Project 400 Update

[Ross]

Breather hose

The one part of the intake that we couldn't fit was the breather hose. This could have been resolved by cutting the pipe before the 90deg. bend where it attaches to the MAF hose, and insering a rubber section to rotate the bend so it points down slightly. The pic below will demonstrate the poor fitment:

[volcano rs]

aren't you using a catch tank ?

[Billman]

Very nice ross.

do you have any pictures of turbo compressor and Turbine side and any wheel diameter measurements.

[Ross]

Initial driving was fine, other than the harsh vibrations caused by the turbo resting on the chassis and the slightly louder exhaust. The car controlled boost well on a custom MRC map designed for the K24. It controlled the turbo well, which started to give positive psig readings above 2500rpm. About 0.5bar at 3k and 1.5bar at 3.3k. There was noticeably more kick - i imagine the turbo produces 1.5bar @ 5krpms alot more efficiently than the K24 and this could account for that! I was easy on it though as I wouldn't wanna max out the injectors :mischeif:

As 2 of my RS2 injectors were knackered I had to buy a set of 37lbs'ers. I also had to fit a 4.2bar FPR and 3bar map sensor prior to remapping.

I also had a problem where the oil return flange cracked within the first 5 miles of driving; this was replaced with another 034 alloy flange that Jon happened to have "spare" (from his car) that was noticeably thicker and more robust. I plan on checking with Javad to see if they've changed the spec (and suggest they go back to the bigger/stronger flange).

I'll write more about the remapping and dyno results later :mischeif: Any questions welcome btw, or BTDT/advise as to changing the engine mount and using a spacer!!

[Ross]

aren't you using a catch tank ?

That's a probable plan, as the car is mapped now without that ***** being ingested, and until then I'll keep it vented to atmosphere (I have an extension pipe fitted that takes it down and vents just in front of the FARB :mischeif: - don't tell the tree huggers!!)

[4WheelDrifter]

Thanks for sharing Ross.
I agree with the comments on a catch tank. Or you could go for a Tom C air filter oiler.

[Ross]

Very nice ross.

do you have any pictures of turbo compressor and Turbine side and any wheel diameter measurements.

Thanks... afraid not, we didn't have the turbo apart for too long and got rather rushed. The turbine is 0.63AR though, the outlet was about 3mm smaller than the hole in the downpipe gasket if that helps... Mihnea commented that it's ALOT more freeflowing that the K26 and even at 2.0bbar there was minimal backpressure; he also said that perhaps the RS2-EM can do more with a better hotside. The car made 428bhp on the rollers (graph to follow) @ 1.8bar and on the road we were seeing 2.0bar during mapping with no problems. Apart from the injectors were maxing out...

Compressor is 0.50AR, 2.75" inlet.

[Jon441cc]

I also had a problem where the oil return flange cracked within the first 5 miles of driving; this was replaced with another 034 alloy flange that Jon happened to have "spare" (from his car) that was noticeably thicker and more robust. I plan on checking with Javad to see if they've changed the spec (and suggest they go back to the bigger/stronger flange).

good job we spotted that after the shakedown

[Ross]

One currently un-explained side-effect is the car's hesitation to hold idle. It only occurs sometimes on the road, and can be induced by stabbing full-throttle to about 5krpm at rest and then backing right off - the revs drop, and rather than catching idle it just dies. ISV tested and cleaned, no difference. Lambda is OK as well.

It's not noticeable generally, but a pain in the butt if you're stopping at lights etc, dip the clutch, and it dies; this can be helped by using 2nd for a few secs before you roll to a stop to keep the engine turning over. Mihnea tried to sort it out while remapping, with no luck. It started occuring before the remap.

It hasn't affected me much in the past couple of days - I pushed a small patch of leather between the turbo + chassis which has greatly dampened the vibrations, and this may point to a possible cause as it's only happened once to me since... I'll keep the thread updated on this issue.

[s2driveruk]

great work I'll have to listen out for it - sure it will be difficult to miss Either that or just watch for the trail of smoke from the credit card!!!!

[porkkis]

If you vent to atmosphere when mapping, you should also do that in the future. Breathed air is also measured in you know.

[Fat Audi 80]

Nice work Ross!

Let me know when you are happy with it and I will come over for a test drive!

Cheers,

Steve.

[Corey]

Apart from the injectors were maxing out...

They will do, you should be using the 44lb injector with the 3071 not the 37lb it's too small.

[Jon441cc]

You should have had my 42lb's for the day Ross, i did offer,

[Ross]

I must've been so knackered I missed that one I guess I took enough other 'donor' parts from the trustee slipper wagon! Is the offer still there? :mischeif: