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View Full Version : Audi blood in my veins.. EFR6758 build went a lot out of control *LONG



Beemer832
11-10-2016, 11:21 AM
Its been awhile since I've been active on the AZ forums. I still hang around the local Audi crew but they've all moved on to new models and more led lighting upgrades and less big turbo's and loud exhausts. My 98 A4 is approaching 185k and the turbo was starting to get noisy. I had crap for power (found out the MAF was bad), so I decided to start troubleshooting. 4 hours later the engine and transmission were hanging from an engine lift and I started making calls and ordering parts.

http://uploads.tapatalk-cdn.com/20161110/0a31db0dcb84de3b54cef88746d0e040.jpghttp://uploads.tapatalk-cdn.com/20161110/22803275f8459df53010ee48e2eb684b.jpghttp://uploads.tapatalk-cdn.com/20161110/9bd11f3978e1afd0e707dbdf2ad66ef5.jpg

The engine had a complete bottom end rebuild about 40k ago. Scat rods, custom 83mm pistons, bored and honed. Bearings, ARP main studs. Like any good Audi, I had oil leaks and the engine was dirty, so sure let's just disassemble and clean and replace things as needed. I had the head gone through from a very reputable shop here in KC and they found some very interesting wear patterns on the 40k old exhaust valves. It seems the springs were worn too much (not stiff enough) and caused the keeper grooves to wear and almost fail. 20 new valves later I was back in business, along with new guides and seals, and supertech springs I had originally purchased as the only "head upgrade".

http://uploads.tapatalk-cdn.com/20161110/c63d5b2c155abda00cbd884729e364b9.jpghttp://uploads.tapatalk-cdn.com/20161110/9566ed5037e7bd9b081ab00553d96acb.jpghttp://uploads.tapatalk-cdn.com/20161110/bf00531deafb5a13b120cfcf030915c6.jpghttp://uploads.tapatalk-cdn.com/20161110/c6a762c5f675e0da3c2ae8e1a7735080.jpg

Because of the high mileage on the car, the suspension really needed some attention. I was running Neuspeed race springs and Bilstein sport struts. The car was a blast to drive but I was getting the typical knocking you get from failed struts. I also wanted something better, height adjustable. I decided on PSS9's and placed the order. As I was disassembling the suspension components there were a few control arms that I had yet to replace overtime. Luck would have it, I ended up breaking ball joints or bending the threaded joins while trying to disassemble. A few new control arms later and I was ready to roll.

http://uploads.tapatalk-cdn.com/20161110/d62f815eb5b424d2b7adb3cf9e68219f.jpghttp://uploads.tapatalk-cdn.com/20161110/7b4bb011d5b4bbee571e3b7addde4f52.jpghttp://uploads.tapatalk-cdn.com/20161110/cd0b55bdec8cd27bdc1471bec3c272c7.jpg

The turbo kit was the purpose of this install and I knew I needed a new fuel pump so I hopped on the 034 site and started looking for the 044 drop in pump. Found it... and then continued browsing. It's not financially safe to leave me in front of a computer screen with shiny parts and a credit card.... 30 Mins later and I had a considerable order on the way. TB kit, front and rear subframe bushings, fuel pump, and some misc odds and ends.
Shortly after going through the rear subframe bushing install (have to remove the subframes to do these). I noticed some rust on the subframe so off to the sandblaster we went and painted it up for protection. The upper strut mounts were also rusted through so I had to source some used ones locally. While shopping at 034 a few weeks back to order the rest of the parts, I noticed those fancy subframe support mounts for the swaybar. Then I found the bigger swaybar. No way could I not spend more $$ on shiny aluminum!! So we went ahead and ordered this too.

http://uploads.tapatalk-cdn.com/20161110/393db9cdeb90c608f995c5174a0297de.jpghttp://uploads.tapatalk-cdn.com/20161110/d2b92ab383008ff50006b4b5ab696c1b.jpghttp://uploads.tapatalk-cdn.com/20161110/8dd1a0a605cd3461be3103bba092c0f1.jpghttp://uploads.tapatalk-cdn.com/20161110/0c5bdbb67c2385bbac71e4cae3a16766.jpghttp://uploads.tapatalk-cdn.com/20161110/4c860182e88b281134e034ee9f183868.jpg

Now you're probably wondering, where's the turbo?! At this point I was more then 1/2 way to my $5k budget on the project and the end was no where in sight. Screw it, it's just $$ right?! I was recommended to give Marc Swanson a call at EFIExpress in NH. I highly recommend this guy. Knows his stuff, very knowledgeable and helpful, and looking forward to working with him on my tune. I was dead set on going with a GTX2967 as the turbo choice. T25 manifold, internally gated, quick spool, price wasn't TOO bad. After a 10 min convo with Marc he had me sold and giving him a CC number for an EFR 6758. I don't really know a lot about these turbos, but man it sure is pretty. Aluminum cartridge housing, big Vband 3" out, internally gated, and T25 input so it will mate up to my APR manifold no problem. I order some injectors (honestly have no idea what he sold me, but I took his advice), and a VEMS standalone ECU with a custom harness to utilize the OEM ME5 harness and sensors.

