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Audi S2 Avant - And other stuff.

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  • Audi S2 Avant - And other stuff.

    The time has come to make a thread about what im wasting all my time on.

    At daytime, i work as a Security technician at Siemens.
    At my spare time i distribute and install VEMS in many different cars. Steetcars, racecars and rallycars.

    Ive also developed my very own Hub-dyno system, everything from hardware to firmware to software. It has the most basic functions. Steady-state, Sweep, Step-sweep(steadystate) and Load vs RPM function.
    Everything to tune all my customers cars
    All my money and spare time has been stolen by this dyno from hell, but i hope it will repay itself.
    It will hold ~1300whp, so should be enough for most people

    Some films ive put on youtube showing some of the functions.
    A little one from my -2011 BMW 318d in the dyno, doing Step-sweep test every 250RPM with 1sec holding at each setpoint:

    http://www.youtube.com/watch?v=VreZ8kSxWxw&feature=plcp

    Did another one at a lower gear, so that the speedlimiter wouldnt hit.
    Result ( notice the logo my brother insisted of putting there ):


    I put my brothers BMW 325 E36 in the dyno and did som testing.
    Look at the Torque gauge ( lowest gauge on the left ) when im switching the headlights on and off while on WOT @ 2500rpm

    http://www.youtube.com/watch?v=wPSoWgwjOKE&feature=plcp

    I have had ~25-30 cars on the dyno so far and it seems to work very well most of the times Mostly BMW Turbos and Volvo turbos, but also Skyline R32, Golf VR6 turbo, some old kadett. A little bit of everything.

    Well... Maybe its time to move on to my Audi S2 Avant instead



    Welded together my own exhaust manifold, turned up real nice at the end:


    Fitted a Garrett GT4088


    And hereĀ“s how it looks today



    Intercooler and a new oil-cooler is fitted.


    Engine specs:

    AAN Block
    Stock pistons with new rings
    H-beam rods
    The head is also from AAN with a nice Mira-job to the seats and valves.
    AAN-intake manifold
    Ebay radiator for a honda civic.
    Garrett GT4088 T4 Singleentry.
    Sachs 707 clutch with sinter
    6-speed transmission
    VEMS standalone with my home-made patch adapter ( 4bar map, LowZ drivers etc..)
    60-2 VAG trigger.
    1200cc injectors
    stock coils without the ignition drivers, using the ones in the VEMS unit instead.

    Custom camshafts(grinded from stock turbo-cams):
    Lift 11,5mm on both intake and exhaust cams
    Duration, 288deg @ 0,01mm - 245deg @ 1,27mm




    Startup is scheduled this weekend
    Some water-piping and intercooler pipes to fabricate - and some fuellines.



    Stay tuned
    Last edited by Erikk; 12 April 2014, 08:23.
    Audi S2 Avant - 600whp

  • #2
    Tested the triggersettings on the starter today, looked really nice! Its also the first time on the starter since the new engine was inserted. Everything sounded well and should be all set for the startup this saturday

    I also made some intercooler pipes.
    Its over 2 years since i drove the car.

    Audi S2 Avant - 600whp

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    • #3
      nice effort,keep us posted
      RED Mitsubishi Lancer Evolution VI TME nĀŗ 16 of 250
      BLACK Mitsubishi Lancer Evolution VI TME nĀŗ 189 of 250
      LWB Audi Sport Quattro project

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      • #4
        Forget about the Avant, more about the hub dyno please! (designed, made, and validated a fully functional MFS sequential water brake concept with a friend/s2 member on here, shame we stopped after getting the hardware working...)

        I play with these puppies for a living now: http://www.horiba.com/automotive-tes...ls/dynas3-879/

        Comment


        • #5
          Originally posted by Erikk View Post
          Tested the triggersettings on the starter today, looked really nice! Its also the first time on the starter since the new engine was inserted. Everything sounded well and should be all set for the startup this saturday

          I also made some intercooler pipes.
          Its over 2 years since i drove the car.

          Does VEMS have a functionality to delay the actual firing after finding the secundairy trigger in order to "prime" the oil pump for lubricational purposes?

