My first Audi - 2001.5 S4 with Custom Single Turbo setup...

[britishturbo]

I will take a few next time I'm at the garage. I have all the pieces to.the pieces to the puzzle, just finishing up the engine. Waiting till summer to put it together. I don't like cold lol.

Sweet :-)
And I know what you mean about the cold... I'm trying to get it on the road before the PA winter hits... brrrrrrr lol

[Tec_Nine]

mother of god, that is such a great job on everything i can honestly say im jelous

[Don Supreme]

Welcome to the community, great project and great work.

I am also happy you didn't create the thread until you were this far a long.... you're legit.

[britishturbo]

mother of god, that is such a great job on everything i can honestly say im jelous

lol why thank you :-)
I'm pretty anal about things though, I see lots that I could have done better... but the urge to move forward and get her driving keeps winning...

[britishturbo]

Welcome to the community, great project and great work.

I am also happy you didn't create the thread until you were this far a long.... you're legit.

Thank you!
And yeah I have been lurking here since I first got the car and Google'd "Audi S4 Upgrades" lol but figured I would wait till I was almost there and had everything figured out.

[britishturbo]

Kinda sucks that I will have to wait almost 3 months before I can post in the Tech sub forums and move this post to the Projects :/

[S4 00 2.7]

Great stuff. Good to see you diving right in without hesitation.

[034Motorsport]

I will be very interested to see your take on the intake manifold.

We are just finishing up our billet 24v VR6 turbo intake manifold; so much tooling but such a beautiful finished product.

I'm glad my project helped fuel yours, and I certainly don't blame you for not wanting to wait!!! I will be interested to see what you think of the air 2 water; they have their advantages, but also disadvantages as well. Going to use any type of pump/exchange?

Keep up the good work. Those Lambo manifolds are nuts.

[britishturbo]

I will be very interested to see your take on the intake manifold.

We are just finishing up our billet 24v VR6 turbo intake manifold; so much tooling but such a beautiful finished product.

I'm glad my project helped fuel yours, and I certainly don't blame you for not wanting to wait!!! I will be interested to see what you think of the air 2 water; they have their advantages, but also disadvantages as well. Going to use any type of pump/exchange?

Keep up the good work. Those Lambo manifolds are nuts.

I've been keeping an eye on your VR6 manifold on facebook ;) What CAD/CAM software do you guys use?

As for the A2W system I have a Bosch pump that is OEM on a Supercharged Mustang and a front mount heat exchanger - looks just like a front mount intercooler lol. I'm excited to see how it works out on the street. I have always uses Air to Air before, but I am using A2W on the racecar and decided to try it on the Audi as well. One of my customers swears by A2W and uses it on every build they do. So we shall see...

[britishturbo]

Stuck at work so while I was waiting for a 5-Axis machine to finish some test cuts I made some quick SAI block off plates :-)

[scottyboyx845]

I wish I had 1/10th of your skill. Can't wait to see the finished product

[tambat]

welcome to the forum man! i love following builds like yours. inspiring stuff!

[UkuRiSh]

This is awesome so many new good projects from last two years . We should all meet not only the single turbo S4 and twin turbo and have a good time and of course race :)

[WillRaceForBeer]

Loving this thread, nice work so far! Looking forward to watching your progress. I to am a S4/Eclipse guy so I appreciate both of your projects.. never.. ending.. projects ;)

[britishturbo]

This is awesome so many new good projects from last two years . We should all meet not only the single turbo S4 and twin turbo and have a good time and of course race :)

I agree man an S4 meet would be awesome!
Btw I wanted to reply to you about your cracked pistons but I can't reply in the tech forums yet :-( The damage is from running too lean causing detonation. I remember reading you were getting AFR under boost of 12.x. This is too lean. On pump gas you should aim for between 11.5 and 11.8 AFR. Any leaner is dangerous and will either melt pistons or cause detonation.

