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

[DiscoPotato]

Is the MAF on the charge piping?

[britishturbo]

Is the MAF on the charge piping?

Yepp. Blow through MAF :-)

[britishturbo]

I'm thinking about not installing the surge tank setup for now.
It will be overkill for the car at this point, so I'm thinking I'll leave the surge tank off until I rebuild the bottom end... Then we'll need it ;-)
So probably an In Tank / Inline setup for now.

[Monty23]

When are you going to start power tuning....

[Smitty2A4]

This thread is amazing and I have enjoyed reading through it so far! You have knowledge and fabrication skills I wish I possessed!

[britishturbo]

When are you going to start power tuning....

Hopefully in the next few weeks... but I'm going to be so busy getting ready for the PRI show at work its hard to say

[britishturbo]

This thread is amazing and I have enjoyed reading through it so far! You have knowledge and fabrication skills I wish I possessed!

Thank you! And I'm just getting started ;-)

[Tec_Nine]

Great build, no doubt

[britishturbo]

A little update for today:

[ElliottG]

EEEEEsh what are the IAT's going to be on this beast lol.

[britishturbo]

EEEEEsh what are the IAT's going to be on this beast lol.

When the firewall is fabbed up and the turbo blanket in place... very low... I.e. outside air temp. Just wait and see ;-)

[britishturbo]

So I changed my mind again. I will do the surge tank and dual walbros now not later. Do it once and do it right I say ;-)
But I'm now going to mount it in the back where the charcoal canister is stock.

[somebody5788]

A little update for today:

Reminds me of the way I had my air filter on my old A4 with the supercharger.





I'd look for a solid mandrel bent Aluminum pipe to do that bend instead. I had a lot of problems with driveability on the supercharger setup and in hindsight I think it might have been due to the way I did that part of the intake.

Also, I had a question. Is it possible to set the intercooler vertical? Or is there just not enough clearance? What if the inlets on it were on the side facing the engine instead? I was thinking it would be neat to be able to use the stock location for the air filter if there could be room made for the filter. Mainly because I would be too lazy to do a battery relocate if I ever did a single turbo haha.

[britishturbo]

Reminds me of the way I had my air filter on my old A4 with the supercharger.





I'd look for a solid mandrel bent Aluminum pipe to do that bend instead. I had a lot of problems with driveability on the supercharger setup and in hindsight I think it might have been due to the way I did that part of the intake.

Also, I had a question. Is it possible to set the intercooler vertical? Or is there just not enough clearance? What if the inlets on it were on the side facing the engine instead? I was thinking it would be neat to be able to use the stock location for the air filter if there could be room made for the filter. Mainly because I would be too lazy to do a battery relocate if I ever did a single turbo haha.

Hey, nice setup you had there.

The Intercooler is too bit to sit vertical I think... plus it wouldn't flow as smoothly as it does the way it sits.
There is actually room to put the air filter in the stock location but I want it in the back there because when I box it all off it will be a true cold air setup...

[britishturbo]

Some updates...

I've been so busy lately working and traveling for work (will have 68 Hrs OT the last two weeks by end of today) that I haven't had much time to work on much :/

Here's a progress pic:


Engine firewall plastic mockup:


Front bumper cover I picked up for much $$$ lol. It's brand new and already painted the factory color:


Brakes and turbo blanket to install:


When I get back home (In Louisiana today then back up to Brodix in Arkansas tomorrow ugh) from working away I havce lots to do...
Also should have nice Fenders waiting for the car too as well as a box full of goodies from a friend... ;-)

[britishturbo]

You'll see I have the hood on the car now too, it shuts perfectly and clears all the added hardware like I planned it that way... oh wait, I did! lol
The downside of having the hood on is that I keep hitting my head on it haha

[S4UCE]

That's a funny looking battery you got there! Great progress, can't wait to see this thing up and running

[britishturbo]

That's a funny looking battery you got there! Great progress, can't wait to see this thing up and running

Haha yeah the battery made its way to the trunk. I welded the battery tray to the CD changer bracket... ;-(

[Meow]

I haven't decided if I'm going to install this in the S4 or if I'll save it for the race car...

PLEASE DOoooo!!!!!!!!!!!!!! That would be fun! :)


edit: Also get a turbo blanket for that thing, will help out a lot!

[britishturbo]

So it looks like over the winter I'll be building a 3.0 bottom end and slapping on some CNC heads :-)

[britishturbo]

Then I'll probably try an AGP Zeta 3.2 turbo.

[Creed]

Great staff, a couple of fresh ideas I see here! So what kind of boost you run? I really like that MAF location, cold air should be no problem, hope it runs smooth under boost

[britishturbo]

Great staff, a couple of fresh ideas I see here! So what kind of boost you run? I really like that MAF location, cold air should be no problem, hope it runs smooth under boost

Have to finish some things and put all the bodywork on before I start tuning.
I plan on running 10 Psi at first while I check everything out, then 20 Psi and up...

