New Piston for 1.8T

[bobqzzi]

ok im confused now jabba have told me that the BAM(and late AMK) have 19mm

Okay..now I'm confused too!!!! Jabba is a pretty darn reliable source. I'll investigate

 

[Yumann]

According to mahle the amk and bam engines all have 20mm wrist pins.

 

[Mitchy]

sorry but now i have a little lapsus !!! i'm italian and now i don't know what are the rods!!

The pistons connect to the rods which connect to the crankshaft, which goes out into your gearbox through a flywheel/clutch and out to the driven wheels Pistons are inside a sealed cylinder which open and close by cams activating valves for induction/exhaust. The camshaft is sync'd with the crankshaft so all the timing is correct hence the timing belt.

Just a quick overview on how the internals make up the engine incase you were unaware

 

[LCR mat]

According to mahle the amk and bam engines all have 20mm wrist pins.

thats the bit between the crank and rod right?
I think its another part which is 19mm not the wrist pins.

 

[wild willy]

thats the bit between the crank and rod right?
I think its another part which is 19mm not the wrist pins.

Is the gudgeon pin 19mm which secures the piston to the conrod?.

 

[LCR mat]

thats the word I was lookin for gudgen........ gudge.... oh what he said

 

[Fl@pper]

they do ali I beam rods that you know of ?

and steel crank if possible

 

[bob corb]

Hi chaps, I've just joined. I was predominatly interested in Audi tuning but I already knew of this forum via another member and came for a look.

I was speaking to Bernard Scouse (Ibiza Sport Man?) today about these pistons. (I work for a MAHLE subsidiary but thats not why why we talking).

I had a look in the corporate database (which you can download from the website). Basically the <180PS engines have 19mm gudgeon pins and the 210/225/240 PS engines have 20mm pins and 9.01:1 compression. These are all stock MAHLE parts available via normal outlets. The forged motorsport piston is a US part and gives a compression ratio of 8.5:1, I was told it weighs 298grams but I dont know if that includes pins & rings.

I bought a set just because I could but now I need to find a Lotus Elise and a BAM engine, IHI VF34 turbo.... It could be along wait... In hindsight I'm thinking 350PS in an Elise might be a bit mental...

 

[bob corb]

Sorry I didn't realise this was such an old thread, has anyone fitted these pistons yet?

 

[ibizacupra]

Hi chaps, I've just joined. I was predominatly interested in Audi tuning but I already knew of this forum via another member and came for a look.

I was speaking to Bernard Scouse (Ibiza Sport Man?) today about these pistons. (I work for a MAHLE subsidiary but thats not why why we talking).

I had a look in the corporate database (which you can download from the website). Basically the <180PS engines have 19mm gudgeon pins and the 210/225/240 PS engines have 20mm pins and 9.01:1 compression. These are all stock MAHLE parts available via normal outlets. The forged motorsport piston is a US part and gives a compression ratio of 8.5:1, I was told it weighs 298grams but I dont know if that includes pins & rings.

I bought a set just because I could but now I need to find a Lotus Elise and a BAM engine, IHI VF34 turbo.... It could be along wait... In hindsight I'm thinking 350PS in an Elise might be a bit mental...

350ps is mental but fun
and in an Elise... wayhayyyy

So are these MAHLE pistons still available then? 9:1 20mm pins std bore?

 

[bob corb]

The 9.0:1 pistons from the std 225 BAM engine with 20mm pins are still in production but MAHLE UK dont have any in stock until the next batch comes in June I was told. I do know that one of my colleagues bought some oversize ones which were off the shelf, they may still have some.

If a moderator is watching I dont work for MAHLE UK and am speaking as a private individual. Sorry if this offends.

 

[wild willy]

The 9.0:1 pistons from the std 225 BAM engine with 20mm pins are still in production but MAHLE UK dont have any in stock until the next batch comes in June I was told. I do know that one of my colleagues bought some oversize ones which were off the shelf, they may still have some.

If a moderator is watching I dont work for MAHLE UK and am speaking as a private individual. Sorry if this offends.

Can you find out what the max specified BHP the MAHLE rods and pistons are manufactured to in the BAM and AMK engines. to have a difinative answer would be quite helpful.

 

[bob corb]

I'm afraid pistons and rods aren't designed with an absolute maximum power output in mind. Usually what happens is that we run a thermo-mechanical simulation on the piston and con rod separately. This analysis tells us the fatigue life of the component (how it wears out with repeated cycles of millions of firing strokes) and we use that in combination with the required design lifetime of the component to calculate a safety margin.

We will do this calculation using the firing loads equivalent to 225PS and at peak torque also. If you stress the components higher than the standard performance levels then they will wear out faster.

Talking to Bernard and seeing the comments on the VW vortex forums it does appear that the BAM type pistons are well up to handling 350PS for a reasonable amount of time.

Sorry I can be more help. I'll ask one of the analysis guys tomorrow if he's ever repeated such an analysis for a higher power level on the same part so we may be able to come up with a rule of thumb although I dont know what the original design lifetime and design margin was in the first place....

 

[bobqzzi]

I have used the BAM/AMU pistons to make 715hp. when I disassembeld the engine, the pistons looked and measured as new (and these were 30,000 mile used pistones to start).

If these pistons were available for a reasonable price (last I checked they were close to $400US each), there probably woudln't be any reason to buy the motorsport pistons (nice though they are!)

 

[ibizacupra]

are your pistons still available then Bobqzzi?

 

[bobqzzi]

Yes they are. [email protected]

 

[BenS1]

Hi chaps, I've just joined. I was predominatly interested in Audi tuning but I already knew of this forum via another member and came for a look.

I was speaking to Bernard Scouse (Ibiza Sport Man?) today about these pistons. (I work for a MAHLE subsidiary but thats not why why we talking).

I had a look in the corporate database (which you can download from the website). Basically the <180PS engines have 19mm gudgeon pins and the 210/225/240 PS engines have 20mm pins and 9.01:1 compression. These are all stock MAHLE parts available via normal outlets. The forged motorsport piston is a US part and gives a compression ratio of 8.5:1, I was told it weighs 298grams but I dont know if that includes pins & rings.

I bought a set just because I could but now I need to find a Lotus Elise and a BAM engine, IHI VF34 turbo.... It could be along wait... In hindsight I'm thinking 350PS in an Elise might be a bit mental...

Apparently the Mk3 Ibiza (Which I have) has the 20mm pins even though its only 156bhp as standard, whereas the Leon etc have the weaker 18mm pins.

Atleast thats what Jabba told me.

Cheers
Ben

 

[bob corb]

Hi, I've changed my mind for now about the Elise Audi turbo monster...

If anyone reading would like to buy a set of MAHLE Motorsport pistons as discussed here please look here http://www.pistonheads.co.uk/sales/67650.htm. - These are now sold.

Cheers

Bob