http://uploads.tapatalk-cdn.com/20161110/d3904b32fda621b70a2fb53d9a27f301.jpghttp://uploads.tapatalk-cdn.com/20161110/7e49a7199db5e6473a79d8c6498c131f.jpghttp://uploads.tapatalk-cdn.com/20161110/1ce69e6514b2324f843deecd1e57763d.jpg

So here I am, credit card bill going up, car is going back together, and I can't stop looking up YouTube videos of crazy HP Audi's or some tuner throwing an EFR turbo on and getting crazy power out of it. Call me crazy, call me dumb.... I don't really care. I'll be sure to snap a selfie of the shit eating grin on my face when I turn up the boost and run through all 6 gears.



More to come!!!
-josh

dalazybastard
11-10-2016, 11:34 AM
Stoked for you. Just waiting for a certain someone to say ahah for your choice in turbo.


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genecan
11-10-2016, 12:02 PM
When the time comes for tune - ditch this medium boost WG actuator. Call FullRace and buy the Turbosmart B1 series EFR twin port WG actuator with 26 psi spring combo. You will thank me later. Consider also upgrading the RV to a piston style one, TS have a very good "shortie plumb back" they call it.

rodgertherabit
11-11-2016, 06:17 AM
finally a good 1.8t build!

Davdraco1
11-11-2016, 06:39 AM
I hope you didn't forget about a clutch.

Beemer832
11-11-2016, 06:42 AM
I hope you didn't forget about a clutch.

I thought the oem clutch was proven to like 500hp??? :-) just kidding. Every supporting mod is already done on this car. Running a light weight aluminum flywheel and stage 3 or 4 ofe Southbend clutch rated for 400-500. I forget the numbers.
Hey if I burn up a clutch because of power, I will have no problem replacing it. That would actually make my day!!
-josh


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Davdraco1
11-11-2016, 10:26 AM
ive been in an aeb 7163 efr..... so much fun.

zandrew
11-15-2016, 02:54 PM
I am amidst my engine build as well, very similar except my stupid ass bought the stroker setup and now has backed out.

I would give a word of caution of the 6758, you are a 98 so you need a MAF. That's not a huge deal but the turbo is longer on the cold side and shorter on the hot side. You may want to try and mock up the turbo to find out if the manifold will work with her.

Beemer832
11-15-2016, 02:55 PM
I am amidst my engine build as well, very similar except my stupid ass bought the stroker setup and now has backed out.

I would give a word of caution of the 6758, you are a 98 so you need a MAF. That's not a huge deal but the turbo is longer on the cold side and shorter on the hot side. You may want to try and mock up the turbo to find out if the manifold will work with her.

Running a mafless stand alone tune. No more me5 limitations.


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zandrew
11-15-2016, 03:00 PM
I would still check and make sure it's not jammed into the back of the headlight.

andyrew
11-16-2016, 09:24 AM
I see an APR manifold, good shit. Thats going to be a PITA to bolt on BTW.. Just be prepared :)


This will be fun! What are you going to rev the engine to?

Beemer832
11-16-2016, 09:27 AM
I see an APR manifold, good shit. Thats going to be a PITA to bolt on BTW.. Just be prepared :)


This will be fun! What are you going to rev the engine to?

The manifold or turbo? I've had the APR kit for the entire time i've owned the car. I have a slew of "special" tools I've fabricated over the years to make the manifold off/on painless. The first time I did it, I wanted to sell the manifold, now not so much.
No clue on rev limit. The top end is ready to handle a higher rate then stock, but not sure what I will gain while still keeping longevity and daily driver in mind.
-josh

nynoah
11-16-2016, 02:45 PM
what wheels did you have on there?

andyrew
11-17-2016, 11:24 AM
The manifold or turbo? I've had the APR kit for the entire time i've owned the car. I have a slew of "special" tools I've fabricated over the years to make the manifold off/on painless. The first time I did it, I wanted to sell the manifold, now not so much.
No clue on rev limit. The top end is ready to handle a higher rate then stock, but not sure what I will gain while still keeping longevity and daily driver in mind.
-josh

It looked like a full apr kit, but I knew you were just going to use the manifold.

Im revving to ~7500 right now and my setup likes it a lot. I plan to bump it up to 8k for a little bit more leeway on the track/autox. I was planning 8250 originally but I think its probably not going to be beneficial. Supertech valve springs/valves as well here. Im only boosting to 10-12psi (10psi wastegate) but the power seems to be there.

https://www.youtube.com/watch?v=ymyGqg5HoTE

Beemer832
11-17-2016, 11:36 AM
Yea man it looks good!! That overlay with car stats is freakin awesome! Finally a good reason to watch GoPro video's!!! Damn I miss the track....
-josh

andyrew
11-17-2016, 03:12 PM
Its even cooler in a 43 year old car :)

(Not meant to distract from your build... just similar motor builds, thought you would enjoy hearing the engine singing)

Michael2200
11-18-2016, 10:48 AM
Awesome thread man, keep us updated!

tesh0boy
11-20-2016, 10:29 PM
Jeeze my friends think I'm crazy spending a thousand at a time on my car...lol Nice garage btw. Having a lift must make things 1000x easier. My car is just about caught up and ready to toss a kit on myself but the b5 is distracting me from my ongoing vrt. I keep forgetting the b5 is supposed to be a simple daily while my vw is the fun car. Was eye balling the RAI EFR 6258 setup myself so I'll be following for spool response times once you get things running with your 6758.

Beemer832
12-18-2016, 10:03 AM
http://uploads.tapatalk-cdn.com/20161218/57661cc9a743680858873ffe7b216a02.jpghttp://uploads.tapatalk-cdn.com/20161218/8ad99117f82424b29b3d991d488bdbde.jpg

Well it fits. Still need to rotate chra and compressor housing. But clearance will not be an issue with the Apr manifold.

-josh


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thrilos5
12-18-2016, 10:42 AM
Nice build, btw what did the VEMS stand alone cost you?

Beemer832
12-18-2016, 11:22 AM
Nice build, btw what did the VEMS stand alone cost you?

I think $700 plus I had a custom plug n play harness made.


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Seerlah
12-18-2016, 11:50 AM
Sweet!!!

migaellefebvre
12-18-2016, 12:41 PM
Yesss not enough efr out there!! I also want to see someone push a 6258 on a 1.8t..


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Believer
12-18-2016, 01:33 PM
Yesss not enough efr out there!! I also want to see someone push a 6258 on a 1.8t..


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Buy my gt28rs and I'll show you lol

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andyrew
12-19-2016, 07:17 AM
Looks good! Lets see the tools you made to install the manifold :)

GOODBYNAAIR
12-19-2016, 04:19 PM
Buy my gt28rs and I'll show you lol

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thought you were running a F21 ? but selling 28rs.?

Believer
12-19-2016, 04:21 PM
thought you were running a F21 ? but selling 28rs.?
Purchased 😉

http://uploads.tapatalk-cdn.com/20161220/453c118effa5c250d8966d04f1116065.jpg

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GOODBYNAAIR
12-19-2016, 04:30 PM
Nice! and good call i'm over my 2860 elim With ATP KKK mani..... dont get me wrong it is a fun set up but its just old tech. The next thing will be EFR but now that I have been working on my house I dont see that happening any time soon lol.. sadly.

Beemer832
12-28-2016, 04:18 PM
Been awhile since I've gotten a chance to work on the car. Made some good progress the last two days. Including the confirmation that the turbo does indeed fit in the car with the Apr manifold. No clue what will need to be done for I take piping but I'll worry about that when I get there.

Here's the proof:
http://uploads.tapatalk-cdn.com/20161229/a12d36e61af0cb95b517c7c0c7edcfbe.jpghttp://uploads.tapatalk-cdn.com/20161229/6ca2a4fe16d45ba05c7c22d1e7759113.jpghttp://uploads.tapatalk-cdn.com/20161229/b94935a749fdf82537319d04f494f5e0.jpghttp://uploads.tapatalk-cdn.com/20161229/d90164e421421610784594b9cfcfe9f2.jpghttp://uploads.tapatalk-cdn.com/20161229/b90205cdcab31733357c5de497a3ae3c.jpg


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b6Hate4
12-28-2016, 04:21 PM
Nice!

Believer
12-28-2016, 07:05 PM
Lookin good

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andyrew
12-29-2016, 07:20 AM
That looks about as much clearance I had with the Comp Turbo on the APR manifold. My big issue was the long CHRA giving me about 2" from the turbo inlet to the headlight back.

Beemer832
12-29-2016, 09:22 AM
That looks about as much clearance I had with the Comp Turbo on the APR manifold. My big issue was the long CHRA giving me about 2" from the turbo inlet to the headlight back.

I'll be running a mafless setup but what did you do for an air filter?


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andyrew
12-29-2016, 01:50 PM
I ran a 130deg elbow to the MAF then a 3" u bend to a cone filter with the thermostat plate. Basically the APR stuff I modified.

With my Blow through MAF setup now I just run a cone on the turbo.. but I have heeps more room in the 914 compared to the A4 (As was my design).

genecan
01-02-2017, 09:52 AM
This will be my favourite thread these days... :)

Beemer832
01-02-2017, 06:50 PM
Car is starting to look like a car again, finally. Exhaust is on. Front clip is attached. I put in the passenger headlight to check on clearance and I have plenty of room there. My issue is the clearance between the turbo inlet and the electric fan on the front clip. I order some 90 degree silicone elbows today and am hoping I can modify one to work. There is no room for a mushroom air filter event. I think I measure 2-2.5" of clearance.

Off to the fab shop for a custom down pipe sometime this week. Tune appointment to get this thing running scheduled for January 13th. Ill be sure to post a video on first start.

