Audi S3 GT3582R stroker Build (previously GT3071r)

[tufftybloke]

See i have 1.5" fittings already, did already try to make it up but kept fouling different parts. My turbo is already as high as it could go without coming through the bonnet so thats no issue at all.
The biggest problem im having is leaving enough space for a 3" dp to go between the mani and mount. Ill get there though, im sure.
That would be great if you could do that, would give me an idea as to wether or not to follow the same general shape of yours.
Yeah ceramic seems to be the way to go, its just the price of it haha, but then again, for good quality wrap, thats not cheap either

As promised....

Had a day off work today to have a faff with the manifold in the car to see if it fits, what clearance issues I may have and where the wastegate might go...

Thankfully there appears to be quite a lot of room... I had to remove the transfer box bracket as the box attached to the mock up block is the older alloy type and I built the mani to my later (and modified) steel one... once removed the mani fitted perfectly..

I knew the bracket for the OE heatshielding would need attention...

...so a bit of tweaking later...

Turbo sat well....

...I also took an opportunity to check for OEM++ ness...

Have started playing with the wastegate position... one thing is clear, the Tial 44mm gate I have is a big bugger... plans are still formulating but will have a further update tomorrow or Sunday on that...

<tuffty/>

 

[rae1001]

There seems to be loads of room there with the ibiza mount. Maybe not enough to get a 3" dp in there too though. Thanks for that, ill have a play with ideas and try get it as perfect as i can.

 

[tufftybloke]

There seems to be loads of room there with the ibiza mount. Maybe not enough to get a 3" dp in there too though. Thanks for that, ill have a play with ideas and try get it as perfect as i can.

I reckon there could be room mate... having the collector between cyl 3-4 gives a lot of room to curve one round and runners 1-2 are quite tight to the block... not having a transfer box and prop in the way may help you too

Been playing with wastegate fitment today... 44mm gate is massive... struggling with it a little tbh... if I go the same sorta way as the TSR mani the gate fouls the gear change cables... facing the other way is plausible but could get in the way of the DP

The older style Tial I currently have is quite a bit taller than the MVR...

...the position I am currently looking into means the MVR is around a finger width clear of the bulkhead... not a massive issue as the engine doesn't move much on the VT mounts and the 20v's rotate back on the mounts anyway under load pulling the gate away from the bulkhead...

however... I am also toying with the idea of taking a stub off the collector runner of cyl 3 so rotating the gate towards the drivers side a little... gives a little more room at the back but obvs brings it closer to the DP etc... will see how it goes...

<tuffty/>

 

[rae1001]

Ace, thanks mate, huge help. Will get started asap now .
That gate looks well on there too, i wish i had that much space. Think ill have to take my gate up top. But then im not going oem haha.
Really look forward to seeing all this with the cover back on

 

[ssbnumber34]

Turbo finally arrived from CR today.... boy was I excited (sad but actual true!)....

Picked up the box from stores just before I left work for home this afternoon so I only had a chance to quickly look at the turbo before I set off... took a couple of pics..

...old housing and turbine...

...new housing and larger turbine...

It was then I noticed the box....

ARSE!!!!

Feck'n dumb ass Fed Ex mother feckers had dropped the box and damaged the V-Band housing....

Feck'n retards!!! will be giving CR a call in the morning to discuss

Took the opportunity to line up a K03, K04, my compact GT30 and Bill's not so compact GT35 for a bit of a comparison...

...hands by Welly (tm)...

...turbine comparisons... no K03 in this one as you can't really see it...

...and finally the difference between a T25 and T3 flanged hotside...

Bit of an anticlimactic day all in all... fixable but shouldn't have happened and of course even more time taking up space and ramp time in the unit to which I am eternally grateful to Bill for but would rather not be taking up space better used for paying customers

Anyhoo... at least I can get started on the coolant lines now even if I can't fit the bloody turbo to my new head yet and get it in the car... bugger!

<tuffty/>

mmm big turbo,,, i run a 35 on my bike

 

[ssbnumber34]

Only just finished reading this thread and Tuffty you are an absolute artist, i love your build, only problem is a have just bought a leon cupra and now have silly ideas for it, just an idea though have you thought about a sniff of nitrous? as a better option than wmi,, would help spool the turbo up really well and drop the charge temps right down too.

 

[tufftybloke]

Only just finished reading this thread and Tuffty you are an absolute artist, i love your build, only problem is a have just bought a leon cupra and now have silly ideas for it, just an idea though have you thought about a sniff of nitrous? as a better option than wmi,, would help spool the turbo up really well and drop the charge temps right down too.

Thanks mate

I have no real interest in using Nos tbh... I only really use WMI for consistency reasons and took me long enough to sort out the installation... lol

Never been a 'Nos' person... sure it has it applications (was aware of the aid to spooling) but its just not something I am massively happy with having in my engine bay...

I know the GT35 will take a little longer to spool but its no big issue for me...

<tuffty/>

 

[Pimped up vario]

This isn't pertaining to your thread but the last post topic. Propane injected in the intake of a diesel has the same effect as nos in a petrol car. Does that mean that propane will cause a turbo diesel engine to spool up earlier?

