Joined
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206 Posts
Bobby Singh's Audi A4 3.0TDI project
21 - 35 of 35 Posts
Joined
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206 Posts
Gear knob arrived - part number 8K2713139S
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JXB performance bearing carrier arrived in case the stock one gives up again:
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Cheers
Bobby
JXB performance bearing carrier arrived in case the stock one gives up again:
Cheers
Bobby
Joined
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87 Posts
Hi, We are always interested in feedback for our products, fancy sending us an Email and let us know your thoughts please? EBC BrakesJune 2019
Haven't had much of a chance to work on my own car recently.
Changed the front and rear pads and discs.
Decided on EBC yellow stuff front and rear pads.
Front disc managed to source some EBC and rear's from ATE.
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Air box mod done - OEM+ look
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(Before everyone starts drilling their air boxes take some pressure measurements as 99% of the owns won't need this)
I'm also working on something special in the background
More details to follow in the next couple of months (I hope)
July 2019
Been fours since the last car detail - special thanks to my cousin @teamspb for all his effort:
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For a car with over 150k on the clock he done a great job.
January 2020
Been a while since I've done much with the car.
Some maybe aware but I bought a used engine last year with ojective to rebuild it. As I mentioned earlier in this thread the PCP are extermely high and main task I wanted to address is compression ratio. With such high pressures the heads have started to lift when using the power for prolong periods causing coolant issues. The car has 160k on it and still being driven and still performs well.
Here are some pictures of the replacement engine:
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Nice to see cross bore drilling:
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Heads cleaned & flattened
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Valves reseated
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12.9 head bolts sourced and modified to suit the Audi V6 engines
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Piston work
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CAD drawings are complete with CNC profile set.
If all goes to plan lowered compression ratio will add scope for more power while remaining within PCP.
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Joined
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206 Posts
January 2021
R110 fuel pump finally running, as per my post in Jan 2020 I've been trying to get this pump running.
I had it running but during high rail pressure it would leak causing the Vee to become a swimming pool.
Here are some pics during the development
Custom gearbox pump plate:
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Rail pressure output valve changes:
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R110 pump:
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Even thought about custom gears to spin the pump faster:
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After long last R110 is now working without leaks.
Thanks to @Horia for his support and many others who support me through other social media sites.
Cheers
Bobby
R110 fuel pump finally running, as per my post in Jan 2020 I've been trying to get this pump running.
I had it running but during high rail pressure it would leak causing the Vee to become a swimming pool.
Here are some pics during the development
Custom gearbox pump plate:
Rail pressure output valve changes:
R110 pump:
Even thought about custom gears to spin the pump faster:
After long last R110 is now working without leaks.
Thanks to @Horia for his support and many others who support me through other social media sites.
Cheers
Bobby
Joined
·
206 Posts
Febuary 2021
Sourced a 4 bar boost gauge in preparation for some more boost Turbosmart Gauge Electric Boost Only 4 Bar
Moved the boost gauge to the pillar pod gauges and the turbo speed gauge to the centre vent.
Gauge comes with a pressure sensor which I mounted in the EGR blanking plate
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Cylinder pressure tool arrived finally - Very expensive sensor:
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Cheers
Bobby
Sourced a 4 bar boost gauge in preparation for some more boost Turbosmart Gauge Electric Boost Only 4 Bar
Moved the boost gauge to the pillar pod gauges and the turbo speed gauge to the centre vent.
Gauge comes with a pressure sensor which I mounted in the EGR blanking plate
Cylinder pressure tool arrived finally - Very expensive sensor:
Cheers
Bobby
Joined
·
206 Posts
March 2021
Been spending some time on pushing the engine further and making decent progress.
I've installed a injector current clamp and now can see the injection events per cycle:
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Learning a lot from this tool for example x deg timing can add y bar of cylinder pressure depending on RPM - having big injectors is a must.
Turbo is now pretty much max (safe limit) and emp is now in the positive range, so measured the exhaust back pressure (still using the stock system apart from the downpipe) and it showed a peak figure of 450mbar.
Looking at the stock back boxes you can see Audi engineers put some thought into the design:
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As a test I decided to open the second port on the back boxes:
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Welded in a 90deg 57mm elbow - JEEZ wow its so loud haha totally unbearable.
End result was 60mbar drop - hardly worth the effort and rather save my ears so will be welding that back up.
Will look into the rest of the system to see if I can gain any flow, but so far I see no benefit of changing the back boxes.
Cheers
Bobby
Been spending some time on pushing the engine further and making decent progress.
I've installed a injector current clamp and now can see the injection events per cycle:
Learning a lot from this tool for example x deg timing can add y bar of cylinder pressure depending on RPM - having big injectors is a must.
Turbo is now pretty much max (safe limit) and emp is now in the positive range, so measured the exhaust back pressure (still using the stock system apart from the downpipe) and it showed a peak figure of 450mbar.
Looking at the stock back boxes you can see Audi engineers put some thought into the design:
As a test I decided to open the second port on the back boxes:
Welded in a 90deg 57mm elbow - JEEZ wow its so loud haha totally unbearable.
End result was 60mbar drop - hardly worth the effort and rather save my ears so will be welding that back up.