On a side note, I need to get some wideband o2 sensors. One is for the VEMS standalone, and the other for my innovate wideband. I've been getting bosch plugs from a 2002 volkswagen jetta at the local auto parts store. They are fairly inexpensive and seem to work. Any issues with doing this?
-josh

genecan
01-03-2017, 12:23 AM
I told you there is no room to put mushroom filter stright on top of the comp housing. 90 degree silicone bends will probably not work either.
You need:
1. https://store.034motorsport.com/034-motorsport-90-degree-3-silicone-cobra-head.html and
2. http://www.intakehoses.com/mm5/merchant.mvc?Screen=PROD&Product_Code=30R25&Category_Code=RIS

A smart thing to do is to put a 3" flow srtraightener in the cobra elbow just before the compressor inlet, layed against the rubber insert.

I have prepared few bits utilizing this http://www.ebay.com/itm/AIR-CLEANER-REAR-INTAKE-DUCT-ADAPTER-CHEVROLET-EXPRESS-GMC-SAVANA-With-Hose-/262782035007?hash=item3d2f07a43f:g:JToAAOSwj85YOw8 W&vxp=mtr , but probably I will get to assmble it way after you finish your project.

One more way to do it is if you are a fabricator to use this http://www.ebay.com/itm/Procharger-Standard-Bonnet-UNPolished-Carb-Carburetor-Hat-/370895378205 . This may also be suitable with some modification but have not invested much time in researching this option: http://www.ebay.com/itm/201563258648?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

chris164935
01-03-2017, 01:15 AM
On a side note, I need to get some wideband o2 sensors. One is for the VEMS standalone, and the other for my innovate wideband.
Just wire the Innovate unit to the VEMS (if you have the LC-1, it will be the brown and yellow wires; one goes to your gauge, the other to the VEMS) and buy one OEM Bosch wideband sensor to plug into the Innovate unit. No need for separate O2 sensors. This way, you will see the same AFR parameter that the VEMS sees.

Seerlah
01-03-2017, 05:53 AM
Also invest in some solid motor mounts. Clearance by the frame looks like the assembly will collide without solid mounts. My downpipe can hit my chassis on harder shifts with 034 Street Density mounts (I can possibly take pics later to show what I mean, if not too lazy). I want to pick up these next.

https://store.034motorsport.com/motor-mount-pair-motorsport-b5-b6-b7-and-c5.html#product_tabs_review

Beemer832
01-03-2017, 06:50 AM
I told you there is no room to put mushroom filter stright on top of the comp housing. 90 degree silicone bends will probably not work either.
You need:
1. https://store.034motorsport.com/034-motorsport-90-degree-3-silicone-cobra-head.html and
2. http://www.intakehoses.com/mm5/merchant.mvc?Screen=PROD&Product_Code=30R25&Category_Code=RIS

A smart thing to do is to put a 3" flow srtraightener in the cobra elbow just before the compressor inlet, layed against the rubber insert.

I have prepared few bits utilizing this http://www.ebay.com/itm/AIR-CLEANER-REAR-INTAKE-DUCT-ADAPTER-CHEVROLET-EXPRESS-GMC-SAVANA-With-Hose-/262782035007?hash=item3d2f07a43f:g:JToAAOSwj85YOw8 W&vxp=mtr , but probably I will get to assmble it way after you finish your project.

One more way to do it is if you are a fabricator to use this http://www.ebay.com/itm/Procharger-Standard-Bonnet-UNPolished-Carb-Carburetor-Hat-/370895378205 . This may also be suitable with some modification but have not invested much time in researching this option: http://www.ebay.com/itm/201563258648?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Thanks for the info man. I will definitely let you know what I come up with. Cars going to a fab shop this week for the downpipe. I'll see if the guys there have any ideas.


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Beemer832
01-03-2017, 06:51 AM
Also invest in some solid motor mounts. Clearance by the frame looks like the assembly will collide without solid mounts. My downpipe can hit my chassis on harder shifts with 034 Street Density mounts (I can possibly take pics later to show what I mean, if not too lazy). I want to pick up these next.

https://store.034motorsport.com/motor-mount-pair-motorsport-b5-b6-b7-and-c5.html#product_tabs_review

I have the track density mounts so not sure if they will cause too much play or not. I'll keep an eye on that clearance. Thanks for the heads up!! Definitely something I didn't think of.


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B5nDisciple
01-04-2017, 02:36 PM
I have the track density mounts so not sure if they will cause too much play or not. I'll keep an eye on that clearance. Thanks for the heads up!! Definitely something I didn't think of.


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I'm curious how much flex they'll be with the track density mounts. Looking good though!

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Beemer832
01-09-2017, 12:22 PM
Car is at the fab shop getting a custom 3" SS vband downpipe made. They are also looking at some options to help me fit a air filter into the turbo.

One issue I've run into is that the shifter is not engaging any gear. I have the JHM solid shifter linkage and this was wroking great before. Now, the rod that connects the shifter to the trans is hitting the tunnel and not shifting any gear. I am "hoping" the shifter just needs an alignment from inside the car, but I dind't have enough time to mess with it this weekend.

Tuning is scheduled for Friday the 13th, but I am not sure I am going to make this deadline with the issues that still need to be fixed.

