Another "Stroker" Project

[Billman]

i also need some advice on the compressor exit of the turbo. I think it is way bigger than the RS2 item. Does anyone know the stock dimentions and has any idea what i could do there? I recall i saw somewhere that they used these adaptor thing from the ring to a plain hose plug. Any ideas?

[lind4hl]

rs outlet is something about 60mm if i dont remember completely wrong,

[Billman]

good thing is i have a spare holset with another compressor outlet (smaller) so i fitted this one on it. So No problems there anymore. I need a solution to the Downpipe flange and fabricate an adaptor fom the smaller cone filter to the big Holset 100mm compressor inducer outlet and i am ready to Holset!!!

[Billman]

Dear Audi lovers, i have some questions that need quick answering!

1. Is it very bad if the compressor cover (compressor housing) is touching the exhaust manifold at a 2mm² surface? What can happen (worst case scenario)?

2. As i pulled the turbo and my lambda sensor out they where quite whitey! Ddoes it has to do with the E50 i run? The readings in WB-Lambda and EGT are good.

3. What is the upper limit i could run on the stock Block-internals? i was thinking of starting with ca. 1.4 bar on the middle range and going to 1.6 bar at the rev limiter. Is it going to be too much! If everything is ok it should run ca. 430 Bhp (i think). This with a Holset.

thanks

[gedu]

1. That's not good, you WILL melt your compressor housing.

2. Normal

3. Well, I ran 1.7Bar with stock turbo and stock internals, so should be no problem.

[Billman]

1. Would it really Melt? If it is really so bad then i am goind to do it again with a thinker plate.

3. 1,7 at the redline?

Also some minor Updates:

Holset Turbo is in!

Here some pictures (items are made to work and not to look nice)

The original RS2 Downpipe flange with the "bottleneck"




and from the Inside:




The original RS2 will be up for sale shortly










The final product!!!




I have set it to 1.4 bar and it spikes at 1.40-1.50 bar. At the redline i have approx 1.35-1.40 bar

On 6. gear (starting with full throttle at 2000RPM)i saw with the RS2 turbo 0.5 bar at 2500 and 1.5 bar at 3000 RPM. With the Holset i am seeing at 2500 RPM 0.3 bar and at 3500 ca. 1.5 bar.

made a run on the 3. Gear starting from 3000 RPM and a half run at 4. Gear starting at 2500 i think (what do you recon powerwise?).

[A80Avant]

a very very rough assumption is that 100-150 was done at about 4.50sec although it is hard to see.If so then your car should be about 380hp.I have counted 3.60-3.80sec in mine which is almost above 400hp.
Bring the car in Athens Bill,at christmas time and ill put it on the perfomance box which i just bought!!

By the way,next year at york dragstrip, if we arrange a meet,we'll have ourselves a dyno session as well! (sorry for the offtopic)

[Billman]

my fingers still bleeding, my heart rate is over 120 the last three days and Vasilis comes with these nice words telling me that my car is allmost as it was with the other turbo

I guess i must shoot the next video not on a steep hill as the ones i posted but on the Munich airfield! Turn the pressure high and go!

[A80Avant]

haha! not to worry,i think this turbo is huge...

[Billman]

The clips in better quality

in 3. gear
http://rapidshare.com/files/171881253/MOV02247.MPG

in 4. gear
http://rapidshare.com/files/171837642/MOV02249.MPG

[Billman]

Happy new year!

Yesterday we went out with a V-Box (Vasilis correct me please on this) and made some pulls with the car set at approx 1.35-1.4 boost. It showed 241 KW on the wheels. What would it mean in terms of Crank HP?

Car is an RS2 with half-full tank, 2 Persons (approx 150kg both and approx 50 kg extra weight = 1825 kg)

On 3. Gear pull it took (road going a bit uphill)

1 50,00 0 0,00 Speed Start
1 60,00 1,83 27,98 Speed Line
1 70,00 3,32 54,88 Speed Line
1 80,00 4,47 78,64 Speed Line
1 90,00 5,36 99,69 Speed Line
1 100,00 6,23 122,81 Speed Line
1 110,00 7,11 148,34 Speed Line
1 120,00 8,00 176,91 Speed Line
1 130,00 8,93 208,94 Speed Line
1 140,00 9,91 245,72 Speed Line
1 150,00 10,96 288,38 Speed End

This is a 2. Gear pull:

1 50,00 1,05 13,11 Speed Line
1 60,00 1,93 26,46 Speed Line
1 70,00 2,79 42,00 Speed Line
1 80,00 3,69 60,73 Speed Line
1 90,00 4,61 82,61 Speed Line
1 100,00 5,58 108,14 Speed Line
1 110,00 6,60 138,01 Speed Line
1 120,00 7,73 173,96 Speed Line
1 130,00 9,03 218,98 Speed End

What do you think?

Today i made some corrections because i had i big spike and as VEMS tryed to correct it got way back with he boost (it hit 1.6 bar (should be 1.4) and then it got back to 1.2 and then again to 1.35). Now it goes to 1.4 and after 5000 RPM to 1.5 and at 6500 to the limiter with 1.6 bar. I was faster than a BMW M5 with the 400bhp engine.

Here is a log of the car today.

A Vid is coming soon!

[A80Avant]

its the perfomance box to be excact

[pnanassy]

Im sorry ,but what are these numbers?

[A80Avant]

numbers represent:
1= run number (ignore it)
second line: km/h
third line: seconds
fourth line: distance in metres

[EspenW]

Happy new year!

Yesterday we went out with a V-Box (Vasilis correct me please on this) and made some pulls with the car set at approx 1.35-1.4 boost. It showed 241 KW on the wheels. What would it mean in terms of Crank HP?

If the pull was in 2nd gear, you lose approx 12hp to aero drag at the speed/rpm for peak power.
3rd and 4th gear gives higher numbers since the turbo is allowed to spool better, and the loss to inertia is lower. A tird gear pull would yield 15-20hp more (after accounting for the higher aero loss (30-35hp at peak power in 3rd).
241kw= 328hp.
Including aero loss, that is approx 340whp.
If one assumes 20% drivetrain loss, that is approx. 425hp at the crank
Assuming 25% loss, it is 453hp.

What was ambient temp, altitude and approx air pressure?

Was the car weighed on a proper scale? Remember that the specific weight of petrol is 0.74, approx 740g per litre.

In gear times seem high, considering the indicated power level. How steep was the hill?
80-120kmh is 3.53s
100-150kmh is 4.73s

Times with my RS2 are 2.13s and 2.97s on E75 fuel (1.9 bar peak boost on Netics E50) (1 deg C ambient)