Audi S3 GT3582R stroker Build (previously GT3071r)

[tufftybloke]

I ran a 75mm (R32) TB for a while and had mild issues but... it was the same issues I had on the 60mm TB at the time only less so and this was really just down to the map...

I would be tempted to see what a 70mm TB would do but have been hunting around for one without much luck... I know where I 'could' get one from but that won't happen for too many reasons...

I don't know why so many people complain about the R32 TB as mine idle sweet as a nut and would drive (when the map wasn't saying no..) perfectly...

The problem I thought I had with the R32 TB (and subsequently on the 60mm TB) went away when I started the map from scratch...

<tuffty/>

 

[tufftybloke]

Got around to fitting the TIP and S4 MAF today...

Had to do a pikey bodge to get a filter on but at least I know it will go...

The ring I had made up for the filter side of the S4 MAF will need to be 100mm not 90mm like I had before... this will allow me to use a 100mm joiner (like I have done with the 90mm one) and fabricate a suitable 100mm joiner to go into the filter... I can then mod the airbox and fabricate the support brackets to keep it all nice and tidy...

The S4 scaling was added to the map and flashed in... all I can say is she feels really different... just wants to rev and pull even at a lowly 15psi!...

Hope to get her on the dyno over the next few days to check everything out... and maybe add boost ;P

<tuffty/>

 

[Dan1720v]

Watching Bill work makes me moist.

Stunning detail as usual Tuffty, I'll be in the queue for one of those manifolds

 

[tufftybloke]

Thanks for all the kind words guys...

Grabbed a bit of time this afternoon to sort out the pikey bodge to secure the filter... George the super hero to the rescue yet again machining me up a 100mm OD adaptor ring for the MAF tube so I could use 100mm from the MAF to the filter...

...then fab'd up a suitable bend in 100mm alloy to join the filter to the MAF

...after painting it (of course ) I set about modifying the airbox so the filter would fit...

...modded the cover a little...

...and of course with all the covers fitted...

...and to prove its actually there...

Got a couple of support brackets to make and check some clearances to prevent rubbing etc but thats more or less it bar WMI fitting (test fitted a tank and thats goes in ok)... all I need now is more boosts!!

<tuffty/>

 

[tufftybloke]

Big thank you to Bill for taking the time to dyno my car today... I pretty much left him to the map changes and stuff today as he has far more experience with it than me so I built engines and kept an eye on stuff letting him work his magic...

Fuelling needed a little fine tuning as he boost levels rose which I expected anyway... however... my car being my car she did put up a fight... this time the Tial wastegate springs... first runs would net higher boost than subsequent ones as the Tial got hot... guess its altering the springs tension when hot and is highlighted more as we are running open loop boost control... ah well... at least it gives me something else to do lol...

Anyhoo... scores on the doors...

A bit more fine tuning to do of course and I need to find a solution to the boost issue... have a few ideas so will see how that goes...

<tuffty/>

 

[wild willy]

Well done mate, Bills done you proud. Nice curves. Thats an easy 400 bhp.
What boost are you running. The issue with the boost altering due to the spring temp is tricky.

 

[m0rk]

To put it in perspective, you should plot the standard 150bhp output below it

 

[tufftybloke]

Well done mate, Bills done you proud. Nice curves. Thats an easy 400 bhp.
What boost are you running. The issue with the boost altering due to the spring temp is tricky.

26psi... plan will be to stabilise the boost first so it does what its told then will look to taper the boost up a tad at the end... depends on how hot things get and what the EGTs are doing... there is a little more in her yet I reckon so this could end up a bit higher and not running WMI yet

To put it in perspective, you should plot the standard 150bhp output below it

I think I can find a dyno run of a std S3 somewhere... Bill has done a couple of stage 1's on them... I'll dig one out..

<tuffty/>

 

[tufftybloke]

As an interesting comparison... the power curves from mine (GT3071, log manifold), Welly's (FP green, tubular race manifold) and a stage 1 S3 (custom code)...

