Ok , I guess I'll start one ...

[California Jay]

No razzle dazzle here... just a blog...
I've recently bought another A4 slowmatic (wreck) and got started recently on the build... Not much right now ... but I'll certainly add as I go...

The car, left one.... (yes I know the lights have gotta go.)



The start of the engine... bare for now.



A few specs!! and a list of items to look forward to on the car.

Engine
ABA/AEB/Diesel crank.
CAT Cams
Custom Wiesco piston @ 9:1
Pauter Rods
GT40R (staged/sequential)
321 stainless, thin guage header
Custom intake, TB Pre-turbo.
AEM Universal ECU
W/A IC
4x 630CC inj, 4x 415cc inj
2x inline walbro.

hp goal... unknown... but I'm looking for spool at 3k (laugh all you want)

Car specs:
Flocked dash
Gated shift console
034 mounts
Tein Drift Spec Sus... so long as I can get them to fit resonably after alterations
Bushings where-ever I can fit them
Stack if I can swing it.

[Russell2686]

subscribed.

Looking forward to this

[Kaytek]

Interesting... will you be keeping the tiptronic or swapping a 5spd in? Or will you be beefing up the tiptronic? Happy wrenching

Cheers,

Kaytek

[Don Supreme]

Tell us about spooling a 40r @ 3k? I don't see any spray in your build list?

[A4Rob]

Tein drift suspension? ???

[oldblu]

lol I like your lights

[California Jay]

lol.. ahh win some you lose some...

Don,
The turbo system is going to incorporate many features found on your small displacement BMW turbo engines. This features a modified twin scroll housing, I'll post some pics soon, as I'm doing it in another customers car as we speak.

[Seerlah]

That is a nice mani in your sig. How much you let those things go for? Any complaints from customers about cracking issues or anything? Anyways, nice build, man . I will be watching this one.

[t1demont1]

very nice, but what about the vw motor behind that motor?

[Don Supreme]

That is a nice mani in your sig. How much you let those things go for? Any complaints from customers about cracking issues or anything? Anyways, nice build, man . I will be watching this one.

You obviously don't know who Jay is. The first a4 into the 10s was running one his manifolds.

P.S. I also run one of his manifolds on my car.


Jay,

So you say the turbo will use a "modified" twin scroll housing. I am assuming you are going to be building a twin scroll manifold to feed this turbo?

[pipe7284]

SEXY keep updated


BTW, i like that Z on the right.

[Seerlah]

You obviously don't know who Jay is. The first a4 into the 10s was running one his manifolds.

P.S. I also run one of his manifolds on my car.


Jay,

So you say the turbo will use a "modified" twin scroll housing. I assuming you are going to be building a twin scroll manifold to feed this turbo?

Nope, I am new to the Audi scene. But I must admit, that is one sexy looking manifold.

[quattro16]

Jay makes " THE " best manifolds by hand that money can buy!

[California Jay]

very nice, but what about the vw motor behind that motor?

That is another engine I'm reworking ... some of you may have seen the car at at WF... Last dyno was 420awhp.









Changing cams, compression, turbo and twin scroll housing also.

So you say the turbo will use a "modified" twin scroll housing. I am assuming you are going to be building a twin scroll manifold to feed this turbo?

Actually no... the manifold will still remain "open". Sit tight I'll show you what I'm brewing.

That is a nice mani in your sig. How much you let those things go for? Any complaints from customers about cracking issues or anything?

We can continue cost questions in another method, ie PM or email. I've been making manifolds a long time...for every level of motorsport now. Very few of mine have cracked over the past years. If a few didn't crack I wouldn't learn.

[California Jay]

Interesting... will you be keeping the tiptronic or swapping a 5spd in? Or will you be beefing up the tiptronic? Happy wrenching

Kaytek

I've already converted the car to accept a manual.

[Euro-Tuner]

looking forward to this one, out of curiosity, what cylinders do you combine on your twin scroll mani? this should be a new step for the B5 community. whats your timeline?

custom IM? why dual injectors instead of 1000cc?

...look out mike...

[California Jay]

Usually I'll pair 1-4 and 2-3... but this one will not be divided...

lol- I'm not out for a hp war or what not... I doubt I'll drag this car. I made Mike's IM so I know what that design and his car are capable of. This IM will be quite different from that. I'll post the model in a few days.

The time line I'm hoping to work with is over the winter.

[clconversion]

what are the specs on that TT ? that looks hot

[California Jay]

more of the TT can be seen here... I think there are some specs at the bottom.

http://www.jrponline.com/forum/topic.asp?TOPIC_ID=139

heres a peek of the housing mods on a t3 ..I'll post more of the t4 progress soon.
as you can see it will evolve into a internal flapper to shut off half of the housing.