Will look into the rest of the system to see if I can gain any flow, but so far I see no benefit of changing the back boxes.
Cheers
Bobby
Joined
·
206 Posts
March / April 2021
Well the second port got welded up:
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The hunt for a exhaust solution continued objective being
Decided on a RS4 exhaust 2 x 65mm pipe work with built in valves
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Stock 3.0TDI 1x65 to 2 x 54mm
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76mm to 2x65mm adaptor
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Note additional mount is required for the centre box and I had the whole flexi section made in 76mm
Diffuser drama
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So I wanted to go with a RS4 rear diffuser but it seems none are available for a S line model.
Went to a exhaust place they suggested pointing the inner back box tip downwards and then building a tip with suitable bends for the stock diffuser.
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Somehow I didn't like that idea and after speaking with a few people I decided to so with a S4 diffuser, idea being the exhaust opening is larger to suit the twin tips of the RS4 box.
Still needed some tips and scanning through ebay I found some C7 RS6 tips for cheap money
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Old diffuser off and vac lines for the valves ran:
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As the RS6 tips are open back I tack welded the tips into the correct position and then made a back plate for both sides and welded them - tips are now stronger than the rest of the exhaust!!
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Very pleased with the end result and a perfect solution for still keeping the car civil.
Purchased this vac unit for the exhaust flap control - works good enough:
Performance
So to recap the back pressure with stock exhaust was 458mbar and with the RS4 exhaust and 76mm flexi section we have 24mbar.
This resulted in 50 deg EGT drop - very impressive and gives further scope for more fuel.
The only disadvantage is weight - the RS4 with its additional centre box and larger pipes does add weight but I can live that to save my ears.
Cheers
Bobby
Well the second port got welded up:
The hunt for a exhaust solution continued objective being
- Slient (as can be)
- no droning
- Good fitment
Decided on a RS4 exhaust 2 x 65mm pipe work with built in valves
Stock 3.0TDI 1x65 to 2 x 54mm
76mm to 2x65mm adaptor
Note additional mount is required for the centre box and I had the whole flexi section made in 76mm
Diffuser drama
So I wanted to go with a RS4 rear diffuser but it seems none are available for a S line model.
Went to a exhaust place they suggested pointing the inner back box tip downwards and then building a tip with suitable bends for the stock diffuser.
Somehow I didn't like that idea and after speaking with a few people I decided to so with a S4 diffuser, idea being the exhaust opening is larger to suit the twin tips of the RS4 box.
Still needed some tips and scanning through ebay I found some C7 RS6 tips for cheap money
Old diffuser off and vac lines for the valves ran:
As the RS6 tips are open back I tack welded the tips into the correct position and then made a back plate for both sides and welded them - tips are now stronger than the rest of the exhaust!!
Very pleased with the end result and a perfect solution for still keeping the car civil.
Purchased this vac unit for the exhaust flap control - works good enough:
Performance
So to recap the back pressure with stock exhaust was 458mbar and with the RS4 exhaust and 76mm flexi section we have 24mbar.
This resulted in 50 deg EGT drop - very impressive and gives further scope for more fuel.
The only disadvantage is weight - the RS4 with its additional centre box and larger pipes does add weight but I can live that to save my ears.
Cheers
Bobby
Joined
·
206 Posts
New barrier broken today everyone Feel free to share it out
603hp / 1080nm (800lbft)
603hp / 1080nm (800lbft)
Joined
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206 Posts
April 2021
A good friend of mine put together this video for me - hope you you enjoy it:
A good friend of mine put together this video for me - hope you you enjoy it:
Joined
·
206 Posts
November 2021
Not much has been done to the car apart boost/EGT gauge change
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Can be programmed as required:
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Longer probe
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Custom support bracket
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In the meantime for those who may not know check out my S2 thread:
www.audi-sport.net
Cheers
Not much has been done to the car apart boost/EGT gauge change
Can be programmed as required:
Longer probe
Custom support bracket
In the meantime for those who may not know check out my S2 thread:
Bobby Singh's Audi S2 avant project
Childhood dream car becomes reality Growing up the in the 80's the dream has always been to own some flavour of the 5 pot turbo engine. Looking around the Audi S2 avant in the Ragusa green became the target, after viewing a few I settled on this: Engine - RS2 spec Engine rebuilt in 2013 RS2...
www.audi-sport.net
Cheers
Joined
·
206 Posts
Feb 2022
Not done much on the car but tried some 0 to 60mph test:
Cheers
Not done much on the car but tried some 0 to 60mph test:
Cheers
Joined
·
206 Posts
Slight improvement on the 60 time:
Still full weight but I think with more rev's (5.6k or so) time could be improved again
Still full weight but I think with more rev's (5.6k or so) time could be improved again
Joined
·
206 Posts
Car has done now 6k @ 600hp so it was time for a oil change and noticed the front discs and pads were finished.
EBC front discs lasted 20k basically but they've been bent for a while.
This time I went with ATE from Macan turbo disc's and stuck with EBC yellow stuff pads:
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Cheers
EBC front discs lasted 20k basically but they've been bent for a while.
This time I went with ATE from Macan turbo disc's and stuck with EBC yellow stuff pads:
Cheers
21 - 35 of 35 Posts
