Audi S3 - Stroker Big Turbo build.

badger5

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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.
 

Scullies

Registered User
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.

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.
 

Scullies

Registered User
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 :)
 

Scullies

Registered User
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.

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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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g60leigh

Registered User
Pics not working bud
 

<tuffty/>

Badger 5 Edition...Its all about the flow...
Staff member
Moderator
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/>
 

Scullies

Registered User
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

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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:
 

Scullies

Registered User
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.

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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.
 

Scullies

Registered User
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.
 

Sam_

Down under
Where did you get the billet shaft from? And what are the little brass bushes for?

Is the DRP the earlier box?
 

Scullies

Registered User
Where did you get the billet shaft from? And what are the little brass bushes for?

Is the DRP the earlier box?

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.
 

g60leigh

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

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


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g60leigh

Registered User
Put it on a classified page.
Not even a 8L so completely off topic


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