After lurking the forums for a while, I thought I'd share my project with you guys.
omg, it's matt black
Car:
1992 Audi urS4, 5cyl 2.2 turbo quattro
Aimed mainly for standing mile, 1000m pulls and street racing
Currently ????? hp @ ?? bar and ???? rev limit
Engine management MoTeC M84
Everything is self-made and it's visible in the quality of the craftmanship
Block:
- 82mm bored stock AAN block
- Custom conrods
- JE-pistons 82,0mm 9,3:1cr with 20mm pin
- ARP studs
- 19-row oil cooler
- Self-made Sport Spec* engine mounts (*sporty because of the hockey bucks)
- A lot of matt black paint
- Dry sump
Head:
- Cat Cams 13,25mm/11,45mm / 289/279deg 0,1mm / 255/238deg 1,0mm
- High load springs with titanium upper retainers and self made bottom retainers
- Solid lifters
- Ported head, gen. 7
- Adjustable cam gear on exhaust and sprocket on intake
- 7A valve cover
- Quite a lot of matt black
Breathing:
- Tube exhaust
- Self made aluminium intake manifold (pictures in the link below)
- 60mm HKS-style Chinese wastegate
- Holset Pro52 (71 intake inducer, 70 exhaust exducer, 16cc turbine housing with split T4)
- 4,5" dp with 4,5" cutout to side exhaust
- 3" boost plumbing
- 2" Stainless exhaust ReWoN Motors Silent Series
- 600x300x100 High Quality China cooler
Engine management:
- MoTeC M84
- Completely rebuilt wiring with a self made loom
- 60-2 "lupo" trigger at the crank
Fuel delivery:
- 3 x Bosch 044
- Carter 455 cm3/min lift pump
- ~4 liter reservoir
- Mallory 4305M regulator
- 10mm Steel braided teflon lines with pressed hydraulic fittings
- Bosch EV14 2200cc injectors
- ReWoN Motors Fuel rail
- E85 fuel
Ignition:
- "034" coils (IGN1A)
- Bosch F5DP0R plugs
- Magnecor KV85 leads
Driveline:
- Tilton OT-II 7,25" 3-plate
- 4,2kg Steel flywheel
- 01E CET gearbox, with 0,68:1 6th added (theoretical top speed of 356kmh@8500rpm)
- Self made short shifter
Suspension, brakes and wheels:
- Suspension will be completely overhauled very soon with home made coilovers
Old setup:
- Bilstein shocks
- Front H&R springs, rear Avant Eibach's, both cut down some
- Front subframe bushings replaced with self made steel brackets
- Powerflex PUR bushings here and there
- Rear brakes with moved stock calipers with ~310mm Ford Mondeo front discs
- 360mm B5 RS4 front brakes with Yellowstuffs
- 18x8" OZ Crono HT with Kumho tires
- A lot of matt black
Coming:
- Visual fixing and detailing (ongoing project)
- Custom coilover suspension (spring 14)
Project stages 1-5
Stage 6-6.5
Stage 7 (season 2012)
Intake manifold in the making
I have a long story about the different stages this car has gone through, but it's in finnish and I just cant be arsed to translate it right now. Instead, here's a quick recap of it.
Stage 1 in early 2010 had HX40 Super with schrick cams, 8,5:1 JE's etc. Dynoed 510hp and it ended in a engine failure due to huge knock on an standing mile pull. This was the first engine I had ever built. It lasted less than 24 hours after the dyno. Engine management was with VEMS.
Stage 2 was done quite slow in the fall of 2010 and the car was running at christmas with the new intake, 034 coils, exhaust etc. And improved det cans After the first engine failure, I spent quite alot of time developing a proper engine end to the knock listening and I have now perfected it. Stage 2 dynoed 606hp with 720Nm at 2 bar boost.
http://www.youtube.com/watch?v=i7tKcB_XJaM
http://www.youtube.com/watch?v=d2iXwcR22SI
Stage 3 had a new HX52 turbo with 65mm inducer and a new 4,5" downpipe. This was the stage I had most of the 2011 season. Worked really well on street, but on the standing mile, the turbo was way too small. At this point I still had the Schrick-head. I had estimated 650-670hp with this stage, it never went to dyno. Won some 900cc motorbikes on 100-250kmh pulls and a lot of cars.
271 kmh was the best standing mile pull for the season (and the only one because of problems in other events)
http://www.youtube.com/watch?v=yrZb37L_Sj4
Stage 4 was came to be in august 2011 and it was a giant leap. New head with proper porting (the old one was self made and I had my doubts as it was the first and only head I've done ever), the roughest CatCams around, solid lifters and a bunch of other stuff. I also bought a new turbo, the pro55 Holset. It was with 71mm inducer and 77mm exducer with 22" T4 turbine housing. I could not get it to spool anywhere reasonable, even with a lot of cam and tuning tricks. Finally by using ridiculous over lap, I got it to spool at a usable range, even though it weakened the upper range a lot.
In the dyno I found out my plug wires struck through and caused a lot of problems. I had the black 034 set at that time. Dyno trip went to **** and I got 671hp/722nm as a result. Could not tune the car as no two pulls were the same.
http://www.youtube.com/watch?v=AIaZiDZ_edQ
This is pretty much the only pull that it worked even a bit
Tried it on the standing mile event
http://www.youtube.com/watch?v=R1ywuHhDgro
The led on the gauge stand is a trigger error warning
http://www.youtube.com/watch?v=PiKYskP9IsU
Note the low spool!
Stage 4.5 with new plug wires was a lot better. I got it to function pretty well, even though the spool was still up in the 6k range. Once it spooled, it pulled like a rocket though. 257kmh for standing 1000m, standing mile season had already ended. At this point the car had something around 700-710hp.
http://www.youtube.com/watch?v=VX0WwgbOcFw
http://www.youtube.com/watch?v=sqJ-iI79qJg
Difference between pro52 and pro55:
http://www.youtube.com/watch?v=s5x5zLlVX3Q
Stage 5 was just before winter in 2011. I bought a Holset Pro52 (the one with I'm running currently) and it worked like a charm.
Winter storage and workshop
Stage 6 is the base of the current setup. I'm still running the stage 2 bottom of the engine, but most of the parts above that have changed at least once. The stage 6 was done in winter 2011-12 and the biggest improvement was the MoTeC M84 engine management system, new triggering and a new wiring loom. I pretty much remade most of the car's electrics.
First smoke with completely pre-programmed config, never had so easy first start
http://www.youtube.com/watch?v=a4oO5fFOi7g
http://www.youtube.com/watch?v=JBKT5Err7Fo
One could argue if the next stage is 6, 6.5 or 7. But for me it is 7th. This stage is the introduction of ethanol fuel. This made the biggest difference in the car's performance so far. The personality of the car changed a lot as well, it's now pretty frisky and easy going
This engine has always been pretty knock-prone and I reckoned that I'd get a lot of benefit from ethanol but the results blew me out completely. I had anticipated something around 750hp..
Videos of the dyno session
http://www.youtube.com/watch?v=TMeJCfwYb5w
http://www.youtube.com/watch?v=z27PMy0kSLg
http://www.youtube.com/watch?v=myf8o_SqKk8
The first one actually is the 830ps pull, the other two are the same ~780hp pull from two angles. Uploaded because of the flames
Dyno chart
Standing mile "log run" with very low TPS% and scared driver
http://www.youtube.com/watch?v=nfbR-9U7Eb0
http://www.youtube.com/watch?feature...HviXbvl8#t=38s
It was really windy that day and there were huge gusts cross field. Note the 0,2G lateral acceleration at about 700 meters in the racelogic log. In the motec log you can see the frightened driver and his throttle foot shivering
As said in the thread, the standing mile goal was reached and new ones had to be set. More about this later on
omg, it's matt black
Car:
1992 Audi urS4, 5cyl 2.2 turbo quattro
Aimed mainly for standing mile, 1000m pulls and street racing
Currently ????? hp @ ?? bar and ???? rev limit
Engine management MoTeC M84
Everything is self-made and it's visible in the quality of the craftmanship
Block:
- 82mm bored stock AAN block
- Custom conrods
- JE-pistons 82,0mm 9,3:1cr with 20mm pin
- ARP studs
- 19-row oil cooler
- Self-made Sport Spec* engine mounts (*sporty because of the hockey bucks)
- A lot of matt black paint
- Dry sump
Head:
- Cat Cams 13,25mm/11,45mm / 289/279deg 0,1mm / 255/238deg 1,0mm
- High load springs with titanium upper retainers and self made bottom retainers
- Solid lifters
- Ported head, gen. 7
- Adjustable cam gear on exhaust and sprocket on intake
- 7A valve cover
- Quite a lot of matt black
Breathing:
- Tube exhaust
- Self made aluminium intake manifold (pictures in the link below)
- 60mm HKS-style Chinese wastegate
- Holset Pro52 (71 intake inducer, 70 exhaust exducer, 16cc turbine housing with split T4)
- 4,5" dp with 4,5" cutout to side exhaust
- 3" boost plumbing
- 2" Stainless exhaust ReWoN Motors Silent Series
- 600x300x100 High Quality China cooler
Engine management:
- MoTeC M84
- Completely rebuilt wiring with a self made loom
- 60-2 "lupo" trigger at the crank
Fuel delivery:
- 3 x Bosch 044
- Carter 455 cm3/min lift pump
- ~4 liter reservoir
- Mallory 4305M regulator
- 10mm Steel braided teflon lines with pressed hydraulic fittings
- Bosch EV14 2200cc injectors
- ReWoN Motors Fuel rail
- E85 fuel
Ignition:
- "034" coils (IGN1A)
- Bosch F5DP0R plugs
- Magnecor KV85 leads
Driveline:
- Tilton OT-II 7,25" 3-plate
- 4,2kg Steel flywheel
- 01E CET gearbox, with 0,68:1 6th added (theoretical top speed of 356kmh@8500rpm)
- Self made short shifter
Suspension, brakes and wheels:
- Suspension will be completely overhauled very soon with home made coilovers
Old setup:
- Bilstein shocks
- Front H&R springs, rear Avant Eibach's, both cut down some
- Front subframe bushings replaced with self made steel brackets
- Powerflex PUR bushings here and there
- Rear brakes with moved stock calipers with ~310mm Ford Mondeo front discs
- 360mm B5 RS4 front brakes with Yellowstuffs
- 18x8" OZ Crono HT with Kumho tires
- A lot of matt black
Coming:
- Visual fixing and detailing (ongoing project)
- Custom coilover suspension (spring 14)
Project stages 1-5
Stage 6-6.5
Stage 7 (season 2012)
Intake manifold in the making
I have a long story about the different stages this car has gone through, but it's in finnish and I just cant be arsed to translate it right now. Instead, here's a quick recap of it.
Stage 1 in early 2010 had HX40 Super with schrick cams, 8,5:1 JE's etc. Dynoed 510hp and it ended in a engine failure due to huge knock on an standing mile pull. This was the first engine I had ever built. It lasted less than 24 hours after the dyno. Engine management was with VEMS.
Stage 2 was done quite slow in the fall of 2010 and the car was running at christmas with the new intake, 034 coils, exhaust etc. And improved det cans After the first engine failure, I spent quite alot of time developing a proper engine end to the knock listening and I have now perfected it. Stage 2 dynoed 606hp with 720Nm at 2 bar boost.
http://www.youtube.com/watch?v=i7tKcB_XJaM
http://www.youtube.com/watch?v=d2iXwcR22SI
Stage 3 had a new HX52 turbo with 65mm inducer and a new 4,5" downpipe. This was the stage I had most of the 2011 season. Worked really well on street, but on the standing mile, the turbo was way too small. At this point I still had the Schrick-head. I had estimated 650-670hp with this stage, it never went to dyno. Won some 900cc motorbikes on 100-250kmh pulls and a lot of cars.
