Budget BT build

[20vpower]

After going k04, the urge has hit me for more power, whats new? This will just be my rough draft for the build and i'm sure thing will change as time goes on. Please feel free to give any suggestions/input. I know that I don't know everything and i'm sure that I could use some advice from people that have done it before.

-Turbo will be JB t3/t4e 50 trim w/ .63 a/r turbine(figured I wanted more hp than a slightly faster spool of the .48 a/r). Reason for going this turbo is price. I am expecting ~20psi around 4k or so I have read from others. I know that T series have double the parts of GT turbos, I know that the spool/respool with the JB will be slower than DBB, I know that the longevity of T series JB will be lower than the new tech GT turbos.
-Oil lines
-ATP T3 Mani
-ATP 3" DP with 4 bolt 2.5" vband adapter(4 bolt 2.5" is because thats all thats listed on the .63a/r turbine) then 3" custom exhaust
-Need to make custom tip
-Tial 38mm WG + dump tube
-Fuel pump (was thinking walbro 255, but then again I have heard bad things about them)
-Tapp Tune
-630cc injectors for tapp tune
-4" lightning maf for tapp tune
-Innovate LC1
-Southbend STG 3 clutch w/ stock flywheel
-Lower end rebuild will be done in a spare motor, keeping 1.8 just want to do rods, bearings, head bolts, gaskets ect....Using AEB engine
-Nuts/studs/Washers

Things I already have
-Apexi AVC-R EBC
-ECS afpr + 034 gauge
-Boost gauge
-Vag
-Ebay IC kit 27X7X2.5 (22" core w/o endtanks; will upgrade when funds are avail)
-007 DV
-BKR7E (will try F6DTC if ngks aren't working well)
-Im sure theres more if you see I am missing something please ask/point out!

Here is my list for turbo/dp/oil lines from atp, will be buying atp t3 mani used
http://i52.photobucket.com/albums/g3...untitled-1.jpg
-Need to find out stock oil filter size for oil feed line adapter

Plan is to run turbo setup on my current in car stock motor on low boost until built motor is ready

Please let me know if you have ANY advice or suggestions to help me along

[AudiA4_20T]

do u want my 50 trim? im selling it super cheap but no one is biting

how much are u expecting to spend btw? I would expect you can do that setup for under $5k

[Don Supreme]

I don't think UNI has a good 630cc file for the AEBs right now.

[20vpower]

do u want my 50 trim? im selling it super cheap but no one is biting

how much are u expecting to spend btw? I would expect you can do that setup for under $5k

what is the turbine a/r? how many miles? and price? pm me please for info

[20vpower]

I don't think UNI has a good 630cc file for the AEBs right now.

any suggestions for different tune or different inj file? what is it that is not good about it?

[AudiA4_20T]

what is the turbine a/r? how many miles? and price? pm me please for info

not sure how many miles, I think its under 10k though, .63 housing and $400+shipping, YGPM

[pisces_0]

any suggestions for different tune or different inj file? what is it that is not good about it?

I heard they're still ironing out a lot of bugs with it.

I'd like to get an update, though, if any forward progress has been made.

[20vpower]

yes shooting for ~5k but we will see how it turns out.

might have to go with ctapp tune if uni is looking questionable, but that means 4 inch maf...

[1fstavant]

.63 ar ftw....48 wont make any power up top just to let you know-i hit full boost by 4000 on the .63

[20vpower]

Back from the dead for an update on a thread I totally forgot about...

Car is running.

However, its on a stock ecu, 440 green tops @ 3bar and 3" maf.

The plan has changed for the tune. I am going with 034 dyno tune. This will be in the next few weeks when I get my tax return and sort out some hardware issues. Just need to rework my IC piping and a few other odds n ends to get it ready for 034.

So the budget wasnt too far off, there was some definate unexpected items... Spent around $3k for the turbo setup. Still need to pay for the tune. Then the engine build will be coming shortly after. I already got a spare 058 block that will be receiving the work.

I have yet to actually push the car hard for lack of tuning. I do have my wideband hooked up and have hit ~10lbs of boost. AFR actually looked nice, didnt get lean started to richen up as rpms rose. Only revved to ~4-5k max right now, dont want to push anymore until this thing is tuned.

OH and when I first got the car running I only was revving to like 2kish and was hitting no boost. I thought I hooked the vac lines up wrong... I later remembered im not dealing with a k03/4 any more

Will update with pics soon as my camera is at the bottom of Lake Mclure thanks to my GF.

[pipe7284]

Will be waiting for pics and vidz

[djwimbo]

Will update with pics soon as my camera is at the bottom of Lake Mclure thanks to my GF.

That sucks, sorry about that.

Good deal on getting it running though.

[20vpower]

Yah I was having problems with it not charging when I first got it running. Funny thing is Poopie called out what happened with in the first response to my problem. It was just a different wire that I somehow skipped over.

He thought it was a starter wire I pinched between the bell housing and the block. Close, but it definatly was a pinched wire that cause major headaches... It was the voltage regulator wire.

Im just glad that mess is over with. However its not all cookies and cupcakes lol. I was driving home today from the store and noticed my coolant just over the middle normal temp. Then my oil temp went to ~250. My coolant light came on right down the street from my house. Pop the hood and boom upper rad hose popped off. NO coolant... Filled her up and got the air bubbles out and its now back to normal.

Im thinking I need to replace the wire clip that holds it in place, I just dont trust it anymore.

OH and my speedo still stops working randomly while driving. Im not to worried about just yet, I like my car not gaining miles lol

[djwimbo]

Im thinking I need to replace the wire clip that holds it in place, I just dont trust it anymore.