[britishturbo]

I wish I had 1/10th of your skill. Can't wait to see the finished product

I'm just stubborn and / or determined Haha.

[britishturbo]

Loving this thread, nice work so far! Looking forward to watching your progress. I to am a S4/Eclipse guy so I appreciate both of your projects.. never.. ending.. projects ;)

Haha awesome. I think I'll always love my DSMs. But the Audi love is hard to resist now lol

[DiscoPotato]

I like where this is going... I like it a lot.

[jibberjive]

Looks like an awesome project! I will be keeping up on this.

[dubzackvr6]

I'm super jealous of that billet of AL.

[JPM-Engineering]

Very nice work !!

Congrats

[laserb5]

Sure... My official job title is "Systems Engineer" I work at a company that makes CNC machines and controls... This company actually: http://www.centroidperformanceracing.com/ / http://centroidcnc.com
So I have access to many nice toys at work... just never have much free time to take advantage of it all.

DUDE!!!! You work at centroid?!?!?! im pretty sure i have had wet dreams about the A532! Lucky man, I'd love to tour that facility!

[britishturbo]

DUDE!!!! You work at centroid?!?!?! im pretty sure i have had wet dreams about the A532! Lucky man, I'd love to tour that facility!

Haha yepp. I am in charge of building the machines among many many many other things lol. And if you like the A532 you need to check out the new A560 Port Block machine. It's beast.
Check it out in this video...



I'm finishing up building 2 of them right now actually.
And any time you want to tour the place you are welcome.
And if anyone makes it down to the Performance Racing Industry show in Orlando in December come hit me up :-)

[britishturbo]

I'm super jealous of that billet of AL.

Luckily I didn't have to pay for it! haha
It's actually split down the middle right now, I can make 2 x 420A runners from it, so I'm going to make one for myself and one for display for work.

[infinkc]

amazing work

[britishturbo]

Thanks for all the kind words guys :-)
I look at everything and see a lot more I want to do yet, so it should only get better :-)
Really wish I wasn't heading to Arizona tomorrow or I could get her running on the road the weekend... But alas I have to go help someone with tuning ;-)

[s4930]

I thought I was a bad ass after changing my downpipes... Way to kill my self esteem.

[britishturbo]

I thought I was a bad ass after changing my downpipes... Way to kill my self esteem.

I think anyone who changes out the downpipes in the car deserves a cookie! Haha
When I pulled the engine the downpipes were a nightmare... partly because I pulled the Engine only and left the tranny in the car... :-D

[Monty23]

Haha yepp. I am in charge of building the machines among many many many other things lol. And if you like the A532 you need to check out the new A560 Port Block machine. It's beast.
Check it out in this video...



I'm finishing up building 2 of them right now actually.
And any time you want to tour the place you are welcome.
And if anyone makes it down to the Performance Racing Industry show in Orlando in December come hit me up :-)

Wow what an amazing job - any job openings for a Penn State graduate with a Bachelor's in Mechanical Engineering and 2 yrs of industry related experience? JK lol

[britishturbo]

Wow what an amazing job - any job openings for a Penn State graduate with a Bachelor's in Mechanical Engineering and 2 yrs of industry related experience? JK lol

Actually... yes lol
http://www.centroidcnc.com/jobs_stat...nsylvania.html

:-)

[lo-lyfe]

Wow what an amazing job - any job openings for a Penn State graduate with a Bachelor's in Mechanical Engineering and 2 yrs of industry related experience? JK lol

Way to network, my man, way to network!

OP--> Reading your forum (and others') and owning an S4 and all the drama that comes with it makes me wish I had gone into engineering instead of finance. Feel like I work f/t as a half-ass mechanic (read "hack") and in my spare time I do what I went to college for. Amazing job so far and looking forward for more. Keep the updates coming!