[Creed]

http://www.audizine.com/forum/showth...=1#post1816106
check it out, MAF seems to work fine on similar config

[britishturbo]

http://www.audizine.com/forum/showth...=1#post1816106
check it out, MAF seems to work fine on similar config

Ha that thread made me laugh. Most of the people posting there have no idea what they are talking about.
Contrary to what they think the Maf sensor is not made from unicorns... its just like other Maf sensors.
Running blow through is common on most other turbo cars.
And just like that guy I don't care what others think I like the sound of a blow off valve.

[Monty23]

I'm very interested in the blow through setup. Awesome work here! What's your plan for the PCV system?

[ggg20t]

car is coming along man! Cant wait to see the final product - I will definitely make a trip up to State College to check it out when you're done!.

[S4 00 2.7]

Can't wait to see some videos.

[damunky]

Wow, what an awesome thread and build. Can't wait to see this running! Great progress so far man

[britishturbo]

I'm very interested in the blow through setup. Awesome work here! What's your plan for the PCV system?

I somewhat have a plan... but I'm saving the pcv system till last. I'll be running a large catch can with all the hoses attached to it. Plus will likely run a line from catch can to intake manifold with a decent check valve so it only pulls negative pressure.

I also will be going to a larger MAF once this one hits its flow limits. But I want to show what can be done with Blow Through using stock Hitachi sensor first.

[britishturbo]

car is coming along man! Cant wait to see the final product - I will definitely make a trip up to State College to check it out when you're done!.

Thanks man! I look forward to hanging out anytime.

[britishturbo]

Turbo blanket:

[JackalS4]

Yepp. Blow through MAF :-)

wwwsssssssssPSSSSHwwwsssssssssssssssssPSSSSHH (burble, burble, pop, cackle)

Worth it!

Great project, keep us up to date as you have been!

[britishturbo]

wwwsssssssssPSSSSHwwwsssssssssssssssssPSSSSHH (burble, burble, pop, cackle)

Worth it!

Great project, keep us up to date as you have been!

Ha! It is indeed worth it, and when tuned and setup right it will run no problem.

I try to keep updated every time I work on the car. I got a couple hours in today.
Tomorrow I plan on finishing the fuel system which includes fabricating and installing the surge tank and inline fuel pump and all related fuel lines. Then I need to change all the brake rotors and pads. Plus I need to fabricate the mount for the intercooler heat exchanger.
Then I have a bunch of wiring to do... A lot to do yet, let's see how much I can get done tomorrow.

If anyone in State College is bored feel free to come help! Ha!

[MileMan402]

I prob wouldn't be too much help but I'll be home for thanksgiving lol. Keep up the great work!

[britishturbo]

Got some of the fuel system upgrades installed today.
Fuel filter to -6 AN feed for surge tank:


Fuel feed for rail and return, ran in place of stock lines:


Surge tank mounting plate mock up:


The surge tank and external pump will mount where the charcoal canister used to be.

[britishturbo]

Wideband controller installed behind ecu:

[britishturbo]

And believe it or not all this work is being done outside... it sucks that its getting cold!

[SpeedWorksAuto]

I somewhat have a plan... but I'm saving the pcv system till last. I'll be running a large catch can with all the hoses attached to it. Plus will likely run a line from catch can to intake manifold with a decent check valve so it only pulls negative pressure.

I also will be going to a larger MAF once this one hits its flow limits. But I want to show what can be done with Blow Through using stock Hitachi sensor first.

Following your build......food for thought :

http://nefariousmotorsports.com/foru...hp?topic=983.0

Not trying to discourage your blow through. I plan to run blow through. After seeing what SnowTrooper went through and the fact that he is a much better tuner than I am, I figureed it would be better off not following donw that same path. Considering you are going to be remapping for the MAF in that location anyhow, might as well start with one that can handle blow through better.

[britishturbo]

Following your build......food for thought :

http://nefariousmotorsports.com/foru...hp?topic=983.0

Not trying to discourage your blow through. I plan to run blow through. After seeing what SnowTrooper went through and the fact that he is a much better tuner than I am, I figureed it would be better off not following donw that same path. Considering you are going to be remapping for the MAF in that location anyhow, might as well start with one that can handle blow through better.

Howdy,

Yeah I am familiar with his experiences...
I am planning on changing the MAF sensor, but because of my radical fuel system changes I want to keep MAF stock at first to make the tuning process a little easier...

The fuel system is as follows:
Stock pump feeding a 3 liter surge tank.
The surge tank then feeds 2 x Walbro 255 inline pumps (only running 1 at first)
The walbros then feed -8AN line to the billet fuel rails
Next after the fuel rail by -6AN is an Aeromotive regulator (set at 3 bar) with -6AN return line to the surge tank.
Oh and it all feed 1680CC injectors :-) Plenty of fuel lol

So once I get things dialed in on the fuel side (@ 10psi of boost) then I will change out the MAF sensor.
Fuel and air to deal with at the same time sounds like a headache to me :-)

I have my base tune ready to go once I finish the fuel system this weekend.
I'll let you know how it all goes!