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Audi S3 GT3582R stroker Build (previously GT3071r)
- Thread starter tufftybloke
- Start date
After a ropey start this morning driving the wifes car to the unit to do a mini service and change her fan belt (that decided to self destruct on me a mile from Bills!!!) I got the manifold painted in the same 5 wheel silver I have used for the cam cover and charge pipe...
Managed to get a couple of runs in the lacquer but I'll flat them down when its had a good chance to dry and polish them out...
Happy with the results... will do the revised charge pipe work next Friday when I am off and just waiting on some taps to do the vac outlets and then hopefully will be fitting it the following week as I have taken time off work...
<tuffty/>
Managed to get a couple of runs in the lacquer but I'll flat them down when its had a good chance to dry and polish them out...
Happy with the results... will do the revised charge pipe work next Friday when I am off and just waiting on some taps to do the vac outlets and then hopefully will be fitting it the following week as I have taken time off work...
<tuffty/>
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thats too Good.
Now to the most important thing, whats it going too add to the install power wise.
I notice in the above logs your map is requesting an AFR of 0.84..... mine is 0.81 what do you generally regard as the best compromise of requested AFR.
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Thanks dude
Now to the most important thing, whats it going too add to the install power wise.
I notice in the above logs your map is requesting an AFR of 0.84..... mine is 0.81 what do you generally regard as the best compromise of requested AFR.
I have tuned my primary fuelling to hit AFR 12.5 under boost, I have of course tuned the protection table (KFLBTS) for when things get too hot etc to run richer...
The map I have in currently is still work in progress... I have run a version with more boost but that went off MAF scale and fuelling control became an issue as there are other maps that need playing with to bring that inline if required but seeing as I am going to use the S4 MAF tube and fitting this inlet manifold I am running on actuator pressure for the time being and will sort it all out properly on the dyno once all the hardware is done...
If EGTs start to become an issue as I turn up the boost then I will play with the tables that handle that so it enrichens sooner but I am happy with the way it is currently and gives me safe and economic fuelling for normal use and extra for protection when required... currently my EGTs never go much about 700 degrees (750-800 deg in K04 terms) at the 15psi I am running at the moment so I have some head room currently..
<tuffty/>
Forgot to answer your first question...
In terms of power increases than I am not sure yet... my car has not made much above 370hp in previous configurations and I haven't dyno her properly on the current setup since I changed to the T3 hotside and went external gate...
Differences this time around from previous setups is the 60mm turbine (from the original 56.5mm one), T3 hotside (from T25), external gate, large port/large plenum inlet manifold, larger FMIC and 63mm pipe work all round except for the S3 top charge pipe, S4 MAF tube and 90mm TIP (S3 MAF and 76mm TIP previously)... overall it should flow better, have less pressure drop and produce more power on less boost...
The target is to see over 400hp... I would like to get at least 420hp so I can say I have doubled the factory power but as long as its over 400hp then all is good... I am sure if I crank the boost to silly levels it will do this easily but I would rather get 420hp at 24psi than 440hp at 28psi
<tuffty/>
In terms of power increases than I am not sure yet... my car has not made much above 370hp in previous configurations and I haven't dyno her properly on the current setup since I changed to the T3 hotside and went external gate...
Differences this time around from previous setups is the 60mm turbine (from the original 56.5mm one), T3 hotside (from T25), external gate, large port/large plenum inlet manifold, larger FMIC and 63mm pipe work all round except for the S3 top charge pipe, S4 MAF tube and 90mm TIP (S3 MAF and 76mm TIP previously)... overall it should flow better, have less pressure drop and produce more power on less boost...
The target is to see over 400hp... I would like to get at least 420hp so I can say I have doubled the factory power but as long as its over 400hp then all is good... I am sure if I crank the boost to silly levels it will do this easily but I would rather get 420hp at 24psi than 440hp at 28psi
<tuffty/>
jesting aside, lovely looking work
We saw lots of benefit changing from t25 housing/wheel on the 3071R to the proper t3 housing and 60mm wheel. More power at less boost and lower EGTs , we should have done it much earlier! You should be on for 420bhp with relative ease I'd have thought?
We saw lots of benefit changing from t25 housing/wheel on the 3071R to the proper t3 housing and 60mm wheel. More power at less boost and lower EGTs , we should have done it much earlier! You should be on for 420bhp with relative ease I'd have thought?
Busy day doing stuff.... test fitted the inlet manifold so I could fabricate the pipework.... the std small port inlet looks a little underwhelming next to the new one ;P
New inlet on....
Fiddled about with the pipes and stuff using welding tape (tm)
...and the outlet for the DV...
...and of course bead rolled the ends
...I really could do with learning to TIG but for now its ready for the big man to sort out when he gets 5 mins..
While the bumper was off I decided to stealth up the FMIC as I had been meaning to do it for a while but not got around to it...
....much better...