[Monty23]

Actually... yes lol
http://www.centroidcnc.com/jobs_stat...nsylvania.html

:-)

The grass is always greener right! Na, I have a wonderful job that I'm very thankful to have. If I wasn't 3+ hours away I would certainly look into the open job positions at Centroid. To have a job that goes hand in hand with one of my true passions in life would be an amazing blessing! I look forward to you sharing more about your projects!

[britishturbo]

A little tease of the future... ;-)

[britishturbo]

They always look like alien fingers to me ;-)

[S4 00 2.7]

Oooh, exhaust manifold?

[Monty23]

head porting....

[britishturbo]

Oooh, exhaust manifold?

Nope...

head porting....

Yepp... a Cylinder Head port design I have laying around... ;-)

[infinkc]

Nope...



Yepp... a Cylinder Head port design I have laying around... ;-)

I have some heads sitting around if you need a tester ;)

[034Motorsport]

While I do feel that this platform is seriously behind in cylinder head design and such, it's worth mentioning how important velocity is pre-turbo. Going big port is not always beneficial, although judging from the fuel system you are going with, I am guessing your Borg turbo is not the final size of turbo you will be testing?

We've done quite a bit of testing over the years concerning 5v porting, ranging from intake and exhaust port testing to oversized valve flow testing, and combinations of both. There is definitely power to be made on the intake side of things, so long as velocity is maintained based on the turbo size and displacement, etc. On the valve side of things, you need to be pushing some serious amounts of air to benefit from oversizing the valves. Power can be lost.

Increasing exhaust valve size and porting can hurt performance, especially if you aren't revving out and running a very large volume turbo. If your goals do not surpass 550whp, you may consider the disadvantages of porting to the levels it seems you want to port.

But probably one of my main points is, what cams will you be running? I hope CAT (or some other aftermarket cam). The stock cams (or even 2.8L) do not have nearly enough profile to properly take advantage of very large ports and oversized valves.

[britishturbo]

While I do feel that this platform is seriously behind in cylinder head design and such, it's worth mentioning how important velocity is pre-turbo. Going big port is not always beneficial, although judging from the fuel system you are going with, I am guessing your Borg turbo is not the final size of turbo you will be testing?

We've done quite a bit of testing over the years concerning 5v porting, ranging from intake and exhaust port testing to oversized valve flow testing, and combinations of both. There is definitely power to be made on the intake side of things, so long as velocity is maintained based on the turbo size and displacement, etc. On the valve side of things, you need to be pushing some serious amounts of air to benefit from oversizing the valves. Power can be lost.

Increasing exhaust valve size and porting can hurt performance, especially if you aren't revving out and running a very large volume turbo. If your goals do not surpass 550whp, you may consider the disadvantages of porting to the levels it seems you want to port.

But probably one of my main points is, what cams will you be running? I hope CAT (or some other aftermarket cam). The stock cams (or even 2.8L) do not have nearly enough profile to properly take advantage of very large ports and oversized valves.

My plan is to find the limit of the stock heads and intake first, then I'll make an intake.
I'm not planning on running any cnc ported heads until after winter really. I haven't decided if I'll be using APB or 2.8 heads ether, but they will be +1mm on the intake side when I do go that route. The stock heads do not have enough intake throat size.
My customers are some of the best head porters in the world so trust me when I say I know a fair bit about heads and have access to the minds of people who do some amazing stuff...

One of the biggest problems people face is the stock exhaust manifolds and small turbos. There is a limit to how much they can flow which will ultimately limit how much the intake side can breath. You can pressurize the intake as much as you like but if the gasses can't escape then you get minimal gains. The extra flow capabilities you get from a single turbo setup should really help.

Oh and the 2.7 would really benefit from a much larger plenum size. In the order of 3.0 liters of volume or more. I really need to work on my plenum design...

And you are correct, I do plan on going with a larger turbo down the road... the injectors in the fuel system pic are 1680cc... so I have a lot of overhead ;-) but again not until I have a built bottom end. The S256 should be perfect up to the limit of stock rods.

Goal for now is just one fun daily driver.