Something a bit unusual.... TFSI Turbo'd 1.8T

[Prawny]

Afternoon chaps!

I thought I'd share this with you, now that it's nearing completion, this is something I'm testing in conjunction with with Beachbuggy Turbos and Parsons performance.



We all know that the TFSI lot got pretty lucky with the k04 turbo fitted to the Golf Ed30, leon Cupra, and 8P S3, for a factory turbo it seems to produce amazing results, 360+ bhp, and seems to be pretty reliable at those outputs too, so it was certainly something which has interested the 1.8T crew for a long while.

I'd already stolen the compressor from an 8P S3 for my k04-023 hybrid, which produced 353bhp / 345lbft on my 1.8T engine in my A3, looking like this:



But now, thanks to Dan at Beachbuggy Turbos having a crazy idea, we've gone one step further with a kit he is developing, and stolen the whole turbo from an 8P!





Bulkhead clearance was a little tight, but aside from that, it fitted great:



We also robbed a TFSI charge pipe:



And added a 1 bar actuator for good measure:



It's all back in now and almost finished:



just a few pipes to finish, and the downpipe.


The engine is a high flow large port 1.8T, with NA cams, forged rods, 3'' turbo back, massive IC, WMI, all the toys.

All thoughts and opinions welcomed

Cheers for reading

Prawn

[Prawny]

Shiney new DV from Forge plumbed into it's new home:



Charge pipework all welded up, painted, and fitted:





With the bracket by the crank pulley, the main cross member is actually really solidly mounted. We were going to brace is, but somewhere it needs to flex for engine movement, and across the length of pipe made the most sense, as the angular change when it flexes will be the least. Long term I will replace the straight coupler with a bellow I think.

We wern't happy with the oil drain we had made either. With the weight on the wheels, the drain sat just 5mm from the driveshaft. Under compression it would hit.

We tried changing the length of the hose, but it just kinked, so intead we took 2 ko3 oil drains, and did a cut and shut to come up with one decent drain, using solid fittings at either end and an unmodified audi flexi section in the middle. This should be much more reliable.



Catch can back in, just needs a few lengths of pipe to plumb it all up, and that's the bay finished!

[Prawny]

More stuff happened.

90 degree pipe offered in and pointed to roughly where we wanted it:





A remarkable amount of room for this, the only thing reasonably close is the gear shift cables, but the DP will be heat wrapped, as will the shift cables.

Flexi on next:



Followed by a 45 degree to bring it into the tunnel:





And that's all there was too it! Made easy thanks to Ben!




All marked up for bosses, EGT, Narrowband 02, WB02 all to be welded in:



Downpipe welded up:


And wrapped:





and fitted:

[Prawny]

A picture of the car it's fitted to, just for good measure:



First test on low boost, 14psi, no meth active here, still on the map from the old hybrid:

http://www.youtube.com/watch?v=hxgCYF-ScJs

[Prawny]

Little mess about at Curborough in the wet last week, putting miles on the new setup:

http://www.youtube.com/watch?v=WrJTlLiqkg8&feature=youtu.be

[Prawny]

then the big bit that everyone wants to know.....

To the dyno!

http://www.youtube.com/watch?v=3_GaW_WFGd8

[Prawny]

Some of you may recognise this place:



And this friendly looking gentleman:





Just a quick check to see that it's fuelling safe and I'm OK to continue driving it before it's mapped. This is still on the old hybrid map, and due to Bills excellent dyno software we were able to make overlays and compare new and old setups.

So, the results.....

Red line is the old ko4 hybrid, blue line is the new TFSI unit, both on actuato pressure at 1bar:



Spool is a tiny bit later on the dyno, but on the road it makes 15psi before 3k, aside from that, on the same actuator pressure they're incredibly similar!

Midrange torque is ever so slightly up on the new setup, whether that's because it's slighly leaner or not I don't know.

Happy that it was running fairly well and things were as expected, we turned the N75 on!



^^^The old full boost map here was from before the last map on the new engine, so previous max power had been 307bhp at Bills. it's a great comparison of spool up though, again roughly 4-500rpm later.

And the plots from Sundays results:





348bhp and 283lbft, or in comparable terms elsewhere, 328lbft (given Bills calc of 16% lower reading on his)

Considering it's made this from just 18psi at the top end, and it made peak power AT the rev limiter, I think we're doing pretty well here on the old map!

EGT peak on the dyno on full boost was just 734 degrees, so promisingly low, and timing pull was absolutely zero across the board after a few tiny cf's on spool up.

All in all, a bloody good result! Roll on mapping on September 5th!

Massive thanks to Bill and Tuffty as always for fitting me into their incredibly busy schedule! you guys are awesome

[Prawny]

On the dyno, boost on:

http://www.youtube.com/watch?v=O7IPe5EDW_k&feature=c4-overview&list=UUivWBehnHJtLnkLw5klNhPw

And with no N75, 1 bar-

http://www.youtube.com/watch?v=Xl9h9K4LIQY&list=UUivWBehnHJtLnkLw5klNhPw

[Prawny]

and finally, a little in car clip:

http://www.youtube.com/watch?v=QNJ4btN2o3E

[GTi_James]

thats just mad really