As far as all questions, I will post as things happen, there are tons of parts involved and I will post all as they go on the car.
As for time table, you should see this build end Late OCT.
So let's start with the engine components.
Basically, the stage 4 kit is a hybrid of the Stage 3 BT kit and a completely built engine.
it is not a "KIT" and it is done on a case to case basis and it is not identical between builds.
The basis for the engine mods are APR motorsport engines and their experience with different changes at the track, modified to accommodate the larger turbo in this kit.
AFAIK I am only the third client that APR is building the stage 4 for and I have also requested some changes from previous builds.
So let's go over the main component, I'm doing this from my knowledge and might miss some points, I am sure APR will be glad to clarify if I did.
• Basic Stage 3 Kit -
the base for this entire build is the standard stage 3 kit . in terms of turbo and surrounding accessories there is no change at all , the difference lies in the built engine and custom software
• Ported and blueprinted head -
both the head and the block are being X-rayed and scanned for any defects.
the head then is blueprinted and go through a 5 way porting process according to CAD files that are based on the motorsport engines.
I don't have exact flow numbers and not sure if APR are willing to share but there is a massive increase in flow through both intake and exhaust ports.
pics will be available later on.
• Ferrera Valve Train -
This is new and has not been done to in previous builds and is being done according to my request , just for the extra strength .
this is a complete kit and should hold much higher revs than the stock valves. Although our engines are limited by other factors such as the HPFP.
• Schrick Camshafts -
Those camshafts were discussed a lot in the forums but rarely used since there is no software on the market apart from APR stage 4 that makes use of the higher lift and duration.
those are a pain to get hold of since they were of limited production and didn't sell well and so not massively produced.
• Dynamically balanced Crank -
The crank is being dynamically balanced (while rolling at high RPM) with the entire moving mass of the engine.
This also includes the clutch Flywheel which is also being modded to fit the rest of the engine's moving mass.
• EGR Delete -
The EGR is one of the largest points of flow interruption and failure in highly tuned FSI's and therefore it is being completely shaven off of the car and the software is being adapted to run without the EGR.
• Rods and Pistons -
the block is being bored slightly to 83mm and a set of JE pistons with IE rods is being installed.
Compression ratio is dropped only slightly (compared to my stock 9.8:1) to 9.5:1
Those are the main things happening in the engine build. There are of-course tons of other misc items around those main parts.
current status is that the engine is already built and I am waiting for some pics to post from Arin@APR (btw : thanks for the amazing pics so far) , which will probably happen once H2O is finished.