271 kmh was the best standing mile pull for the season (and the only one because of problems in other events)
http://www.youtube.com/watch?v=yrZb37L_Sj4
Stage 4 was came to be in august 2011 and it was a giant leap. New head with proper porting (the old one was self made and I had my doubts as it was the first and only head I've done ever), the roughest CatCams around, solid lifters and a bunch of other stuff. I also bought a new turbo, the pro55 Holset. It was with 71mm inducer and 77mm exducer with 22" T4 turbine housing. I could not get it to spool anywhere reasonable, even with a lot of cam and tuning tricks. Finally by using ridiculous over lap, I got it to spool at a usable range, even though it weakened the upper range a lot.
In the dyno I found out my plug wires struck through and caused a lot of problems. I had the black 034 set at that time. Dyno trip went to **** and I got 671hp/722nm as a result. Could not tune the car as no two pulls were the same.
http://www.youtube.com/watch?v=AIaZiDZ_edQ
This is pretty much the only pull that it worked even a bit
Tried it on the standing mile event
http://www.youtube.com/watch?v=R1ywuHhDgro
The led on the gauge stand is a trigger error warning
http://www.youtube.com/watch?v=PiKYskP9IsU
Note the low spool!
Stage 4.5 with new plug wires was a lot better. I got it to function pretty well, even though the spool was still up in the 6k range. Once it spooled, it pulled like a rocket though. 257kmh for standing 1000m, standing mile season had already ended. At this point the car had something around 700-710hp.
http://www.youtube.com/watch?v=VX0WwgbOcFw
http://www.youtube.com/watch?v=sqJ-iI79qJg
Difference between pro52 and pro55:
http://www.youtube.com/watch?v=s5x5zLlVX3Q
Stage 5 was just before winter in 2011. I bought a Holset Pro52 (the one with I'm running currently) and it worked like a charm.
Winter storage and workshop
Stage 6 is the base of the current setup. I'm still running the stage 2 bottom of the engine, but most of the parts above that have changed at least once. The stage 6 was done in winter 2011-12 and the biggest improvement was the MoTeC M84 engine management system, new triggering and a new wiring loom. I pretty much remade most of the car's electrics.
First smoke with completely pre-programmed config, never had so easy first start
http://www.youtube.com/watch?v=a4oO5fFOi7g
http://www.youtube.com/watch?v=JBKT5Err7Fo
One could argue if the next stage is 6, 6.5 or 7. But for me it is 7th. This stage is the introduction of ethanol fuel. This made the biggest difference in the car's performance so far. The personality of the car changed a lot as well, it's now pretty frisky and easy going
This engine has always been pretty knock-prone and I reckoned that I'd get a lot of benefit from ethanol but the results blew me out completely. I had anticipated something around 750hp..
Videos of the dyno session
http://www.youtube.com/watch?v=TMeJCfwYb5w
http://www.youtube.com/watch?v=z27PMy0kSLg
http://www.youtube.com/watch?v=myf8o_SqKk8
The first one actually is the 830ps pull, the other two are the same ~780hp pull from two angles. Uploaded because of the flames
Dyno chart
Standing mile "log run" with very low TPS% and scared driver
http://www.youtube.com/watch?v=nfbR-9U7Eb0
http://www.youtube.com/watch?feature...HviXbvl8#t=38s
It was really windy that day and there were huge gusts cross field. Note the 0,2G lateral acceleration at about 700 meters in the racelogic log. In the motec log you can see the frightened driver and his throttle foot shivering
As said in the thread, the standing mile goal was reached and new ones had to be set. More about this later on
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