 

[tufftybloke]

This isn't pertaining to your thread but the last post topic. Propane injected in the intake of a diesel has the same effect as nos in a petrol car. Does that mean that propane will cause a turbo diesel engine to spool up earlier?

The fuel of the devil has no place being discussed here... (;P)

<tuffty/>

 

[Pimped up vario]

Any fuel that can produce that much torque must be evillllllll . I was quite surprised to see that the audi le mans diesel engine race car makes peak power at 3500 rpm or so. I thought it would be higher like the way all the petrol engine race cars make peak power at engine speeds that are way higher than road going cars.

 

[ssbnumber34]

Thanks mate

I have no real interest in using Nos tbh... I only really use WMI for consistency reasons and took me long enough to sort out the installation... lol

Never been a 'Nos' person... sure it has it applications (was aware of the aid to spooling) but its just not something I am massively happy with having in my engine bay...

I know the GT35 will take a little longer to spool but its no big issue for me...

<tuffty/>

No worries mate just an idea you may consider, we tried it on our race bike and it works amazingly, we just run a single small shot straight into the up pipe, and just makes everything so smooth, we are not currently running it as have fitted twin intercoolers but its still fitted and will probably be used again next year. you can't beat that turbo though they are awesome, we run 30psi but have been struggling with the boost blowing the spark out so have just fitted a new nlr ignition amplifier so should be about to run 36psi next year hopefully

 

[ssbnumber34]

This isn't pertaining to your thread but the last post topic. Propane injected in the intake of a diesel has the same effect as nos in a petrol car. Does that mean that propane will cause a turbo diesel engine to spool up earlier?

Why not just use nos in a diesel ? works in the same way as in a petrol car really

 

[tufftybloke]

No worries mate just an idea you may consider, we tried it on our race bike and it works amazingly, we just run a single small shot straight into the up pipe, and just makes everything so smooth, we are not currently running it as have fitted twin intercoolers but its still fitted and will probably be used again next year. you can't beat that turbo though they are awesome, we run 30psi but have been struggling with the boost blowing the spark out so have just fitted a new nlr ignition amplifier so should be about to run 36psi next year hopefully

Sounds fun if not a little scary on a bike lol...


So... made a rather monumental f*ck up... drilled the hole for the wastegate and the hole cutter snagged when it punched through the collector ripping a couple of my somewhat dodgy tack welds off and launching the mani to the floor where it proceeded to dissemble itself...

So... had another go....

Decided to sort a couple of things I was slightly unhappy with... this was a bit of a journey quite frankly... I am a patient person by this did really push my patience to the limit... clearly fluked the first one... tried number one runner a few times before I got it workable... was a right pain... tape stuff, tack stuff... cut tacks, break apart, clean fittings and start again.. 12 hours later....

Slight differences to the previous version... and still have runner 4 to do but it broke me this time lol...

Will finish it off next weekend (use stronger tacks this time) and hopefully it will be off to be welded (and may even stay in one piece this time!)

<tuffty/>

 

[ibizacupra]

<tuffty/>

before

 

[tufftybloke]

Got a little more done this weekend...

Got started on runner 4

...at this point I thought I had better check the heater matrix coolant pipes to see how it would all come together...

I cut the top hard pipe off the main one as the Forge hose kit I had didn't have these hoses anyway but the one it did have came straight off the coolant housing so will use that... applied a little heat to the pipe to help it bend taking care not to over do it as some of the outlets are brazed on... and bent the pipe away and more upright to the compressor housing as it was hitting it in its original position... this gives me enough clearance for the turbo...

With that done I tacked runner 4 ready for final tig welding...

Phew!... not doing the wastegate now until the mani has been fully welded as I want to see where it all ends up... still not finalised the position but that will happen when the mani is done

Bill has a couple of projects ongoing for the new year all using Garrett/Tial turbos so lined them up for a bit of a turbo pr0n photo shoot

Left to right... GTX2867, GT3071 (HTA billet wheel Owens upgrade) and my GT3582

Now making a list of stuff I still need to get and do... seems a fairly large list of small but significant items, this will get ordered up in the new year... I have a bit of time off over christmas and I'll be flitting between mine, the Lupo and whatever else is kicking around...

Mani should be going off tomorrow to the guy doing the welding but not sure when it will be back...

Still... its progress and the list of jobs is going down slowly...

<tuffty/>

 

[Pimped up vario]

Lovely job, nicely done. My list goes down a bit and then tends to grow again.

 

[rae1001]

That turbo really is massive! Must weigh a bit?

 

[tufftybloke]

That turbo really is massive! Must weigh a bit?

if (heavy==true)
{
horsepower++;
}

<tuffty/>

 

[Pimped up vario]

Did you look at compressor maps and all that. Just curious as to the energy input/flow at the turbine side that it works best at and what air flow it yields at the compressor side.

 

[tufftybloke]

Did you look at compressor maps and all that. Just curious as to the energy input/flow at the turbine side that it works best at and what air flow it yields at the compressor side.

Nah... just bang it on and see what happens

I know it works... just have to see how it reacts to a stroker and its 0.63 hotside...

<tuffty/>