mounts 1J0199117AT/ 8N0199555G or use OEM S3 mounts, the fit except on transmission site you are missing one bolt and there is chance two wont hold it in place BUT 1J0199555BB seems to have right bolt pattern and looks like it fits, I have not tested it.
    - DSG shifter from Passat B6, touran dont fit to 4wd, see pic
    106782443_10213758774722417_8353891115735235058_o.jpg
    Optional:
    - better clutch pack 02E398029C, I am going with OEM cus I dont plan pushing over 600Nm nonstop and ppl say that this OEM pack should hold 650Nm without slipping if you program it to clamp harder
    - Oil filter housing made from aluminium with fins for better cooling. I bought mine from china and it was ******, idk did i get unlucky since others bought same and they got great item.
    - CAN support cluster to see what gear is engaged, I skip this for now or make external that shows me it but I dont really need it for now.
    - Paddle shift, basically on/off switch for Ignitron and digital inputs

    My list for parts from where I got them from:
    - Sachs flywheel 2295 000 541 (Autodoc)
    - Sach bigot bearing 1863 869 047
    - CASCO starter motor: CST10444AS (Autodoc)
    - Elring DSG cooler O-rings 886.810 (Autodoc)
    - Vaico repair kit with DSG oil pan, oil filter, O-rings for electrical round connector, 6litres of DSG oil V10-5138(Autodoc)
    - Elring park gear axle gasket(renew if leaks) 886.780 (Autodoc)
    - Elring metallic gasket for oil pump DSG 149.060(Autodoc)
    - Shifter from Passat B6 junkyard
    - Driveshafts left fits, right one you need to cut 40mm DIY
    - One way water valve 1J0122351
    - Cover for clutch pack and hydraulic block gasket maktrans poland, almost all gaskets are one time use on DSG as listed below
    - 16mm and 19mm ID diameter water hoses with 90 degree corners on them, they are cheap and must. Even better to get few of the ones that have several curves, makes things easy.

    Repair parts for DSG, these are bare minimum you need to open box and assemble:

    - 02E321385A Gasket for oil pump, needs to be renewed (
    - 02E301580C gasket for hydraulic block, needs to be renewed(cant get from VAG they don make it but eg. maktrans poland makes it)
    - 02E301205C cover for clutchpack, has to be renewed -everytime
    - 02E301859A Lock ring for clutchpack cover, has to be renewed
    - the round electrical connector needs new o-rings everytime too.
    - DSG cooler needs new 2x O-rings

    For sealant to use, when mating casings back together, Elring AFD2018 was the one I went for. Anaerobic, I could not find anywhere what they use when they make DSG so I saw one elring video they used this.

    So what else?
    G25-660 is now in
    Wastegate is turbosmart hypergate 45 instead of Tial
    Battery is in trunk now, 50mm2 welding cables full copper, small strains version(better conductivity)
    Start and stop battery 75Ah
    300A automatic fuse

    Also amps are in spare wheel cowl, pics are from not ready state
    118970052_10214134383272396_1618532047617524692_o.jpg 117109541_10213949826338588_5961028685908413089_o.jpg

    Wiring DSG connector
    118926728_10214134396352723_3674228488679095008_o.jpg
    DSG pinout, these are from my car but this is the pinout on 20pin ones almost all same, to my knowledge. Please check your gearbox one before doing this. I am not resposible for errors.
    118922761_10214134404712932_4759702292155252433_o.jpg
    DSG shifter pinout
    118918948_10214134406192969_2290639322180913290_o.jpg
    New subframe because old ones dogbone nuts got loose inside of the frame and I could not get them to stick or weld.
    107117628_10213778633538875_3680894287854533347_o.jpg
    Had to cut triangle out of body so the DSG would fit, the OEM intercoolers hook into that. I dont know why but gearbox would not fit without removing that. There seems to be different version of S3 where that thing dont exist (?) since few ppl said they dnt have it. I know A3 might not have that but they said they have S3. and no, I did not cut the frame, only the triangle what is made of thin metal. So frame integrity is still same
    108109789_10213823510660775_5424586640753645431_o.jpg
    Passat shifter in, I broke the button from this when I tried to remove it. It had crack and got loose. I have been trying to find new button but not luck yet.
    118979596_10214134387032490_7402201149345785009_o.jpg
    Lathe cut the right driveshaft
    106913152_10213772157816986_6132192102636746685_o.jpg 107051071_10213772157536979_6542558167852958124_o.jpg

    Tig welted shaft ready for paint
    118936237_10214134381632355_5421119525199420609_o.jpg
    Making new engine mounts, Shore65 rubber. Cheapest mount and 1litre kit approx 60pounds and they do not move :D
    106079800_10213745866119710_3267960850704399921_o.jpg
    Getting there but still to do and tidy stuff up. I put vacuum block top of intake. I know my engine room is nothing beautiful like others but I make it so it works. The line to air filter too is going to be different, that was just a test
    118914367_10214134388352523_528500198548725006_o.jpg
    Final waterlines for DSG . I put extra bolt on that tranmission mount, made threads to the one connected to transmission but I have the right mount too. I was thinking of testing this and to see is that 1 extra bolt enough, so you could use S3 oem mounts. If it moves I replace it.
    From picture you can figure out how the water lines for DSG go too or at least I think you can make it out
    115806207_10213904955776852_5858219404535280055_o.jpg

    thats it so far. I cant list all the trouble I have had with this project and I think its last time I touch the car. No more changes :D
     

    Attached Files:

  28. Bluepower

    Bluepower Registered User

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    Ha, no more changes..... but you do keep talking about an 07K swap :p
     
  29. Warsuperior

    Warsuperior Registered User

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    Shush you vile temptress! :tearsofjoy:
     
  30. Dextermann

    Dextermann New Member

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    moro! en nyt millään löytänyt keinoa lähettää sulle yksityisviestiä, niin laitan nyt tänne.
    Luin jossain ketjussa, että sulla saattais olla tuommoseen 1.8t AGUun valmis ohjelma. vieläkö löytyy?
     

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