-josh

chris164935
01-10-2017, 09:50 AM
Both rods bolted to the the transmission? One bolts to the trans housing and the other bolts to the mechanism that is moved to change gears inside the transmission.

genecan
01-19-2017, 01:50 PM
UPDATES!!!!!!!!!!!

B5nDisciple
01-19-2017, 06:36 PM
UPDATES!!!!!!!!!!!
I second that motion!

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Beemer832
01-20-2017, 05:14 AM
Down pipe is complete. Turbo piping is in a workable state yet temporary.
Went to start the car last weekend but no go. Not getting voltage to fuel pump so not sure if it's a wiring or programming issue on ecu.
Out of town next week so no progress :-(
I did order a 90 Inlet adapter for intake and cut it down. I think it will work to fab up an Intake for the turbo. It is a little compressed from the sharp turn and sitting against front clip but it seems strong enough to not collapse under vacuum. I guess time will tell.
I also figured the shift linkage issue out. I had installed the linkage on the wrong side of the gear selector on the trans. This pushed the whole linkage up an extra inch or so and at a steep angle. That's what you get for rushing!!!

https://uploads.tapatalk-cdn.com/20170120/d20ffbea2ca7cf22ee06b8bbffe7d017.jpghttps://uploads.tapatalk-cdn.com/20170120/ccc5f503effdbd163e65c28474186eae.jpghttps://uploads.tapatalk-cdn.com/20170120/13434ad4e7451edbd7a756006b27d068.jpghttps://uploads.tapatalk-cdn.com/20170120/27d199abd7016f2e6ca503b311a34081.jpg


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genecan
01-20-2017, 06:02 AM
I did order a 90 Inlet adapter for intake and cut it down. I think it will work to fab up an Intake for the turbo. It is a little compressed from the sharp turn and sitting against front clip but it seems strong enough to not collapse under vacuum. I guess time will tell.

Which one did you ordered exactly, any pictures of it on the turbo?

Beemer832
01-20-2017, 06:55 AM
I found a basic 6" length, both side, 90 degree, 2.5" inlet from amazon. I tihnk it was $35 or something. Then I just cut down on one side as much as I could still keeping the 90 and enough room to clamp on turbo. I will get some pictures in a week. I am on vacation for a week, so the car will sit until i get back.
-josh

genecan
01-20-2017, 08:11 AM
I found a basic 6" length, both side, 90 degree, 2.5" inlet from amazon. I tihnk it was $35 or something. Then I just cut down on one side as much as I could still keeping the 90 and enough room to clamp on turbo. I will get some pictures in a week. I am on vacation for a week, so the car will sit until i get back.
-josh

Regular 90 degree elbow will not do the job appropriately, beacause either - the side going into the turbo will be too long and will hit the fan or the turbo compressor inlet housing will stick within the lumen of the elbow creating a choke point and turbulence. Get the cobra from the 034 and the sleeve reducer + flow strightener :)

http://i44.photobucket.com/albums/f16/rembrandt/IMG_1453_zpsxr8wf8ue.jpg (http://s44.photobucket.com/user/rembrandt/media/IMG_1453_zpsxr8wf8ue.jpg.html)
http://i44.photobucket.com/albums/f16/rembrandt/IMG_1458_zpswpqdesc5.jpg (http://s44.photobucket.com/user/rembrandt/media/IMG_1458_zpswpqdesc5.jpg.html)
http://i44.photobucket.com/albums/f16/rembrandt/IMG_1460_zpsrqrfvmru.jpg (http://s44.photobucket.com/user/rembrandt/media/IMG_1460_zpsrqrfvmru.jpg.html)
http://i44.photobucket.com/albums/f16/rembrandt/IMG_1461_zpsynqaioq3.jpg (http://s44.photobucket.com/user/rembrandt/media/IMG_1461_zpsynqaioq3.jpg.html)

Images are courtecy of Rockersteady - thank you for being so detailed.

Beemer832
02-07-2017, 05:57 AM
I found the cobra head adapter, but where did you get the reducer and screen from? What is the purpose of the screen? Just trying to understand what the purpose is and where you got them from.

At this point I am just trying to get the engine to run so I am not even running anything on the inlet. Before it hits the road I will need something though.
-josh

Regular 90 degree elbow will not do the job appropriately, beacause either - the side going into the turbo will be too long and will hit the fan or the turbo compressor inlet housing will stick within the lumen of the elbow creating a choke point and turbulence. Get the cobra from the 034 and the sleeve reducer + flow strightener :)

http://i44.photobucket.com/albums/f16/rembrandt/IMG_1453_zpsxr8wf8ue.jpg (http://s44.photobucket.com/user/rembrandt/media/IMG_1453_zpsxr8wf8ue.jpg.html)
http://i44.photobucket.com/albums/f16/rembrandt/IMG_1458_zpswpqdesc5.jpg (http://s44.photobucket.com/user/rembrandt/media/IMG_1458_zpswpqdesc5.jpg.html)
http://i44.photobucket.com/albums/f16/rembrandt/IMG_1460_zpsrqrfvmru.jpg (http://s44.photobucket.com/user/rembrandt/media/IMG_1460_zpsrqrfvmru.jpg.html)
http://i44.photobucket.com/albums/f16/rembrandt/IMG_1461_zpsynqaioq3.jpg (http://s44.photobucket.com/user/rembrandt/media/IMG_1461_zpsynqaioq3.jpg.html)

Images are courtecy of Rockersteady - thank you for being so detailed.

