Project: RS2 ABY

[AndyP]

Great result

[Billman]

You managed close to 500hp with an RS2 turbine wheel in a 8 housing?

Great fats time btw!!!

[Sonic]

wow great result guys! A happy ending to a long and surely emotionally draining project!
So what's the final spec then Andy?

Yeah i'm seriously impressed with everything. The turbo is awesome... and it all looks relatively stock which is exactly what i was aiming for! Amazingly something went to plan

Emotionally draining for everyone, but hopefully economically reviving. Needless to say i made up for the lack of fast driving over the last 2 years yesterday whilst mapping the car

The final spec... crikey! Better update my profile!

Rebuilt I5 from JNLRacing with 81.5mm overbore, Wossner pistons, re-balanced, new guides, inlet/exhaust valves and lifters (JP which ones were these?), crank re-grind, Aronmatic h-beam rods, head ported/polished, baffled sump.

Samco boost and coolant hoses, Forge 007 DV, Behr radiator, relayed Bosch 044 fuel pump, RS2 exhaust cam, 034 Adjustable cam pulley, sump-return breather system with swirl-pot and catch-tank, Bosch EV14 510cc injectors with anodized aluminium adapters and spacers, Setrab oil cooler, KX500 k26/27 hybrid turbo, Zeitronix zt-2, remap by Dmitri (prj).

Stainless 3" turbo-back exhaust de-catted with Miltek 2.75" rear silencer and back-box, RS2 airbox, RS4 MAF with Roose Motorsport MAF hose, Pipercross filter, Wagner k26 exhaust manifold, reverse inlet manifold, intercooler and crossmember, billeted throttle cam.

Audi RS6 8-pot Brembo's with 365x34mm discs and 1-piece 7075 aluminium carriers. Rear UrS4/6 setup with 280x22mm vented discs.

Adjustable Koni shocks, H&R springs, RS2 FARB, Whiteline RARB, Bambridge solid rear diff mount.

Rebuilt gearbox, new springs and sychros, Southbend stage 3 endurance clutch and pressure plate.

congratulations Andy,Dmitri and Will ¡¡

Andy,you was deserving something like this after all you have passed

Cheers mate Oh and don't forget JP as well, i bet he didn't expect to be building the engine twice after he did the head the first time

Excellent, look forward to going for a spin with you on Wednesday?

The car is up at VRS just to get a few loose ends sorted, but hopefully Will can have it ready for Wednesday, i'll catch up with him tomorrow.

[Error404]

It sounds awesome Andy and the best part is that you are happy with with it.
How is the boost response?
We await videos

[TimE-J]

Congratulations! Great to see its finally running well and mapped!

[newsh]

First post in this thread was on 7th Jan 2009

[Sonic]

Remapping started with Dmitri wiring in the RS4 MAF, which Will had already expertly mated to the RS2 airbox, and Dmitri modding the ECU for the RS4 MAF, removing the MAC WGFV which was causing a boost leak, replaced with a stock N75 which Dmitri says are far better for mapping with, and replacing a couple of slightly worn vacuum hoses, although these were only worn on the fabric i just wanted to be sure.

Dmitri got all his kit plugged in and the car was still running far too rich. We ran a fuel pressure test and fuel pressure was way to high, which seemed to answer about why the car has always run rich.

At this point we suspected a blocked fuel return line or a FPR problem. We tried another FPR and fuel pressure was still really high, so we swapped out the 4-bar for a 3-bar, and fuel pressure was still consistently too high, which rules out a return line blockage. We then got into the fuel tank to check everything was ok, it was, and we tried an adjustable FPR.

The end result is that the car is continually producing .6 bar more fuel pressure than it should, but it's consistent and linear, so was easily mapped out.

Time was getting on and Will had very kindly stayed way past his closing time to help us get the car working.

We headed out to find some good road to map the car, and Dmitri set to work... after a few fun hours everything was complete

We then tested out some launch control stuff, Dmitri was varying the way this works using ignition timing, fuel cut etc... which gave us lots of options from 1 - 2.3bar at 4-6krpm, and we also had HUGE flames and seriously loud bangs coming out of the exhaust which appeared to scare the hell outta people travelling past us on the dual-carriageway

The map ended up with launch control at 1.5bar at 5krpm, no flames sadly (fun, but not practical or good for the turbo), and 1.6 bar up to 4krpm, then 2.2 bar onwards, producing 2bar to redline with FATS of 3.1s.

[Sonic]

First post in this thread was on 7th Jan 2009

Yeah seems like a long time ago! The project has changed dramatically since it's inception i think, at least the final product has, but lots of the key upgrades that contributed to the project were completed since i first got the car, and really started the project, in July 2007.

[Rocco]

do you know the loads or do you hve Dmitri´s final log?

[Sonic]

No, i'm sure Dmitri will post them up.

[newsh]

Mine has taken years too and is still not finished!

I am really curous to know the cause of the excessive fuel pressure, maybe a problem in the fuel rail?

[220bhp]

I am very happy for you Andy,Well done for sticking with it.You deserve a pat on the back.
Enjoy your car now,and with that kind of boost take it easy

[Sonic]

Mine has taken years too and is still not finished!

I am really curous to know the cause of the excessive fuel pressure, maybe a problem in the fuel rail?

Yeah, neither of us were certain either. The 044 pump came from James, who i think sourced them from various people that used them for racing. Not sure if it would be possible to modify them in same way? The fuel-rail is a good point also, not sure how that could affect it. Either way, it seems consistent and was in some way resolved luckily for me

I am very happy for you Andy,Well done for sticking with it.You deserve a pat on the back.
Enjoy your car now,and with that kind of boost take it easy

Cheers mate

I can't remember who said it now, either Ross or Jamo i think... "life begins at 1 bar, gets exciting at 2 bar, and ends very quickly at 3 bar".... i feel like i have a good compromise with 2.2bar

[Thuppu]

Nice nice nice!

[Billman]

Where did you measure the fuel pressure?