...and of course I had to take a pic of the engine bay assembled before putting it back as it was with the (rather pathetic looking) std inlet..
I have the NPT taps now to do the vacuum fittings... tomorrows job..
<tuffty/>
New inlet on....
Fiddled about with the pipes and stuff using welding tape (tm)
...and the outlet for the DV...
...and of course bead rolled the ends
...I really could do with learning to TIG but for now its ready for the big man to sort out when he gets 5 mins..
While the bumper was off I decided to stealth up the FMIC as I had been meaning to do it for a while but not got around to it...
....much better...
...and of course I had to take a pic of the engine bay assembled before putting it back as it was with the (rather pathetic looking) std inlet..
I have the NPT taps now to do the vacuum fittings... tomorrows job..
<tuffty/>
I would like to start by saying.... Bill you are a f*cking legend!!!!!!!... he got back from holiday today and was straight on welding my charge pipe up...
...et voila!...
...so of course I painted it
Got the vac points drilled, tapped and fitted too...
Soooooo..... nowt much left to do now but dyno, fit it and dyno again
<tuffty/>
...et voila!...
...so of course I painted it
Got the vac points drilled, tapped and fitted too...
Soooooo..... nowt much left to do now but dyno, fit it and dyno again
<tuffty/>
Lovely looking manifold / engine bay... Well everything, as m0rk says excellent attention to detail. 
That looks better than new tuffty a real work of art... I'm sure the effort will be worth while not just in cosmetic upgrade but power too. Nice welding Bill very neat. Is there nothing that can't be made at Badger 5. Well done both.
I'm sure the effort will be worth while not just in cosmetic upgrade but power too. Nice welding Bill very neat. Is there nothing that can't be made at Badger 5. Well done both.
Lovely looking manifold / engine bay... Well everything, as m0rk says excellent attention to detail.
That looks better than new tuffty a real work of art...
Thanks guys... my OCD is on overdrive at the moment ;P
<tuffty/>
So today was essentially dyno car with std inlet, fit large inlet, dyno car again...
Car on dyno... ran the car up on the std inlet... I am running on just actuator pressure at the moment until I have the S4 MAF and 90mm TIP in place as I don't want to be buggering around chasing my tail on the mapping until all the changes I know I am going to make are done...
First run had some boost creep for whatever reason and made 310hp @ 17/18psi peak... subsequent runs were 15psi consistently so maybe the Tial needed some heat in it to get it working right... second run netted just over 280hp... the EGT's were low 700's only spiking at 750 on lift off (no flow through the engine to cool)... that was at a steady 15psi..
Then fitted the manifold.... cover off...
Cover on...
Results were impressive...
17ish hp gain just by bolting on the fabricated inlet... was happy with that...
Clearly the map needs tweaking but then this is the first time the car has been on the dyno with any of my maps on so overall very happy with the result considering its been tweaked from road logging etc..
Fuelling is going into component protection (KFLBTS) as I have the EGT trigger set quite low... logging EGTs showed this can be upped a tad so will sort that later... it going rich cost me a bit of power top end too so if AFR had carried on rather than get rich then it could have made another 5-10hp based on what I normally see on the dyno
Overall really happy with the result, happy with the map and looking forward to getting the S4 MAF and 90mm TIP sorted hopefully next week..
<tuffty/>
Car on dyno... ran the car up on the std inlet... I am running on just actuator pressure at the moment until I have the S4 MAF and 90mm TIP in place as I don't want to be buggering around chasing my tail on the mapping until all the changes I know I am going to make are done...
First run had some boost creep for whatever reason and made 310hp @ 17/18psi peak... subsequent runs were 15psi consistently so maybe the Tial needed some heat in it to get it working right... second run netted just over 280hp... the EGT's were low 700's only spiking at 750 on lift off (no flow through the engine to cool)... that was at a steady 15psi..
Then fitted the manifold.... cover off...
Cover on...
Results were impressive...
17ish hp gain just by bolting on the fabricated inlet... was happy with that...
Clearly the map needs tweaking but then this is the first time the car has been on the dyno with any of my maps on so overall very happy with the result considering its been tweaked from road logging etc..
Fuelling is going into component protection (KFLBTS) as I have the EGT trigger set quite low... logging EGTs showed this can be upped a tad so will sort that later... it going rich cost me a bit of power top end too so if AFR had carried on rather than get rich then it could have made another 5-10hp based on what I normally see on the dyno
Overall really happy with the result, happy with the map and looking forward to getting the S4 MAF and 90mm TIP sorted hopefully next week..
<tuffty/>
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Worked on the TIP today... took the current 76mm OD one off (yes, its smaller than Bills K04 TIP's!!) so I could use it as a kind of template for the new 90mm OD one...
After some faffing about I cut up the 90mm bend hoping that what I had in my mind is how it might turn up... thankfully it did
Using the power of welding tape and a bit of trimming of the hoses and pipes I ended up with...