Seerlah
02-07-2017, 07:21 AM
Screen is to create accurate readings for the maf sensor element. This is also why the stock housing has one. It breaks up the intake air mass so proper grams per second can be measured. If not...you basically will have an unseen big dense glob of air being read by the sensor element as it passes by. This is also why people suggest at least 3" straight section before the maf...also for a more accurate reading.

When adding a screen you also must take into consideration the total volume blockage ot creates. I used to run just a screen and now run a filter. Despite the fact of unfiltered air with dirt being sucked into combustion (scratches bores very tiny...air quality dependant), people hqve done testing and found filters are better. I run a Vibrant filter but have an Injen dry setup I had for years. Won't fit. Placing on a tubular manifold spring time (at friends house for a couple years and built it for me) and will actually now be able to place it on!

Believer
02-07-2017, 07:24 AM
The placement of the flow straightener is confusing; it is supposed to be installed before the MAF sensor and the pictures it appears to be placed after the sensor. Am I missing something?

Beemer832
02-07-2017, 07:28 AM
GOT IT! okay I am lucky, not MAF for me!!!! Ill get this pipe ordered today with reducer. Thank you for the explanation, this makes more sense now.
-josh


Screen is to create accurate readings for the maf sensor element. This is also why the stock housing has one. It breaks up the intake air mass so proper grams per second can be measured. If not...you basically will have an unseen big dense glob of air being read by the sensor element as it passes by. This is also why people suggest at least 3" straight section before the maf...also for a more accurate reading.

When adding a screen you also must take into consideration the total volume blockage ot creates. I used to run just a screen and now run a filter. Despite the fact of unfiltered air with dirt being sucked into combustion (scratches bores very tiny...air quality dependant), people hqve done testing and found filters are better. I run a Vibrant filter but have an Injen dry setup I had for years. Won't fit. Placing on a tubular manifold spring time (at friends house for a couple years and built it for me) and will actually now be able to place it on!

APC123
02-07-2017, 09:09 AM
Awesome!


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genecan
02-07-2017, 03:18 PM
The insert (reducer) is coming from intakehoses.com - see post # 37 for the link I gave you before. The straightener do come from a 3" MAF - VR6 or TT 225 hp.

I am a little disappointed that nobody got the idea behind the scheme. It has nothing to do with air flow-metering. It has a lot to do with flow dynamics. The elbow you are using has a very short radius of the curve, as well as few changes of the cross-section shape within short distance, hence creates circumstances for turbulence initiation. Turbulence means less total flow/time i.e. obstruction. Next thing is that this turbulent flow would hit directly the blades of the compressor wheel and I would bet in this situation it would decrease the wheel efficiency too. With the flow straightener you bring back the flow to laminar condition just before the compressor wheel leading to all positive characteristics and consequences. You could search on youtube for videos of the effect of flow straightner on the flow - I found very nice colored flow examples.

The total area of fins of the straightener facing the flow is negligible. Under the text I will post a drawing. There is a crossed cone area behind the straightener. The difference between the cross-section surface of the entrance and the exit from this area is bigger than the total surface area of the fins meaning that the cross-section of the "clear" ducting space within the straightener is still bigger than the intake tubing of the compressor housing. Just pay attention to the edges of the insert (trim a little the inner edge) as robust changes in piping also tend to create areas of turbulence.

http://i44.photobucket.com/albums/f16/rembrandt/Intake%20scheme_zpszfdvhyuh.jpg (http://s44.photobucket.com/user/rembrandt/media/Intake%20scheme_zpszfdvhyuh.jpg.html)

I was going to bet that the effect of all this flow preparation may not be that significant, but the guy who actually did it (and he is an experienced one - he does tuning for living) claimed it makes a difference. I will do it this route for sure.

Operator
02-08-2017, 05:43 AM
Look forward to the finished build! The 6758 has been an awesome performer.

Beemer832
02-14-2017, 09:55 PM
Wiring harness should be back hopefully Thursday.

What's everyone's though on this guy? I did t realize you could find such low profile filters.

http://www.knfilters.com/mobile/mProduct.aspx?prod=RC-0850


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Beemer832
02-21-2017, 03:34 PM
Alright AZ'ers.... The car finally started last week after I got the harness back from Marc over at EFIExpress. We had to do some minor tweaking to get the car to run, but it's running and it's idling all on its own. Very happy week.

Today, I needed to get the car out to get some logging done. 75 degree weather here in Kansas City, so I took advantage of it. The car went out for its first drive and boy was it fun. I was instructed to keep the boost levels down while breaking in turbo and dialing in the tune, but I may have gotten a little happy and boosted close to 10psi. Even at 5-6psi this things pulls hard. I am guessing that around 3200rpm is where the boost really starts, but the transient response of this turbo gets you 5psi almost right off of idle.

