Dan@SJM Posted August 30, 2015 Report Share Posted August 30, 2015 (edited) I'll just add quotes as it's a lot easier than transferring it all!So with the ph1 dying of rust, I collected this shell: Porkies old cup, complete with safety devices full cage. This thread will be a build log more than a thread. Slowly things are coming together for the engine build, things have been turning up slowly, but surely. Spec will be based around the following, with minor details changing. 1.8 20v turbo, bored and stroked to 2.0 Large port head with super tech valves,springs and retainers Badger 5 cams Wiseco Pistons (9:1CR) ZRP Rifle drilled forged con rods GTX3071 (may even go GT35) Suspension will be the Roll centre kit and b14's, but these will be changed to possibly BC's but I've got something planned for the future so this may wait. Interior Will have a Dash2, and remote pedal box to get rid of my clutch issues (master cyl over heating due to turbo/manifold) Here's the pics of stuff I e already gathered... 2.0 crankshaft ZRP Rods Large port head And a weathered block Few more bits have turned up... ARP head studs and main bearing studs & remote pedal box (I'll grab a picture tomorrow) My GTX3582r with a gt30 compressor housing machined to suit. Dash2 Just waiting on the wiseco pistons and supertech valve train to arrive before I can get the motor built. ARP's Pedal box: Edited August 30, 2015 by Dan@SJM Link to comment Share on other sites More sharing options...
Dan@SJM Posted August 30, 2015 Author Report Share Posted August 30, 2015 ACL's arrived, let's hope they're within tolerance when I build it all up! Supertech valves, titanium valve springs and retainers have all been ordered, just awaiting delivery. Supertech package here Pistons Bit of help from [uSER=86056]@Stopherson[/uSER] today. He came up, and we got the pedal box positioned, seat roughly positioned, then attacked it in the form of making it lighter. Any unnecessary wiring removed (stereo/airbag/alarm etc) Little update.. Loom is all back together, [uSER=86056]@Stopherson[/uSER] has popped up a few times and we've had the seat rails welded in, sadly no pics of that. Meanwhile engine parts are arriving thick and fast. Downpipe parts: Turbosmart compgate external waste gate Then popped up to badger5 today as I was on trackday support for a few guys, and ordered my cams, but also came away with a billet interference fit crankshaft sprocket, ARP Crank bolt, ARP Flywheel bolts. Engine is coming out the grey one this weekend to raid the clutch and flywheel to get the whole bottom end assembly off for dynamic balancing. Sonar Daddy 1 Link to comment Share on other sites More sharing options...
govich Posted August 31, 2015 Report Share Posted August 31, 2015 That's a fecking huge turbo for a FWD 2L. What are your plans with this thing? Do they have equal length driveshafts? Link to comment Share on other sites More sharing options...
Dan@SJM Posted August 31, 2015 Author Report Share Posted August 31, 2015 It was running a 3071 on a 1.8 @2bar. Which gave 401.6 bhp + 385lb-ft in the last shell. No equal length shafts here unfortunately and a quaife diff made for some interesting torque steer! Long term plan is to 4wd it, but the rolling road I use only does 2wd so I'll build it all, map it then work on the 4wd setup. TriggerFish 1 Link to comment Share on other sites More sharing options...
govich Posted August 31, 2015 Report Share Posted August 31, 2015 Sounds ridiculous, in the best way possible Expecting all the boost by 3500-4000rpm I assume? The only thing I have experience with in this size is SR20s, most street/track guys i knew in oz used a 2860 or 2871 on those. Gotta love the rush of a big turbo though! 4wd sounds like a job and a half.. you madman Link to comment Share on other sites More sharing options...
Dan@SJM Posted August 31, 2015 Author Report Share Posted August 31, 2015 Hell no, it's like that at the moment. Gt35's tend to spoil about 4-4500 and being a GTX it'll be slightly laggier again. So probably about 5k, but it'll spin to 9k, so I'll make the most of it. Link to comment Share on other sites More sharing options...
