Time for a build thread....big turbo

[S3Alex]

I got so much information from Andy that it's taken me a while to put it all together.....

He's a superb guy and his enthusiasm really shines through in the time he takes to explain things.

A few other points came through....yes,it will run over 600bhp currently,but there are a few things in the longer term that would make that power level easier,and with less stress on the engine.

The exhaust manifold and downpipe are fine,but the rest is beginning to restrict things,and would need to go before we could routinely run more.

That in turn would mean being able to run more timing,and get more from the engine again.

 

[S3Alex]

Both Andy and Ryan from Syvecs noted that the engine flows plenty of air,with no obvious limitations there,so that bears out the feelings about the head design being pretty good from the factory.

The car is currently running the extra port injectors,above the point at which the S3 injectors begin to max out,and they're only really at about 40%,so there's a LOT of potential there,but as they said,the mapping on them is quite unusual,as they only come in at high boost,so the flow delivery has to be altered to compensate for the effective back pressure of up to 2 bar.

The Autotech HPFP looks fine,but the factory LPFP clearly needs the USP auxiliary pump to cope with the fuelling demands.


I don't have any data from today yet,but this printout from the 3076 shows a few things.....



Firstly,everything begins at around 4000rpm,and is pretty much over by 6500rpm,with the torque really rolling off after that.

By 7000rpm,the 3076 really has had enough,and torque is down to under 300lbs,whereas the 3582 is still pulling somewhat over 400lbs at peak rpm.

 

[COSTA_P]

that is impressive. what sort of bore would you have to go on the exhaust side of things? straight through 3.5"?

 

[S3Alex]

that is impressive. what sort of bore would you have to go on the exhaust side of things? straight through 3.5"?

I've used a sort of straight thru before and God was it loud.
The neighbours actually complained.

So what Storm suggested was contacting BCS to see what they can offer in terms of a switchable system with the back box in place for most of the time and out of circuit for higher power.

I'm waiting to see what they say.

For the moment running 550bhp but with over 100lbs more torque is a good result and I'd take 100lbs over 100bhp any day.

It also gives me time to get used to the Syvecs and touchscreen display.

 

[COSTA_P]

torque, talks. The pace that thing will go round some twisties will be mind blowing!

 

[S3Alex]

torque, talks. The pace that thing will go round some twisties will be mind blowing!

Both said that on boost its fast.

Also needs the suspension tweaking.

 

[superkarl]

Try and get dyno printouts without AMDs stupid smoothing of the plots. I hate that lol.
This is great news for you, congrats on pushing the boundaries once more.
Amazing the gains up top considering you scrapped the cams and stuck with stock

 

[Sayam]

Amazing thread to read as always

What about when you're off the turbo though? 0-4000rpm with little/no boost is a fair Rev range.... 4000 - 7500 means you have the same power band as a Diesel engine (2000-4500 ish)

And that's a genuine question, I re-read my post and it sounds c11ntish but isn't meant to be at all.

 

[S3Alex]

Amazing thread to read as always

What about when you're off the turbo though? 0-4000rpm with little/no boost is a fair Rev range.... 4000 - 7500 means you have the same power band as a Diesel engine (2000-4500 ish)

And that's a genuine question, I re-read my post and it sounds c11ntish but isn't meant to be at all.

No it doesn't at all.

It drives well enough as before and from what Andy described it's as easy to drive as it was.

With the 3076 it pulled well enough off boost but the push in boost was something else....now it sounds like the boost comes in at the same point but much harder.

 

[S3Alex]

Try and get dyno printouts without AMDs stupid smoothing of the plots. I hate that lol.
This is great news for you, congrats on pushing the boundaries once more.
Amazing the gains up top considering you scrapped the cams and stuck with stock

The plots etc from Storm should arrive tomorrow with some pics.

The gains aren't just from the much bigger turbo and better exhaust but also fuelling control and cam timing that the Syvecs can alter.

 

[S3Alex]

Try and get dyno printouts without AMDs stupid smoothing of the plots. I hate that lol.
This is great news for you, congrats on pushing the boundaries once more.
Amazing the gains up top considering you scrapped the cams and stuck with stock

You're up as late as I am....