Long story short.. I am very happy with the tune and turbo setup thus far. I still need to figure out a permanent mounting solution for the VEMS box, and do a little more cable management. The bumper still needs to go on, but there isn't any reason why it won't fit.

Anyway, I figured I report in and let everyone know how things are going. I am currently waiting for another tune to come my way to fix the idle issue. Once that is done I am hoping we can crank up the boost a little and see what the car can do!!!

I'll leave this here for proof!
34800
-Josh

Seerlah
02-21-2017, 05:46 PM
Didn't even realise you are from Kansas City. Was going to visit a woman I met years ago that lives there. Time moves on, and almost totally forgot about her. As time moves on...probably will altogether, and her me.

Other than the tangent, nice to hear. If the standalone can fit in the stock weatherbox, use that. Use the rubber seal from the stock harness and basically get creative. If not that...glove box never really gets old.

genecan
02-22-2017, 07:30 AM
How did you solve the turbo intake piping?

b6Hate4
02-22-2017, 08:39 AM
How did you solve the turbo intake piping?

Looks like he went MAF-less.

Beemer832
02-22-2017, 08:57 AM
How did you solve the turbo intake piping?

Still using a 90 degree sillicone hose I bought and chopped up. Instead of the cobra head option, I think I may try to cab up some sort of an aluminum plenum. That way I don't have to worry about the hose collapsing under vacuum. What I have works okay for now, so we will see.

b6Hate4 - Correct this is a mafless tune.
-josh

genecan
02-22-2017, 03:25 PM
Get pictures

tesh0boy
02-25-2017, 03:19 AM
What did you end up doing to the old turbo, 2860 I'm guessing being an apr kit?

Beemer832
02-26-2017, 08:09 PM
What did you end up doing to the old turbo, 2860 I'm guessing being an apr kit?

I have two of them actually. One has a broken shaft but the compressor and turbine housings look to be in good shape.

The second one is the one that came off the running car. That turbo has a solid 150k on it so I wouldn't define it as being "okay" just due to the mileage. That being said, the shaft play is minimal and it wasn't making any noise when it was removed.




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Beemer832
02-26-2017, 08:13 PM
Got a second iteration of the tune finally. The car is idling much better but still needs some tweaks. Finally gave it full throttle and boost and it feels great. Boost starts coming on just under 3k and builds fast from there.
I am stuck with the stock spring rate for the wastegate at like 12-13 psi so that's all I'm getting, but, it still drives great.




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Beemer832
02-28-2017, 10:00 AM
Anyone have any ideas on where to mount this damn ECU? It won't fit in in the ECU box with the harness adapter and everything else. The harness isn't long enough to reach the glove box. I am thinking maybe under neath the driver knee bolster (under the dash) but will be a tight fit.

-josh

Seerlah
02-28-2017, 11:53 AM
Maybe plastic weld to the stock weatherbox to accomodate for the longer standalone unit.

chris164935
02-28-2017, 10:39 PM
I mounted my stand-alone ECU on the driver's side knee bolster (on the inside). It basically sits right next to the relay panels and to the left of the steering column. My ECU is about 7" by 7" by 2". I used some 3M velcro strips.

genecan
02-28-2017, 10:59 PM
Glove box?

Seerlah
03-01-2017, 04:43 AM
Noticed KC made top 10 dangerous cities 2016. We made the FBI list 2014. We have something in common. Hahaha

Refusal to move because I was raised here and will die here, God willing. This is home...to murderers, thieves...and those on the total opposite end of the spectrum. Maybe one day complete a statistic. Home is where the heart is!

Beemer832
03-02-2017, 06:22 AM
Noticed KC made top 10 dangerous cities 2016. We made the FBI list 2014. We have something in common. Hahaha

Refusal to move because I was raised here and will die here, God willing. This is home...to murderers, thieves...and those on the total opposite end of the spectrum. Maybe one day complete a statistic. Home is where the heart is!

Where do you live?!


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Seerlah
03-02-2017, 08:46 AM
PM sent

nynoah
03-02-2017, 08:53 AM
If it were my car, I would break out my soldering iron and extend the wires for the ECU to mount it in the stock location.

Beemer832
03-06-2017, 01:23 PM
I ended up hacking up some of the plastic inside the OEM ECU box and got the harness and VEMS unit in there securely.

Next up is getting some new intercooler piping fabbed up to fit behind the bumper. They are going to look and see if they can put some sort of plenum together for a reasonable cost for the intake. If not, I will give the 034 cobra pipe a shot.

Realized the car hasn't been tagged for this year so I will need to get that done, and a wheel aligment and then i THINK I can start driving this thing daily. I need to dial in the suspension and set the ride height so it's more even. Need to get a better air filter and fab up a heat shield to keep the turbo heat from killing my intake temps.

Oh I also need to figure out how to wire the throttle body stepper motor into the vems so I can get a good idle. Right now I have no control over this motor but found a writeup on AW or maybe Vortex about someone doing it and it worked.

