JonnyC's Audi S3 Project..

[WhiteGTI]

Great thread so far, looking forward to that day at Santa Pod 

[Phil Mcavity]

Great thread so far, looking forward to that day at Santa Pod 

x2 

[snapey]

Massive respect for the way your dealing with this dude. If you achieve your goal I can't think of many things out there that are going to be able to touch it.

Luke

[Hedge]

Hmm.. Well going to have to see really.. Would love to still make it for the next planned forum meet, early September I think?

Nice one. I guess once its run in then soon after.

Hopefully I shall have some nice glassware pointed in your direction.

[Janner_Sy]

How do you think this will handle on a track day once its done jonny, that going to be a lot of power to rein in on cornering and exit. is it possible to adjust the bias for power a little more to the rear wheels on an S3.

[Hedge]

I think Jonny has already mentioned an uprated Haldex.

[vRStu]

How do you think this will handle on a track day once its done jonny, that going to be a lot of power to rein in on cornering and exit. is it possible to adjust the bias for power a little more to the rear wheels on an S3.

One of these little fella's ought to sort that out -

http://www.hpamotorsports.com/haldex.htm

[jonnyc]

How do you think this will handle on a track day once its done jonny, that going to be a lot of power to rein in on cornering and exit. is it possible to adjust the bias for power a little more to the rear wheels on an S3.

It will be fine, the S3 chassis is very capable, this power should wake it up! Im buying a race haldex controller with switch soon..

Update..

So lots of things are happening pretty quickly now, coming along really well..

First of all this little thing arrived yesterday!! Thanks to Neil and Ollie at THS..



Core is rated to 600hp so should be up to the job!!!

First of all the engine build.. Parts are all here now and the head is all built up. Ported and polished and fitted with the new Supertech parts!

Head back from being skimmed, 30 microns were removed, so not much.. At this point the internals of the head had not had any attention!

Before..





About an 1/8 of an inch of build up!! Crazy really..



After..




Check out the inlet ports!!

Before..



And after, you can see a small difference!!



Everyone that has seen the state of the inside of this engine has been shocked. Its got nothing to do with the piston problem that I had. This is just how the 2.0T FSI runs with the stock PCV system, pretty nasty really!!

More bits, stretch bolts, seals, gaskets etc etc etc.. Now the bottom end is all built up, oil pump is back on, everything cleaned up and a new filter!!






Happy about all of the progress on the engine build! Nothing is being left to chance so everything is being replaced.. Not the cheapest way of doing things but I know for sure that im giving the engine the best chance possible of lasting and being strong enough to cope with the power.

Final spec of the engine is as follows..

* Head skim
* Block re-bore & hone to 83MM
* Integrated engineering non-tapered 2.0T FSI connecting rods
* JE 83MM bore 8.5:1 compression forged pistons
* JE pistons rings
* ARP 2000 rod bolts
* Calico coated rod bearings
* Ported and polished inlet / exhaust head
* Supertech stock size inlet and exhaust inconel valves

Turbo is on its way from the states now.. Should have some pics from BSH and a video of there 450WHP GTI running pretty soon.. Apparently the dump tube sounds incredible!!

[joesgti]

that build up of crud is shocking!!! im doing the quick fix on mine fo sho,

cant afford a catch can atm. 

[Janner_Sy]

is there not some sort of mixture that we can spray into the intake or mix with the fuel, like red ex that would stop that, or at least clean it a little prior to fitting the PCV fix. is this caused by early detonation of the fuel mix, if so would water meth fix that as it prevents early detonation by cooling(if i understood it right)

[jonnyc]

is there not some sort of mixture that we can spray into the intake or mix with the fuel, like red ex that would stop that, or at least clean it a little prior to fitting the PCV fix

Inlet manifold off is quite a job on these cars.. To be honest, if your going to loosen off the muck then it has to be ingested by the engine then spat out of the exhaust. After seeing the bits that were on the valves and inlet of the head I know I wouldn't want it going through my engine..

Only way of doing it properly would be to remove the head and clean everything that way.. Is it worth it? Im honestly not sure, depending on your state of tune maybes not, but for sure these engines are going to be a state with 100k miles on etc..

[DanGB]

why have you chosen 8.5 rather than 9.5 compression ration?

[jonnyc]

why have you chosen 8.5 rather than 9.5 compression ration?

I wanted the option for going to a 35r turbo in the future, it would be a simple bolt on modification if I decided to do it because of the turbo kit that I have chosen.. I only want to build the engine once so I decided to go lower on the compression.. Plus, it will allow me to run a load more boost and timing on pump fuel..

Difference in spool from 9.5:1 to 8.5:1 will only be a few 100 RPM's with the 3076R so its not really going to make a huge impact..

[DanGB]

ok so the 8.5 with increase spool time a bit then over the 9.5's?

[jonnyc]

ok so the 8.5 with increase spool time a bit then over the 9.5's?

Yeah, less cylinder pressure off boost so it will add some time to the spool, the higer you go on compression the more bottom end / faster the spool time but it limits the boost / timing you can run as the cylinder pressures go through the roof.. Bit of a balancing act really, I know 8.5:1 is a little on the low side for the size of turbo that im running for now, but that will all change when I can get fueling sorted for 700+.. Then it will be a GT3582R with Tial exhaust housing.. Laggy as hell, boost comes in at around 5k but it will make some serious power top end..

Power will come in 1k later than the 3076R turbo but I would sort that out by allowing the engine to rev to more like 9k with head work etc.. So the useable power curve would remain at around 4k revs..