On waking up again I knew there was something else....the cams I tried basically caused serious timing issues,and caused knock even with the ignition wound right back,so with no way then of dealing with dynamic cam timing,we just couldn't use them.

Of course at the time,I didn't even know Syvecs existed,and we would likely have the solution to that issue now.

The more I think back to the chat last night ,the more I'm amazed by the versatility of the Syvecs ECU,and aside from the exhaust pipework,there is another project that Storm would be able to provide via the new ECU.....a DSG box.

 

[Sayam]

a DSG box.

Do it!

 

[S3Alex]

Couple of piccies....

Inside first...




And under the hood...

 

[COSTA_P]

i just got told off for looking at porn on work computer

 

[S3Alex]

i just got told off for looking at porn on work computer

Yes...but it's the best kind.

Multi stage ALS and TC

 

[COSTA_P]

Are you thinking of putting the cams again now youve got the syvecs ecu? id imagine its capable of timing in with all the advances over the standard computer.

 

[S3Alex]

Are you thinking of putting the cams again now youve got the syvecs ecu? id imagine its capable of timing in with all the advances over the standard computer.

Not for a while,if at all.

I want to get used to what's just been done,and get a feel for the Toucan controller etc first.

Then it's the exhaust,then who knows,maybe DSG.

 

[Sayam]

How about a TTRS FBMFSW once the DSG has gone in..paddles mmmm lol

 

[S3Alex]

And it makes a noise now.....

 

[Alex_Wil]

This face pretty much sums up what mine was like listening to that !! great work Alex!

 

[Alex_Wil]

where is the flat bottom steering wheel as well

 

[S3Alex]

This face pretty much sums up what mine was like listening to that !! great work Alex!

You know how I feel about the car going on the dyno.

It's the sound of impending doom....

Anyhow,to my ears it's never sounded better on that,and it doesn't smoke any more.


Actually on second thoughts this is sounding good....

It's lost weight,stopped smoking,and gained strength.

 

[Dean_T]

It's alive!!!!!

 

[S3Alex]

It's alive!!!!!

Its alive and it's come home after a 2 month holiday......

 

[S3Alex]

 

[Sayam]

What are the specs of your wheels buddy? In terms of size, width and offset please?

 

[S3Alex]

What are the specs of your wheels buddy? In terms of size, width and offset please?

Offset I really don't know,but AMDTuning might,if they still have the details.

They're Team Dynamics 1.2s

245 x 40 x 18.

Drove it for the first time in 2 months today.

Sounds very different to before.....much deeper engine note and very sharp throttle response.
Idles from cold at 1500rpm(way higher than before)
Runs much smoother from cold(previously ran like a bag of nails until it hit 85c)
But.....got my first engine trip as well which I think was a temperature protection trip to stop me doing daft things before the engine is fully warm.

 

[S3Alex]

One thing I must say before dribbling on any further...

The help,support,and time invested by the following people really are worthy of thanks...

Andy and Alex at Storm Developments(Andy especially for being available all weekend if I have any problems)

Ryan at Syvecs for taking the time to talk me through the likely issues today.

Tim at JT Innovations(the manufacturers of the Toucan touchscreen interface for the Syvecs)

OK.....that aside,as I said,the car threw up an error code and went into a limp mode on the way in to work,which was my first drive.

I noted the fuel level was a bit low when I started it up,but was sure there was enough to run down to the local Shell garage,but the pump(s) were a bit louder than I had ever noticed before.

Drove a few miles and up came the error,with the engine limited to 3000rpm,so got to the garage,filled up and away went the code.

It translates to a very lean lambda,and the pump noise was the pumps cavitating and likely pulling some air into the fuel line,so it protected itself.

 

[Sayam]

Offset I really don't know,but AMDTuning might,if they still have the details.

They're Team Dynamics 1.2s

245 x 40 x 18.

Drove it for the first time in 2 months today.