-josh

Beemer832
05-24-2017, 04:59 PM
Sorry for the long time between updates. I just installed the 034 cobra head intake pipe. Fits perfect with the efr6758 on the Apr manifold. I had some 2.5" hose I used as a reducer and it tightened up. Will try this again as the old elbow was collapsing under high boost.

Just need a few more ecu tweaks for idle when cold and to turn the boost up another 30%. Holding 24psi now and it pulls awesome.


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Seerlah
05-25-2017, 11:15 AM
Sounds good 👍

nynoah
05-25-2017, 01:26 PM
Don't go over 24 with an EFR6758. You will overspin the turbo and those turbos blow up when they overspin.

Beemer832
05-25-2017, 01:35 PM
Are you kidding me? I thought those were rated for like 30psi?? Oh well. I guess we will have to work on keeping the boost down and tweaking the timing and fuel to get the power that I want. Still an incredibly fun and fast turbo to daily drive. I guess I'll have to get it dyno'ed one of these days to actually see what I am putting down.

-josh

nynoah
05-25-2017, 01:38 PM
You can run more boost but you need to monitor it to make sure you are not overspinning the blades. People are using these to monitor.

https://www.full-race.com/store/efr-series/components/borgwarner-efr-turbo-speed-sensor-kit-2/

http://www.roadragegages.com/whatsnext.htm

Beemer832
05-25-2017, 01:41 PM
Cool man thanks for the info. I will be checking this out ASAP
-josh

Seerlah
05-25-2017, 07:25 PM
Not in the mood to backtrack, but what fuel are you running? Less boost does not mean less power has to be settled on.

Beemer832
05-26-2017, 07:50 AM
Not in the mood to backtrack, but what fuel are you running? Less boost does not mean less power has to be settled on.

91 non ethanol. Because I want to keep this daily driveable as possible, I'm not sure I want to go the meth inject route.


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Seerlah
05-26-2017, 08:32 AM
You don't need to. You can mix octanes with drums kept at your house, and end up with octane of your choosing. Now you can add more ignition timing, while retaining same amount of boost. Or skip the bull and keep drums at your house of whatever fuel you want. Saves a trip to the gas station. Place one of these the drum pump, and one more way to go about it is there for you.

http://www.shop.perma-cool.com/Fuel-Filter-Water-Separator-Systems_c21.htm

Beemer832
06-04-2017, 12:39 PM
Question for everyone.... why would I be getting 6-8oz of fluid after a day of normal highway driving? I emptied yesterday and checked today and there was way more than I expected to see. I'm going to do a leak down test to make sure the rings are okay but they only have 30k on them.
The other option is the valve cover vent. I am wondering if the cam is throwing too much oil up and it's just sucking it down the vent tube. What am I missing here?
Also using the 034 block vent adapter. They both route into a T fitting then into the catch can.


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Rodgman15
06-04-2017, 01:08 PM
Question for everyone.... why would I be getting 6-8oz of fluid after a day of normal highway driving? I emptied yesterday and checked today and there was way more than I expected to see. I'm going to do a leak down test to make sure the rings are okay but they only have 30k on them.
The other option is the valve cover vent. I am wondering if the cam is throwing too much oil up and it's just sucking it down the vent tube. What am I missing here?
Also using the 034 block vent adapter. They both route into a T fitting then into the catch can.


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I'm assuming you're​teasing about a catch can?

If your valve cover is vented, that's where it's coming from. These engines piss blow by like nobody's business. I got so sick of it I re routed it through a scavenger setup into my exhaust. Or just leave the drain open and let it run everywhere 😂

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Beemer832
06-04-2017, 01:16 PM
I'm assuming you're​teasing about a catch can?

If your valve cover is vented, that's where it's coming from. These engines piss blow by like nobody's business. I got so sick of it I re routed it through a scavenger setup into my exhaust. Or just leave the drain open and let it run everywhere [emoji23]

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Yes catch can. Okay so this is normal. I usually do leave it open ;-) but going to a track day this weekend and that's a little frowned upon. Maybe a little unsafe too.

So you just route the vent tubes to the down pipe and let the heat burn it?


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Rodgman15
06-04-2017, 01:19 PM
Yes catch can. Okay so this is normal. I usually do leave it open ;-) but going to a track day this weekend and that's a little frowned upon. Maybe a little unsafe too.

So you just route the vent tubes to the down pipe and let the heat burn it?


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There's a fitting similar to an o2 fitting that I welded into my downpipe, then a Venturi type fitting...

Fuck it here's the link lol

https://www.kseriesparts.com/cr/VIB-1189.html?gclid=CjwKEAjw387JBRDPtJePvOej8kASJADkV9 TL48r_7ttFwSMkMTQ-2D1iSC72DEK4kj5z8H58jjjeKhoCuTjw_wcB

Not where i bought mine FYI, first link that had it. Allows the exhaust to pull it through and burns it there. Get a little weird smoke every now and again but nothing drastic, quick second or two.

Clarification - valve cover and crank case to catch can, bottom fitting on can to scavenger.

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