80q b4 2.2 20vt project

[_ShurikeN]

Nice DP, Thomas. I've started designing mine and it comes out pretty similar at some point.

[_ShurikeN]

I use on my b4 in front S8 brake discs (314mm) 17 inch wheel is minimum.

There are lots of 16" rims which would fit on these brakes well. Including many OEM wheels from 4A and 8D audis.

[s0_big]

Nice

Nice work as always! A bit jealous of your fabrication skills

[Thuppu]

Got a genuine Tial diaphragm for the knockoff wastegate. Fits 99% PnP. Made just a few small tweaks, machined a little bit deeper grove on the valve shaft, made deeper countersinks on the body because the bolt heads hitted the diaphragm body and the valve didn't close properly. Also machined off ~0.3mm of the body inner ring that keeps the diaphregm in place, so when screwing down the cover it dosn't cut the diaphragm. There was some marks of too tight fitting on the orginal diaphragm, small cutting in the material. Assembled locking screws with soft lock, so they hopefully won't come loose again.







Needed also to do a new seat ring as the old one was totally wrong size. It was tight when the valve pressed it down, but when it opens the ring was loose and the valve wouldn't seat properly. It was wrong size in all directions, also too small diameter. I don't understand how I didn't saw this when I fitted the wg for the first time..? Now the new ring will stay fit when the wg is mounted to the manifold.

[Thuppu]

Fitted a catalytic converter with v-bands, just to clear MOT and the emission test. Easy to change to a stright pipe if it is restricting.





Welded on a bracket that fits the mount on the transmission, to keep the weight off the turbo and manifold.

[quattro-nick]

there are no problems to mount a big brake setup on 4x108
all you need to do is to make everything custom
my front brakes 330mm vent disc with k sport 8-piston calipers
my rear brakes 300mm vent disc with urs4 calipers
dubble vacuum booster from rs4 b7

when is the second dyno day thomas?
powergoal was around the 500hp?

[extreme327]

I use on my b4 in front S8 brake discs (314mm) 17 inch wheel is minimum.
And rear in S4 discs.[QUOTE]

[Nuno_Cristiano]

I have same problem Brakes...

Good Project Thuppy!

[Thuppu]

I use the 2.8l stock brakes(same as S2). I don't think this will see much track time.

[geryS2]

nice, which brakes are u gonna use ?, cause i see u stayed with 4x108

[Thuppu]

Small test on closed track.

https://youtu.be/kbCnabFzXXo

[BLAMM0]

Loving such videos

[Thuppu]

Ok, so I had a dyno day today. Always so stressing...

Positive things was that almost everything worked nicely, no trigger errors, car liked timing, turbo feeled nice etc. But there was one mechanical problem, the knockoff "Tial" wastegate failed at first 1.7bar pull, with a result of the boost to hit cut limit. Later I opened the wastegate and the valve had come loose from the diaphragm. Also the seat ring was bad, the gate leaked a little even at idle.

So best pull was something like 402hp/490Nm if I remember right(I will get the plots to my email soon) with 1.5 bar boost. No problems with the small turbo hot side, at least not yet at this level.





Also a small vid...

https://www.youtube.com/watch?v=VBLt8hbTZNk

[Thuppu]

Final small things have been done. Welded the screamer pipe and added a mount to it, fitted Turbosmart boost tee, checked the timing with timing gun, changed oil and filter(Gulf Competition 5w-40 + Mann), fixed a minor coolant leak. Have test drived the car few times, and used Vems live analyzer for the base VE map, so I can drive the car to dyno. Havn't tried any hard pulls yet, of course, but it seems to boost very early, 0,4bar at 2400rpm. We shall see how it chokes on high rpm's..?

[quattro-nick]