Sounds very different to before.....much deeper engine note and very sharp throttle response.
Idles from cold at 1500rpm(way higher than before)
Runs much smoother from cold(previously ran like a bag of nails until it hit 85c)
But.....got my first engine trip as well which I think was a temperature protection trip to stop me doing daft things before the engine is fully warm.

Damn, the offset is the bit I really wanted! Never mind lol...I'm trying to calculate what offset I need to use 235/40/18 on the front of my car rather than 225/40/18...

That aside, congrats on getting the car back and going for your first drive!

 

[S3Alex]

Damn, the offset is the bit I really wanted! Never mind lol...I'm trying to calculate what offset I need to use 235/40/18 on the front of my car rather than 225/40/18...

That aside, congrats on getting the car back and going for your first drive!

Sorry!.....it's something that I've never quite got the grasp of,,and always leave to someone who does know.

I am so pleased to have the thing back on the road,and I need to get some miles under it before we make any changes to the software.

 

[Sayam]

Sorry!.....it's something that I've never quite got the grasp of,,and always leave to someone who does know.

I am so pleased to have the thing back on the road,and I need to get some miles under it before we make any changes to the software.

Don't be silly, no need to apologise!

So to summarise - all the major hardware work is done and now you're beginning the process of bedding in/tuning/tweaking settings to get them how you want?

PS white is the best colour!

 

[S3Alex]

Don't be silly, no need to apologise!

So to summarise - all the major hardware work is done and now you're beginning the process of bedding in/tuning/tweaking settings to get them how you want?

PS white is the best colour!

Totally agree...colour wise,white is the new black,or soon to be the old black...LOL
Good until you need to wash it.

The hardware for now is done.....
But I do have a list:

1.New exhaust,as the current one is holding things back
2.Likely DSG conversion
3.....leave that vacant for now.

Software is running,and seems on a very quick look to be exactly what I wanted.

Switchable,very mild ALS,although it does already seem to spool better anyway.
Staged TC
Launch control
Super quick throttle response.

 

[Alex_Wil]

2.Likely DSG conversion

I KNEW IT

 

[S3Alex]

I KNEW IT

Well...maybe I'll give in to temptation,but at least it will be easier than the journey Decked had.

I need some time to get used to all the functions and settings this thing has....it's worse than some of the things I use at work.

 

[Mario8P]

Well...maybe I'll give in to temptation,but at least it will be easier than the journey Decked had.

I need some time to get used to all the functions and settings this thing has....it's worse than some of the things I use at work.

How sexy it would be fitting a Dodson clutch packs into a DSG transmission

 

[S3Alex]

How sexy it would be fitting a Dodson clutch packs into a DSG transmission

I think this is what Decked is looking at,and I know Stattlers have been as well.

In the longer term,this is a good plan for me to look at,as it will minimise shift times,and so cut down on gear-to-gear lag by keeping the engine right on the boost.

I need to drive this for a bit,but my initial impressions were that although Andy said it was pretty laggy,to me,it was significantly less laggy than with the non M-Spec 3076,and I'm sure the throttle sensitivity may help,along with the obvious help from a less restrictive exhaust manifold.

BCS have quoted me for a system running from the end of Nortech's downpipe,to the rear,with a 90mm diameter pipe and a huge FIA race rated cat,with the same open area as the piping.

 

[S3Alex]

And another milestone .....

Views: 100,006

I never thought that would happen!

 

[Mario8P]

Hehehe I told you earlier you are our idol Alex

 

[S3Alex]

Hehehe I told you earlier you are our idol Alex

LOL...but I'm just leading myself and other forum members astray....

 

[Sayam]

Totally agree...colour wise,white is the new black,or soon to be the old black...LOL
Good until you need to wash it.

The hardware for now is done.....
But I do have a list:

1.New exhaust,as the current one is holding things back
2.Likely DSG conversion
3.....leave that vacant for now.

Software is running,and seems on a very quick look to be exactly what I wanted.

Switchable,very mild ALS,although it does already seem to spool better anyway.
Staged TC
Launch control
Super quick throttle response.

Not that I have any technical knowledge but out of that lot I'd be hunting the DSG conversion down before doing anything else.