..which fits nicely...
So then had to think about how the filter would attach... still looking at filter options.. a 90mm necked version of what I have would be ideal but they don't do one
All the was left was the DV inlet....
Should be getting welded up at some point this week and I am waiting on some adaptor rings that will take the 85mm OD of the S4 MAF to 90mm...
The end is in sight
(although it never really is the end is it ;P)
<tuffty/>
After some faffing about I cut up the 90mm bend hoping that what I had in my mind is how it might turn up... thankfully it did
Using the power of welding tape and a bit of trimming of the hoses and pipes I ended up with...
..which fits nicely...
So then had to think about how the filter would attach... still looking at filter options.. a 90mm necked version of what I have would be ideal but they don't do one
All the was left was the DV inlet....
Should be getting welded up at some point this week and I am waiting on some adaptor rings that will take the 85mm OD of the S4 MAF to 90mm...
The end is in sight
(although it never really is the end is it ;P)
<tuffty/>
Yay!... TIP is now done... big thanks to George (again!) who came up trumps with the adaptor rings for the S4 MAF to take its OD to 90mm.. interference fit with a bit of sealant for good measure...
Gas arrived too so Bill kindly welded up the alloy parts of the TIP and of course I painted it satin black... was toying with filter selections also... Bill has a few filters in stock so looked at using one of those...
The Green is out purely as its 80mm neck ;P.... the K&N is a possibility as this filter can be used with a velocity stack which I can get in 89mm... the JR is long... it won't fit in the airbox... but its 100mm do can be made to fit my setup and as I like a challenge... I choose...
Watch this space... it could be an epic fail lol...
<tuffty/>
Gas arrived too so Bill kindly welded up the alloy parts of the TIP and of course I painted it satin black... was toying with filter selections also... Bill has a few filters in stock so looked at using one of those...
The Green is out purely as its 80mm neck ;P.... the K&N is a possibility as this filter can be used with a velocity stack which I can get in 89mm... the JR is long... it won't fit in the airbox... but its 100mm do can be made to fit my setup and as I like a challenge... I choose...
Watch this space... it could be an epic fail lol...
<tuffty/>
Your RR power upgrade is excellent especially considering such low boost. Its going to be worth its weight in gold at normal boost levels. I would like one of these in my life, are they economically viable for Badger5 to produce compared to the new kids on the block (IE and 034).
Your Tip looks great and coupled with your maff will bring the goods for sure. The question is not case of if it can make a reliable 400bhp i thnk its more a case of how much over.
But... Naughty boy wheres the meth install.
Your Tip looks great and coupled with your maff will bring the goods for sure. The question is not case of if it can make a reliable 400bhp i thnk its more a case of how much over.
But... Naughty boy wheres the meth install.
Your RR power upgrade is excellent especially considering such low boost. Its going to be worth its weight in gold at normal boost levels. I would like one of these in my life, are they economically viable for Badger5 to produce compared to the new kids on the block (IE and 034).
Your Tip looks great and coupled with your maff will bring the goods for sure. The question is not case of if it can make a reliable 400bhp i thnk its more a case of how much over.
But... Naughty boy wheres the meth install.
Funny you should mention it... Bill is looking into making a few of these inlets... they will not be 'finished' like mine as that was all me... details to follow in Bills section no doubt..
Meth install will come later... I don't need it as badly as you K04 boys ;P... once the filter is done then I will know how much room I have left for the WMI bottle etc and will be going in as and when... with the cooler weather its less of an issue... intake temps and EGTs are low enough and I am not tuning for meth... the setup I have should do over 400hp on its own... meth will be used to keep IAT's low when M3's try their luck ;P
<tuffty/>
The Badger5 intake manifolds are the natural progression for you guys and i look forward with interest.
I just realised that your RR result above is with a stock throttle body which shows the true gains of the manifold on its own as i'm sure a larger TB will add to the gain. I know we've discussed this before but did you compromise driveability with the larger 75mm TB you tried in the past. When i ran a SEM on a 80mm Hemi TB my APR software didn't like it and it was temprimental to say the least. Would you be confident of being able to map your car to the same level of driving refinement with a 75mm TB say incomparison to the stock throttle body. It would be great to see how your car was to run on say a 70mm TB with your new mani..... a 65mm VR6 TB would be a good test too.
I just realised that your RR result above is with a stock throttle body which shows the true gains of the manifold on its own as i'm sure a larger TB will add to the gain. I know we've discussed this before but did you compromise driveability with the larger 75mm TB you tried in the past. When i ran a SEM on a 80mm Hemi TB my APR software didn't like it and it was temprimental to say the least. Would you be confident of being able to map your car to the same level of driving refinement with a 75mm TB say incomparison to the stock throttle body. It would be great to see how your car was to run on say a 70mm TB with your new mani..... a 65mm VR6 TB would be a good test too.
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