Audi S3 GT3582R stroker Build (previously GT3071r)

[tufftybloke]

Busy weekend....

Brakes are now fitted and bled. I have tried them with both my OEM RSTT 18's and my 17" Avus's. Both sets of wheels need spacers to clear. I have 10mm spacers on the front atm which clear fine on both but wouldn't recommend anything less for the RSTT with an ET of 33... the Avus's would need a minimum of 5mm I reckon although you could measure the gap with a feeler gauge between the spokes and the caliper and I wasn't gonna risk damaging my calipers . I have also painted out the yellow 'TVR' with matt black paint.... stealth++

The oil drain pipe issue has been solved...

Charge pipe has been modified...

Hit a few problems with the oil feed pipe, apart from it being a little too long, it doesn't have a reducer in it to limit oil flow to the turbo bearings. The Garrett GT30 I am using has a roller bearing whereas the K04 has a sleeve type bearing that uses high pressure oil to lubricate it. The roller bearing doesn't need this so a reducer is used to reduce pressure. This is currently being sorted... I also need a hole drilled and tapped in the exhaust mani to take the EGT probe that is usually fitted on the turbine housing of the K04.

Once that is all sorted, I can bolt it to the head properly and offer it into the car for clearance checks before finally bolting in the head... WooHoo!!...

more to follow....

 

[tufftybloke]

...continued...

In the meantime, here are a couple of pics of the turbo mocked up on Bills spare engine. This one done to make sure everything fitted as it should... good job we did this

Big turbo?... what big turbo???...

...oh, THAT big turbo!!!!

Think my OEM look is coming together ;P

I feel a bit like Marks Evans... A Big Turbo Is Born!!!! LOL!!

See you next time my big turbo chums....

<tuffty/>

 

[ibizacupra]

no pix dude

 

[tufftybloke]

???... pix are there mate... sure your firewall not blocking??

<tuffty/>

 

[ibizacupra]

hmmm dunno now..
avatar pictures come up..

cleared cookies, logged out and in.. and still no pictures?

 

[mat20vt]

pics work here...

looking good tuffty!! someone's been busy! good work

 

[ibizacupra]

test post.. I can see this picture but not yours paul..

 

[Ruddmeister]

I can see the pics in post #61 & #62

 

[ibizacupra]

yea, tis the oh so crappy network I'm on at the minute

 

[IbizaAlex]

Will the dp not be in the way of the driveshaft?

 

[ibizacupra]

lol 3wd S3

very much bunged on and taped together for a picture.
well spotted..
if only it would go together as well in real life in situ

 

[tufftybloke]

Hello my Big Turbo chums.... tonights update....

EGT probe has now been fitted. The mani was spot faced as there wasn't enough metal to allow the normal fitment of the probe so the probe was welded to the nut in the correct position and screwed in using a copper washer to seal it.

The problem of the missing reducer is now sorted... a drilled insert has been welded into the oil feed banjo bolt (turbo end)

Fitted the mani and turbo to my head!! WooHoo

So, the good news is that tomorrow night I will be able to get the head fitted. Got a few things to do in the morning like pick up some bits from Audi (bought 13 exhaust nuts as a precaution and they cost £1.55 each!!! + vat) and wait for the posty as he should have my plugs (BKR8EIX) then off to do final prep for getting the head on.

The list of things left to do just doesn't seem to end but the DP and custom TIP needs to be fabricated, inline fuel pump fitted and fuel filter relocated and of course putting the engine bay back together with all the stuff I had to remove etc..

It would appear that I was a little optimistic hoping to get it all done in 2 weeks and while we had no major probs, there were a couple of minor hurdles to overcome and its the fiddly bits that will take time.

Still may have to extend the wiring for the injector rail as the 630cc injectors are taller and I am also using a phenolic insulator on the inlet mani which makes it all a bit taller.

With that in mind and with Bill mate going off on a much deserved holiday, the car may not be fired up until at least he is back. Still, gives me time to get everything sorted right and I want it to be right.

More next time my BT chums etc...

<tuffty/>

 

[DPJ]

I thought Bill disliked pre-turbo EGT sensor siting.....

 

[tufftybloke]

The EGT probe fits into the hotside on the K04 and as the ECU uses data from this then figured we need to get it close as poss without actually drilling the housing.

Here is where the fitting is on the K04.

<tuffty/>

 

[DPJ]

The EGT probe fits into the hotside on the K04 and as the ECU uses data from this then figured we need to get it close as poss without actually drilling the housing.

Here is where the fitting is on the K04.

<tuffty/>

I see the logic of that.

 

[ibizacupra]

I thought Bill disliked pre-turbo EGT sensor siting.....

Its not where I stick my egt probes on gauges no, but as tuffty says, for his Me7.5 control of EGT's it seemed wise to keep it in as close a relative location as stock K04 mount would have... else the known temp gradient on downpipe side it could be running colder than std control.

 

[wild willy]

Its not where I stick my egt probes on gauges no, but as tuffty says, for his Me7.5 control of EGT's it seemed wise to keep it in as close a relative location as stock K04 mount would have... else the known temp gradient on downpipe side it could be running colder than std control.

I'd like to think that the better flowing big turbo and manifold combination will result in lower egt temps than the crappy k04 setup.
The ECU is programmed to reduce injector duty cycle at temps in excess of 950 degrees, you should be ok with this as a max temp.

 

[ibizacupra]

I'd like to think that the better flowing big turbo and manifold combination will result in lower egt temps than the crappy k04 setup.
The ECU is programmed to reduce injector duty cycle at temps in excess of 950 degrees, you should be ok with this as a max temp.

hoping so.. its step change bigger bore manifoold and turbo.. fingers crossed. 950'c is somewhere I dont expect it to run to.. my ibiza does just about but off a lot more power/boost

reduce duty cycle = leaning out?

you sure it does that and not the opposite asnd reduce boost at same time?

 

[tufftybloke]

Been a mixed bag of a day....

Started by sorting out some jobs I needed to do before lifting the head on. Cleaned out the head bolts threads in the block, fitted the THS gearbox mount, made sure stuff was out of the way so as not to impede the fitting of the head then moved onto looking at fitting the inline pump. I wanted to fit this out of the way so I am looking to fit it where the fuel filter is currently located and look to relocate the filter.

I have been mocking up the fitment and pipework and will finish it off when the head has been fitted.

next, the evenings fun and games....

<tuffty/>

 

[tufftybloke]

.... this evening hasn't been the best... all geared up for putting the head on complete with turbo and mani and the head would sit right... thought it maybe a trapped pipe or just not on the dowels properly but no... the comp housing was well and truly hitting the transfer box!!

This is where it was 'touching'...

...so drilled around thus...

...and removed using a little assistance...

...still some more to remove...

...and some more...

I am going to sort all that out tomorrow, I also noticed I managed to cut through the oil level sensor wiring while removing the old turbo bracket with a disc cutter (DOH!!) and that our lovely oil drain needs modding to fit (again) and the water pipe from the turbo to the block will foul the driveshaft!!!

Left the workshop tonight feeling very sorry for myself as both Bill and I were told this kit would fit a quattro tranverse engined car.... not without some Badger 5 magic I think... and a hammer

Ah well... more next time... and hopefully the head will be on...

<tuffty/>