OH and my speedo still stops working randomly while driving. Im not to worried about just yet, I like my car not gaining miles lol

Now replace that clip on a heater core line behind a 2.7T, talk about a headache.

Speedo inop intermittently? sounds like a cluster issue. Those seem to be popping up more often now that our cars are all getting past or near the 10 year old mark

[Poopie]

Yah I was having problems with it not charging when I first got it running. Funny thing is Poopie called out what happened with in the first response to my problem. It was just a different wire that I somehow skipped over.

He thought it was a starter wire I pinched between the bell housing and the block. Close, but it definatly was a pinched wire that cause major headaches... It was the voltage regulator wire.

Im just glad that mess is over with. However its not all cookies and cupcakes lol. I was driving home today from the store and noticed my coolant just over the middle normal temp. Then my oil temp went to ~250. My coolant light came on right down the street from my house. Pop the hood and boom upper rad hose popped off. NO coolant... Filled her up and got the air bubbles out and its now back to normal.

Im thinking I need to replace the wire clip that holds it in place, I just dont trust it anymore.

OH and my speedo still stops working randomly while driving. Im not to worried about just yet, I like my car not gaining miles lol

Doh, pinched wires the loss. I hate burping the 1.8t coolant system. It seems to take forever to work out all the air bubbles. That rad hose was probably not clipped in properly. The speedo issue is pretty important for other things though like the gas gauge. don't ask, but for some reason it acts up when the VSS is not functioning. 80% of the time its just a dirty connection. Its one of the two connectors near the divers side axle flange on the bell housing. take the coolant res off and disconnect the coolant level sensor. reach down and unclip the plugs and spray some electrical cleaner in them.

[FLACO X3]

cool, how much power are you expecting?

[20vpower]

Yah my gas gauge was acting up while that stopped working. I remember thinking of pulling the tranny as well when I had the engine out, so I unclipped that clip. Ill have to check that tomorrow and clean it.


As for power, I really dont have a clue what Im going to be making. Im sure 034 will take care of me Plus im going to be limited with these 440s. Im thinking that when I get the motor built and ready to push more, ill uprade the injectors and tweak the tune. For now I just want something safe for daily on stock internals.

Or am I just going at this ass backwards?


Oh and about that 2.7t, I dont even want to know, and I can only imagine

[Poopie]

i would have them tune for 630s and keep the boost down.

[20vpower]

That crossed my mind, just gotta get some 630s then. Im gonna see what they have say when I go for the appt to make sure my hardware is good

[Poopie]

I have 630s for sale possibly. I'm stepping up to 870s or 1000s

[bassed]

any suggestions for different tune or different inj file? what is it that is not good about it?

They don't have a tune for that turbo in general, that's what. It's not comparable to any Garret setups they've presently done.

[AudiA4_20T]

They don't have a tune for that turbo in general, that's what. It's not comparable to any Garret setups they've presently done.

hes doing a custom tune tho, they didnt have a map for jakes dads car on 870ccs but they started with 630s, maxed them out, and just put 870s in there

[20vpower]

Ok heres some pics, still need to finalize fmic hot side piping. Also need to re hookup n75 for 034 (they said they like to tune with it). I will need to rig up some sort of heat shield because the maf wires are pretty much touching the comp housing.

Heres one of the VEI gauge


One of the rats nest i have from re wiring ign switch wires, new vei gauge, lc-1, and ebc...


The motor out with old k03 on it, (note: dont set motor on ground, i broke a motor mount setting it down to get more leverage on it)


Some of the old flywheel before resurfacing


Is this too much of an angle for the return line?


Wastegate setup



TIP setup


The short block waiting new parts


Where it all went down

[pipe7284]

how much HP are you expecting to get out of that turbo with the 440cc?

[AudiA4_20T]

is that a dual mass flywheel? it doesnt look like it is

[bassed]

hes doing a custom tune tho, they didnt have a map for jakes dads car on 870ccs but they started with 630s, maxed them out, and just put 870s in there

Jakes dad's car was tuned by Javad if I recall, not Unitronic in Montreal on Unitronic's dyno. Or did Javad have Mike send him base files and work from there? If I am wrong please clarify.

[20vpower]

Yes stock dual mass.

As for power, 4inmaf made 24Xwhp on 440s at 13 lbs. I dont plan on pushing it to max hp just yet, so that is fine for my daily. The engine is still stock but will be getting a stronger rebuild hopefully soon.

However I need to talk to 034 to see what they think about the 630s so when I get it built I can push those more.

[1fstavant]

those pipes worked out well huh, its looking really good-def upgrade to 630s and youll be very pleased

[20vpower]

yeah worked out great, just need to get a heatshield by the tip. looks pretty familiar huh? Oh and im definatly running an extenstion on that cut out, it dumps right on the axle lol

[MikeWasHere05]

Looks great, congrats on the K04 upgrade man. I'm still sitting here barely tapping 200 wheel :-/

[sean1.8t]

Jakes dad's car was tuned by Javad if I recall, not Unitronic in Montreal on Unitronic's dyno. Or did Javad have Mike send him base files and work from there? If I am wrong please clarify.

base 630 file tuned @ 034

[20vpower]

Back again.

Ended up getting a good deal on tapp tune/maf/inj and i just got done installing it.



Idle is smooth and under 1k (much better than 440 green tops)
Only ran it around the block to get it used to the car so far. Feels smooth. Still only on WG pressure (10lbs) Need to find my charger for my palm pilot for logs. Also need to find out how to log multiple blocks on my Prodiag VAG program.

Also need to find out about a heatshield.

Only issue right now after one drive is when coasting out of gear to a stop, idle and AFR bounce. When i get to a stop it settles. Need to go drive a bit more to get it to adjust.