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Unread 23-07-15, 10:11 PM   #1
momento1
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Project fast S2 to faster S2 - Australian Edition

Hi guys
thought i would start a project thread here too like i have on the local forum in Oz.

So a bit of an update...
This is what my car looks like


Current specs are
Standalone EMS computer and eBoost 2 controller (so no MAF or N75)
tuned to E85 fuel
1600cc injectors
Wagner Evo exhaust manifold
Wagner Intercooler and reverse intake manifold
GT3071 with 0.63 ar
7a cams

it made 307kw (410hp) at the wheels at peak 28psi with crap loads of fuel for safety.
And as you can see it pulls very linear and nicely all the way. Dont ask me why it stops at 6500, i think the tuner got scared of hitting redline a bit too early
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Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw

Last edited by momento1; 10-07-16 at 10:46 PM.
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Unread 23-07-15, 10:26 PM   #2
momento1
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So now i am about to start the next stage...

im looking at is building the bottom end and larger turbo going for that magical 400kw (530hp) at the wheels hopefully

so i have acquired the following parts (some are yet to arrive)

GTX3582 turbo with 0.82 ar
FCP X-beam rods rifled drilled
FCP High rate springs and titanium retainers
Supertech standard size intake and exhaust valves with bronze guides new seals and lightweight hydraulic lifters
Adjustable cam timing pulley
ARP Head studs
ACL racing bearings (rods and crank)
034 10mm thick Main girdle and studs
New oil pump
Copper composite head gasket
034 custom regrind Cams (267 degree with 11.2mm lift)
Lightweight flywheel and full faced carbon (feramic) clutch

engine bores will be cleaned up and stock pistons with new rings will be used
Engine will be completely balanced with the lightweight flywheel









any thoughts and input would be nice for people that have BTDT and have some suggestions or pointers while ive got the engine out, especially if there could be anything i have missed....

thankyou
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Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw
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Unread 24-07-15, 09:37 AM   #3
jade
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Quote:
Originally Posted by momento1 View Post
So now i am about to start the next stage...

im looking at is building the bottom end and larger turbo going for that magical 400kw (530hp) at the wheels hopefully

so i have acquired the following parts (some are yet to arrive)

GTX3582 turbo with 0.82 ar
FCP X-beam rods rifled drilled
FCP High rate springs and titanium retainers
Supertech standard size intake and exhaust valves with bronze guides new seals and lightweight hydraulic lifters
Adjustable cam timing pulley
ARP Head studs
ACL racing bearings (rods and crank)
034 10mm thick Main girdle and studs
New oil pump
Copper composite head gasket
034 custom regrind Cams (267 degree with 11.2mm lift)
Lightweight flywheel and full faced carbon (feramic) clutch

engine bores will be cleaned up and stock pistons with new rings will be used
Engine will be completely balanced with the lightweight flywheel









any thoughts and input would be nice for people that have BTDT and have some suggestions or pointers while ive got the engine out, especially if there could be anything i have missed....

thankyou
Forget the light weight lifters they are not up to the job with the uprated valve springs
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Unread 24-07-15, 10:44 AM   #4
V6quattro
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Why would you use a Copper composite head gasket? The stock steel one is fine.
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Unread 24-07-15, 11:01 AM   #5
Error404
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Stock MLS headgasket.
Personally, I would rebore and sleeve or use new pistons for this kind of output, you want the bores to be round and clearances correct.
Probably not necessary on E85, but if you ever plan to run regular pump gas you might want to consider dropping the CR. The head would benefit from some work at that kind of output too.
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Unread 24-07-15, 11:03 AM   #6
momento1
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Quote:
Originally Posted by jade View Post
Forget the light weight lifters they are not up to the job with the uprated valve springs
Thank you for your input. Considering im going with custom
Cams you are most likely right in going with a stronger weight lifter. Or possibly my stock lifters are still good enough to use but i wont know until i pull it apart
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Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw
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Unread 24-07-15, 11:04 AM   #7
momento1
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Quote:
Originally Posted by V6quattro View Post
Why would you use a Copper composite head gasket? The stock steel one is fine.
Its actually 2 outer steel layers coated in rubber with a centre copper layer. And its all very close to stock thickness
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Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw
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Unread 24-07-15, 11:37 AM   #8
momento1
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Quote:
Originally Posted by Error404 View Post