Dan@SJM Posted September 2, 2015 Author Report Share Posted September 2, 2015 Few hours here and there have allowed me to tack the downpipe and EWG Pipe up. Which is being picked up by SAS Welding services tomorrow Ashley1995, The Laird and TriggerFish 3 Link to comment Share on other sites More sharing options...
Ashley1995 Posted September 3, 2015 Report Share Posted September 3, 2015 Link to comment Share on other sites More sharing options...
simonlpearce Posted September 3, 2015 Report Share Posted September 3, 2015 That's mental, and also some serious skill . Look forward to seeing the finished product. Link to comment Share on other sites More sharing options...
Dan@SJM Posted September 7, 2015 Author Report Share Posted September 7, 2015 Manifold all done! Big thanks to SAS Weldimg services again, faultless work and always willing to 'just do that bit aswell' Few pictures.. theworkerbee, bungers and Kermitthefrog 3 Link to comment Share on other sites More sharing options...
Dan@SJM Posted September 16, 2015 Author Report Share Posted September 16, 2015 Bit more of an update. Car is back from having a full 3" exhaust fitted. And the cams have turned up from Badger5. Only waiting on the solid lifters and then the engine can be assembled. Cylinder head is being done by a local machine shop, having all new supertech guides done, very light skim and a dip. Craig_09 and Stonesie 2 Link to comment Share on other sites More sharing options...
govich Posted September 16, 2015 Report Share Posted September 16, 2015 Excellent. Are you planning to shield the head from the turbine? I'd be worried about the oil in that area otherwise.. Link to comment Share on other sites More sharing options...
Dan@SJM Posted September 16, 2015 Author Report Share Posted September 16, 2015 Yes, it's going to be wearing a turbo jacket, and the manifold/down pipe and hot side are all going for ceramic coating over winter once it's been shaken down. Link to comment Share on other sites More sharing options...
TriggerFish Posted September 16, 2015 Report Share Posted September 16, 2015 Excuse my ignorance, but this is a vag 1.8t right? It would explain all the badger5 stuff if so. Link to comment Share on other sites More sharing options...
Dan@SJM Posted September 17, 2015 Author Report Share Posted September 17, 2015 You'd be correct. It's originally a 1.8t, but bored and stroked to 2.0 TriggerFish 1 Link to comment Share on other sites More sharing options...
TriggerFish Posted September 17, 2015 Report Share Posted September 17, 2015 Awesome! Workmanship on that exhaust is exquisite too, I bet your happy! Link to comment Share on other sites More sharing options...
das_flo Posted September 17, 2015 Report Share Posted September 17, 2015 That manifold is seriously impressive. I opened this thread expecting to see the usual half hearted, destined for failure type project, but you're smashing it. Subscribed! Dan@SJM 1 Link to comment Share on other sites More sharing options...
Dan@SJM Posted November 1, 2015 Author Report Share Posted November 1, 2015 Well lots to update.. Should update this really, bottom end built, head back from having the solid lifters Lash caps machined. Sump arrived from forge. Just waiting on the manual tensioner and ARP camshaft bolt from Integrated engineering, and a new cam chain tensioner. Box of electrical bits turned up from simtek, stuff like heat shrink, plugs, and a Neptune connector to do a bulkhead break point.Currently debating ripping out the loom and rewiring the whole car from scratch with a modular fuse box. simonlpearce and TriggerFish 2 Link to comment Share on other sites More sharing options...
Dan@SJM Posted December 2, 2015 Author Report Share Posted December 2, 2015 Oh.. It's ready :D The ARP Camshaft bolt turned up, along with the integrated engineering manual cambelt tensioner. Having a day off soon, so stopherson is coming up and going to help me get it in the bay. Also bought a modular fuse and relay box to completely rewire the car so loosing the UCH etc. Well [USER=86056]@Stopherson[/USER] came up a few weeks back to Give me a hand and to get his MOT done. So we cracked on with the cup. No pictures taken, but the subframe got welded up a bit more substantially this time, so no cracking! Then we set about getting the new engine in. And these are the only 2 pics for the day lol. I've bought a pipe bender and some pipe to attempt hard piping the intercooler, but it just seems to want to kink no matter what I do :( tried the usually compacting with sand but it didn't work. Gear Cables are off at speedy cables to be made longer, other than that it's wiring and fluid systems and we're Ready to go! Link to comment Share on other sites More sharing options...