[Don Supreme]

more of the TT can be seen here... I think there are some specs at the bottom.

http://www.jrponline.com/forum/topic.asp?TOPIC_ID=139

heres a peek of the housing mods on a t3 ..I'll post more of the t4 progress soon.
as you can see it will evolve into a internal flapper to shut off half of the housing.

Holy fuck, an internal flapper? Who makes that, how much does it cost? Whats the largest A/r t3 you can get that hot side made in?

[California Jay]

I machined it out and I'll post the design later... no one makes it really

the largest twin scroll t3 is 78ar, from Garrett at least. I think Owens in the UK will make it bigger but not sure.

[onemoremile]

That is a really interesting idea.

[Don Supreme]

That is a really interesting idea.

I knew you would like it.

[joshsd]

subscribed, cant wait for more

[slopoke]

In for this!!! Your intake and exhaust manifolds are so0o00 sexy!

[onemoremile]

I knew you would like it.

Takes it from low volume high pressure to high volume high pressure.

[sean1.8t]

this is the first thread that i have actually subscribed to.

in for progress

[maxspeed]

this build looks insane.

[California Jay]

A lil side tracked here, but thought some of you might want to see.

I've never had this happen to a Tial unit, the TT I'm upgrading had some rattles coming from the mani as I was doing final assembly on the engine b4 install, just from moving it around in my arms. I took the Turbosmart wg apart (new style) to source the issue, rusted to hell and all three set screws had fallen out holding the valve. This is only after 4000kms and 80 pulls on the dyno.



Not impressed.

[Don Supreme]

80 dyno pulls holy hell........

but seriously, Tial FTW!

[onemoremile]

That spring looks like it has been through hell.

The flapper sounds really cool. I've got it pictured in my head and could describe it but don't want to spill the beans. I want to see if yours looks like what I'm thinking. Equal flow when open and smoothly diverted when closed. Dead simple too. Great idea Jay!

Are you going to do the intake manifold on this car?

[California Jay]

Yes there will only be two copies of the IM until testing is over... one on my car and one with Bob Q... they will be totally machined until I can finish a die for stamping half the plennum. The TT owner above actually has a die stamp machining company, i lucked out on doing his while replicating a hypertune model and adapting to the stock base.

Yes the flapper is simple but the complicated part is the expansion of the metal under extreme load, accuracy in fittment, and keeping a nice seal during high boost. Compare it to a flapper on an internal wastegate and its a totally different environment... its never under pressure really. I'll be using 300M for most of it with a bit of machined cast block.

[onemoremile]

You aren't going to get a complete seal without tapering the edges so the flapper sits in a pocket like a stopper. That really only works well when round and that pocket is in the way of airflow. Given the rectangular smooth walled port and other limitations I still think you'll get a big benefit from this.

I'm going to sketch up my idea and see what you think.

[onemoremile]

Sketch complete.

This turbo model has sloped walls in the turbine ports so my cut made some extra edges in there. I think it gets the point across though. My cut wasn't deep enough so my flapper isn't long enough to get the right angle when closed. Those sloped walls just made it look stupid when pocketed too deeply.

http://i23.photobucket.com/albums/b3...erisotrans.jpg

The green position is wide open and the pink position is closed. Since it is hinged at the bottom it would be angled when closed to help channel airflow and that tangential contact will allow it to seal consistently over a wide temperature range. The sides would be loose when cold and I can't think of anything to do about that.

http://i23.photobucket.com/albums/b3...erisotrans.jpg

[onemoremile]

Of course Jay is a lot cooler for doing this sort of stuff in real life. Making it work is the real tricky bit.

[California Jay]

Yes thats close to what I'm doing... I'll be continuing the flapper into the collector though... that will aid in the flow...I have to work with my documented runner cuts and flanges that I usually cut to get the outline of the flapper correct.

you are faster at the modeling of course... lol. I will still get my version up. I'm posting once in a while after lunch and a break here and there at work while putting other items together. Usually I'll program/model in the evening.

[onemoremile]

You're totally on the right track. Longer flapper = smoother transition.

[quattro16]

interesting

[dougyfresh]

80 dyno pulls holy hell........

but seriously, Tial FTW!

80 pulls ain't nothing. The motor in my car has a couple hundred and counting...


Nice concept Jay. This intrigues me primarily from a concept and design standpoint. I am looking forward to seeing the outcome.

[Don Supreme]

80 pulls ain't nothing. The motor in my car has a couple hundred and counting...


Nice concept Jay. This intrigues me primarily from a concept and design standpoint. I am looking forward to seeing the outcome.

Dyno can be hard on a car.