          Comment


          • #6
            Haha, sure i can post more about the hubdyno. I can rewrite some of my notes to english, when i get some spare time


            No. But it requries full sync before it will fire anything, most people wants superfast sync/startup.
            You can press and hold full throttle while cranking and the ecu wont open your injectors, a flood-clear function but can be used for priming the oilpressure (if you want to go advanced you could connect a oilpressure switch to the vems and disable injection/ignition when the switch is inactive. It would definitely give me headache though )
            Audi S2 Avant - 600whp

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            • #7
              Some info from one of the BMW Turbos (a friend of mines)

              A dynorun caught on film from the owners facebook account:
              https://www.facebook.com/photo.php?v=10150988601672798

              Testdrive afterwards:
              http://www.youtube.com/watch?v=1BaM2...ature=youtu.be

              Result:



              One test i did to test the repeatability of the dyno.
              I made three pulls. Added 1deg per pull over 4500rpm.
              Results:



              Two runs after eachother, to test repeatability (because of temp difference etc, every run is a bit different, but i think the repeatability is excellent)


              0,7bar VS 1bar boost
              Audi S2 Avant - 600whp

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              • #8
                Tell me the basics then, do you use retarders or hydraulic motors? How do you dissipate the energy?

                But using a pressure switch to enable ignition... sounds like a very big opportunity in terms of **** ups... Or you should add extra code making an active window only to monitor it during first secs after start + x seconds extra.

                Didn't know about the anti bore-wash option, good info.

                Comment


                • #9
                  Excellent repeatability for backyard dynoing...
                  How did/do you calibrate your dyno?

                  Comment


                  • #10
                    Originally posted by quattro84 View Post
                    Excellent repeatability for backyard dynoing...
                    How did/do you calibrate your dyno?
                    Deadweights. The most accurate method for calibrating.

                    Infact, the repeatability is better than most dynos you can buy.
                    And the speedcontrol is far better than for egs. the land-and-sea dynos, which is terrible.
                    Every time ive been on a L&S dyno (enginedyno or chassi/hubdyno) it looses the RPM of the engine totally when the engine is gaining torque rapidly and later on it loads the engine up to much and the acceleration is almost gone.
                    Terrible control

                    Ive put many hours in making my dynocontrol very good. Im planning to fabricate and sell some dynos in the future.

                    Originally posted by quattro84 View Post
                    Tell me the basics then, do you use retarders or hydraulic motors? How do you dissipate the energy?
                    ItĀ“s eddy current retarders and the torque is messured with S-beam loadcells.
                    The retarders can hold ~4900nm (~1300whp) at steadystate (1minute)
                    Probably ~1500whp on sweeps.



                    Having a dyno of my own istheshit.net
                    Audi S2 Avant - 600whp

                    Comment


                    • #11
                      Originally posted by quattro84 View Post
                      I play with these puppies for a living now: http://www.horiba.com/automotive-tes...ls/dynas3-879/
                      Whats the specs of one of those?
                      Max torque/rpm ?
                      Is it a AC motor which is driven by the engine?

                      How is it compared to the popular Superflow and the Depac systems?
                      Audi S2 Avant - 600whp

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                      • #12
                        Originally posted by Erikk View Post
                        Whats the specs of one of those?
                        Max torque/rpm ?
                        Is it a AC motor which is driven by the engine?

                        How is it compared to the popular Superflow and the Depac systems?
                        It is a very expensive A/C motor, torque measuring accuracy of 0,05% FSR up to 4000Nm, responsive torque control < 3ms with rpm's on our beds for heavy duty limited to around 4k rpm.

                        It is ment to be used as a full transient dyno to mimic actual road driven cycles, so actual vehicle data can be rerun within an enclosed environment which can be fully controlled (IAT, humidity, CAC temp, ... )



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                        • #13
                          Up and running .

                          Badass camshfts 0,1bar vacuum at idle 1200rpm

                          ;-) Very nice after all this time
                          Audi S2 Avant - 600whp

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                          • #14
                            Great project.... Look forward to your results on your dyno
                            Audi Nut!!!

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                            • #15
                              I uploaded some evidence to youtube

                              ~20kpa vacuum at 1300-1400rpm - later lowered the idle to 1100 and got just 10kpa. Its probably not any problems.


                              I need to check the valve clearance.
                              Because of the grinded camshafts, i use lashcaps and volvo b234 hydraulic lifters.
                              It will probably be better after the oil gets some serios temperature and starts to fill the lifters

                              http://youtu.be/2pC7r9AHYQQ
                              Last edited by Erikk; 21 October 2012, 01:44.
                              Audi S2 Avant - 600whp

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