<tuffty/>

 

[tufftybloke]

I think I found the boost issue... I forgot that I have had the banjo air fitting on the Tial come loose a few times in the past... didn't much of it at the time but check it lunch time and it was loose... again!... so tightened it up for the drive home (will make it more permanent later) and it appears to be holding consistent boost of around 1.7/1.8 bar (didn't look too much as the roads had those annoying 'other' motorists on it!!)... might try and grab a video of the boost gauge tomorrow if I can get the phone secured ok on the window...

Unfortunately the roads have other issues besides people who think they have to be using it at the same time as me... potholes! and I managed to clip one with a fairly healthy jolt...

Tyre looks ok, wheel 'looks' ok but the steering feels dead so its definitely knocked something out... typical... as seems to be the way, just as you solve one issue another one takes its place... so will check the tracking when I get over to Bills and tweak accordingly... its the near side wheel that took the hit so should be a case of half a turn and all good again else its back over to Chris Mullins in Glos for a laser alignment... bugger..

Liquid was showing healthy airflow (assuming I have the scaling right which I believe it is) and tried the 'power gauge' for a giggle..

Whilst I think its a little optimistic its good pub ammo ;P

Gonna log a few things tomorrow as now I have boost again I need to check timing etc...

As I may have mentioned before... its never really finished...

<tuffty/>

 

[tufftybloke]

Did a quick video pulling out from a junction on the way to work this morning... more to see if boost was holding as the roads were too busy to watch the gauge and the road at the same time...

http://youtu.be/4njTLkNE9oQ

Will have to do some more vids I think... seems to hold boost well to the redline so happy with that

<tuffty/>

 

[Gulfstream]

<tuffty/>

Me got warm and fluffy feelings for your top end power. You got cams yet?


Much much better over 6k than my motor..... hmmm

 

[tufftybloke]

Me got warm and fluffy feelings for your top end power. You got cams yet?


Much much better over 6k than my motor..... hmmm

No cams... not yet at least... just glad to have got it this far

<tuffty/>

 

[tufftybloke]

While I know there is a little more to come power wise with fine tuning, WMI etc I did sort out a power graph showing a completely std S3's power compared to where she is now with a GT3071...

<tuffty/>

 

[Gulfstream]

Would you mind sharing your timing, AFR and coil dwell numbers as I must be doing something wrong. Look how much I loose over 6000rpms:

 

[tufftybloke]

AFR is 12.5 (0.85) when on boost... timing wise I just added a few degrees at a time through unisettings and logged... if it took it then I added it across the board until pull occurred then pulled it back as required at the rpms the pull occurred..

tbh... your graph looks flow/boost related... would need to see plots of boost and logs of airflow...

<tuffty/>

 

[Gulfstream]

ok, and your coil dwell Is prolly unknown. Well, not two setups are the same. You see I added some coil dwell and I suspect it killed top end. My boost level remains steady at 20psi until I let go of gas. E85.

Cool, Ill still sneak around and see what youre up to here

 

[tufftybloke]

Minor update... got a little pressie from great mate Mark at ADI... dipstick tube bracket for an AEB A4... doesn't sound like much but its ideal for my inlet manifold..

This fits to the centre fixing bolts of the inlet manifold and holds the dipstick tube between runners 2 and 3... had to mod it a little to fit right as my runners are a little shorter due to the fabrication but bit of paint and all sorted...

Here it is on an AEB...

...and on mine...

Car is driving nicely but map still in need of tweaking as its got more to give and I want to smooth off some of the little rough edges (OCD++)

<tuffty/>

 

[anthony37]

excellent build!!! Well done, clean and very detailed!!

 

[ReDBull]

That was an enjoyable read and a very nice car! Like it's been said love your attention to detail and how you've managed to keep it looking standard ish under the bonnet (at least untill you fitted that wacking great inlet manifold!). I wish I'd of bought a S3 now!
I'm thinking of relocating my battery to the boot also. Is there a reason why you didn't fit a inline fuse in the boot near the battery? Are they not needed or can you not get a fuse big enough? Looking forward to seeing what you've got planned next!