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If that waste gate is cheep china crap I would ditch that also before it goes wrong and decides not to open when it should. Just plumb a standard one in , then you know it will work fine.
From day dot it banged, and we were trying to isolate the problem ever since.
When the ECU was reflashed there was a standard fuel pressure regulator on it and AFAIK a new N75 too. The boost showed little sign of being under control, and the banging was present. As the N75 appeared to be new this was one of the last things we looked at. It was checked even though the possibility it was faulty was dismissed on this thread. I agree it is unlikley, but you never know!
A fuel pressure gauge was needed on the rail to see what the fueling was like, so the original FPR one was chopped off and another one was installed that had a gauge. Around this time the fuel pump was changed too.
As it turns out, replacing the fuel pump was a step in the right direction, but changing the FPR was not. Even with the original one back on it still banged at high revs, and it wasn't until the N75 was replaced did the engine run sweetly.
There was a little leak in the weld around the original FPR, and in fixing this, it has been messed up. So we need to now replace the rail and FPR with an original. Nevertheless, the problem has been found!
The boost leak test was very helpful. Not only did it highlight the N75 problem and find a couple of other leaks, it enabled us to check the behaviour of the FPR under 1 Bar and 1.5 Bar of boost.
So, in summary the problems were - leaky N75 (mainly), duff FPR & perhaps a substandard fuel pump.
The buggy was spinning a little in third gear, and from what I hear, does pin you back in the seat. There are traction issues though, but unfortuanately Quaife don't seem to make a diff for the Audi 80 gearbox. So I think wider tyres are in order, and we have a spare diff welded ready to be put in, but I'm not sure if that is a good idea.
Wastegate - It is Chinese, I'l mention it to Al.
Formula Student - This looks like seriously good fun. I think QUB participates in this, it's almost worth doing the course for the sake of this alone. Sometimes I wish I had done Motorsport Engineering, it wasn't offered here in NI :-( Nice project.
With the N75 and fuel problems sorted out, she went like a treat.
As you would have guessed, another problem has reared its head. She goes off a cylinder when (well) hot and at high boost (1.5-1 Bar) it is okay at 0.4-0.5 Bar and is okay when cold/warm at high boost.
I think we are talking around 95 degrees or so. I'm just rememebering that the fan did not kick in until near the last, and it wasn't until then did it start to go off a cylinder.
Its not over heating.
We turned down the boost after the misfire, it ran perfectly at 0.5 bar.
It also ran quite a wile at high boost before it began to go of cylinder.
Cool - nice looking buggy and private roads in use :-)
Great to see my software in something lighter than a 1500kg quattro - must be a mad handful with it spinning wheels in most gears - hilarious.
Would like to see it someday now that wrinkles are ironed out. If you have the obd wiring attached it would be possible to collect some running data and push that turbo harder if you are game. Strongly suggest you change / upgrade coilpacks to TTRS / RS4 flavour first though.
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nice 
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