Dan@SJM Posted December 21, 2015 Author Report Share Posted December 21, 2015 Gear cables are back. Booked in this week with my welder fab guy to make the centre console for the selector tower and switch panel etc. And hopefully enough time to get the hard piping done on the intercooler. On another note, the bilsteins have been sold, and I've purchased these.. Today's pictured progress.. Hard piping done. Link to comment Share on other sites More sharing options...
Dan@SJM Posted February 24, 2016 Author Report Share Posted February 24, 2016 Mega update I guess!! It'll be very brief as I haven't got many pics. Engine was in, then I set about wiring: Then did the interior loom (no pics) but did set it up so I can have mains only (just as a 'I'm coming' setting on track after having a few near misses with people underestimating my approach speed. DASH2 wired up and functional. Total weight. Then it was onto running in and mapping. Unfortunately this didn't go to plan. After running in and an oil change I started doing the low end mapping. This all went well. Decided to try a couple of gate pressure runs. First pull with a footballer map (rich and retarded) did 249 at 0.6bar peak. Tweaked the fuel table and started another in which I noticed a rattle on the way up so immediately killed the ignition and got out to investigate. With the Fuchs Titan race pro being red, the dyno cell looked like a murder scene. Nice spray mark right up the wall. And about 3L on the floor. f**k. Set about investigation as to what had failed. Then noticed the oil filter had pulled off on 1 side. (This would explain the lack of oil pressure lights!) as it was still pumping but not enough pressure to sustain clearance from 3krpm. But why had this happened? Well, turns out the local Audi specialists parts lady had given me the wrong part. It was too small to notice the thread was different (M18 against 3/4unf.) - about 1mm difference, which would explain why I didn't notice it. So in urgency I popped over to the local factors and found the cheapest m18 oil filter I could. Just so I could start it and see if the motor had survived. It had thank god. But I called it a day to pull the sump off and inspect, rather safe than sorry! Upon inspection all the shells were scrap. However the crank was unharmed. Then managed to get a set of mains and big ends of King racing bearings from TSR. Fitted them and have done about 50 road miles with it. All seemed well so booked the dyno again. Took it up to the dyno and started doing the mapping again. Did a base run that came out at 246, then added 3 degrees of timing, 269, then another 3 and got 304. Cleared the screen and went to get another run. This time 298. But noticed a rattle. Argh!!! This time it was box related. Pulled the end cap off the box to be greeted by a snapped circlip. Well atleast it was an easy fix. Hopefully!! Circlip a due tomorrow AM. Here's a pic of the power graph. Happy with that at 0.6bar! TriggerFish 1 Link to comment Share on other sites More sharing options...
TriggerFish Posted February 25, 2016 Report Share Posted February 25, 2016 Impressive figures! Over 300bhp per tonne! (gcse maths is doing me proud!) What sort of boost are you expecting it to hold? Must be some more to come? (or is it a stock engine, I can't remember) Link to comment Share on other sites More sharing options...
Dan@SJM Posted February 25, 2016 Author Report Share Posted February 25, 2016 Far from stock, fully forged with cams and 2.0 stroker. Aim ultimately will be 550-600, but this will only be used when 4wd happens. simonlpearce 1 Link to comment Share on other sites More sharing options...
govich Posted February 27, 2016 Report Share Posted February 27, 2016 Very nice and sounds like a good save with the filter. It looks like it's only getting started, 9k should be fun! Have you got a category in mind for this? Time attack? Link to comment Share on other sites More sharing options...
Dan@SJM Posted April 4, 2016 Author Report Share Posted April 4, 2016 On 23 February 2016 at 22:20, Dan@SJM said: Running 1 bar of boost now, still on a 'footballer' map (mappers term - rich and retarded) so plenty of power to come yet. Had an outing at Combe, where the aux belt failed causing a drop in voltage to the coils which caused a misfire and brought me in. On board;http://youtu.be/fV-S54YL5Ek Fly by Link to comment Share on other sites More sharing options...