Stock MLS headgasket.
Personally, I would rebore and sleeve or use new pistons for this kind of output, you want the bores to be round and clearances correct.
Probably not necessary on E85, but if you ever plan to run regular pump gas you might want to consider dropping the CR. The head would benefit from some work at that kind of output too.
I wanted to change pistons also but keep stock comp as im now going to be sticking with E85.
Problem is its not easy to find stock comp pistons at stock bore or slightly larger bore

The head has had some flow work done but nothing big
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Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw
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Unread 06-08-15, 08:07 PM   #9
momento1
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some more goodies arrived today...

Another package is still stuck in customs also....

all the delrin stiffer engine mounts, tranny mounts, diff mount and strut mounts.
Also new oil pump and slave cylinder
and 10mm main girdle to complete the bullet proof bottom end



Of course the voice inside my head got the better of me so ive come to my senses and i am upgrading pistons too now from FCP Engineering
Molybdenium coated skirts and maintaining stock compression of 9.3:1 because im sticking with E85 fuel. New wrist pins and rings
Also boring out the block to 82mm so effectively it will now become a 2.3L.
Only downside cause they have to be custom made is i wont see them for a month or so which inevitably delays the start of the build now.

Waiting.... Waiting....
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Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw
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Unread 07-08-15, 02:51 PM   #10
zafra
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the pictures are not visibles
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Unread 10-07-16, 10:52 PM   #11
momento1
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been a delayed start to this project but it has finally commenced!!!

engine out and sent away to be machined and decked.

stock pistons and bearings look immaculate still!!
Not bad for 300+kw at the wheels and 215,xxxkm

cylinder bores were also perfect with no ovalness or scoring...

Still i will be machining out to 82mm now with higher comp pistons 9.8:1
becuase im using E85 i wanted higher comp to help reduce the laggyness with the larger turbo






this means i will have some parts and the old setup to sell shortly....
keep an eye out
__________________
Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw

Last edited by momento1; 10-07-16 at 10:59 PM.
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Unread 05-09-16, 09:21 AM   #12
momento1
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Project fast S2 to faster S2 - Australian Edition

Ok slow update

So engine back from machine shop last week and the girdle was test fitted. Just gapping the piston rings now.





Just recieved the Head back. Ports have been touched up and all new valves, stems, guides and lifters installed with the new cams. Also it was good to discover not a single crack in the head.



Once the pistons are gapped correctly then the bearings, rods and crank will be sorted.

Also you can see evidence of the flywheel having been balanced with the crank (note drilled holes lower right in face of aluminum flywheel in second photo)



By this week hopefully have the engine complete together and gearbox rebuilt also
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Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw
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Unread 05-09-16, 10:19 AM   #13
geryS2
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Nice work !
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Unread 05-09-16, 10:52 AM   #14
macspring
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You were obviously right to rebore and use new pistons at this level of preparation / power.

While I'm in there etc. You only want to do it once.

What is the car to be used for as it is too stiff and powerful to daily ?

Maybe you should consider keep all your old parts and making up a spare engine to have on the shelf ?

Nothing is getting for S cars is 'common as muck' these days, especially where you're based. Just a suggestion.

Thanks for sharing.





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Unread 05-09-16, 09:57 PM   #15
momento1
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Quote:
Originally Posted by geryS2 View Post
Nice work !


Thank you
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Current:
1993 Audi S2 Kingfisher Blue - GTX3582r w/ E85 = 430kw atw

Past:
2002 Audi S4 Nogaro Blue Stage 3+ - 250kw+ atw
2001 Audi S3 Silver - 169kw+ atw
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