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

**britishturbo** · 09-28-2012 12:42 PM

Originally Posted by infinkc

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

Are they stock APB heads? I won't have time to work on heads anytime soon... But when I do I'd like a set of APB heads and a set of 2.8 heads to work with.
I do have a cpl APB heads though already...

**britishturbo** · 09-28-2012 02:43 PM

Originally Posted by Max@034

While I do feel that this platform.s 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.

Oh i forgot to add that an example of what heads can do on a 2.7. One of my customers did some cnc heads with +1mm intake valves and gained 70HP over the stock heads.
I can't mention their name just know they do heads for many ppl.
I can get their head program for my car if I want ;-)

**britishturbo** · 09-28-2012 10:47 PM

Well it looks like my customer I'm visiting in Tuscon Arizona this weekend already has some CNC Ported 2.8 heads with +1mm Supertech valves for me.... Hmmmmm :-D

**1illA6** · 09-28-2012 11:18 PM

Originally Posted by britishturbo

Well it looks like my customer I'm visiting in Tuscon Arizona this weekend already has some CNC Ported 2.8 heads with +1mm Supertech valves for me.... Hmmmmm :-D

I'm in Tucson, you should bring me a set of heads as well;)

**britishturbo** · 09-29-2012 09:01 AM

Originally Posted by 1illA6

I'm in Tucson, you should bring me a set of heads as well;)

I'll get right on that lol :-P

**Austonwerner4** · 09-29-2012 07:43 PM

Originally Posted by britishturbo

That is the flange for the Tial wastegate.
You can see it installed here:

How did you plug the back of your intake manifold?
I pulled out the 3 pieces and am going to tap threads to full them with plugs.

**tekazgtr1984** · 09-29-2012 08:37 PM

Amazing thread. Your skills are awesome, OP. Keep up the good work and I can't wait to see the finished product.

**britishturbo** · 09-30-2012 12:22 PM

Originally Posted by Austonwerner4

How did you plug the back of your intake manifold?
I pulled out the 3 pieces and am going to tap threads to full them with plugs.

I'll probably be using all but one of them which I will just cap.
When I make my billet intake though I will have more ports than I'll need threaded just to be safe.

**haggard69er** · 09-30-2012 12:49 PM

Originally Posted by britishturbo

Sweet and thanks!!! You have any pics? Curious to see how your setup is!

Hey! I was at my garage yesterday and snapped a few pics.

Some of the parts i have collected so far. Btw, the cnced heads look so beautiful!

**britishturbo** · 09-30-2012 05:32 PM

Originally Posted by haggard69er

Hey! I was at my garage yesterday and snapped a few pics.
Some of the parts i have collected so far. Btw, the cnced heads look so beautiful!

Cool, I got some of my parts from mandrel-ends.com too. Good stuff.
And thanks on the heads. They are nice, I won't be installing them until after the new year though more than likely.

**haggard69er** · 09-30-2012 05:44 PM

Originally Posted by britishturbo

Cool, I got some of my parts from mandrel-ends.com too. Good stuff.
And thanks on the heads. They are nice, I won't be installing them until after the new year though more than likely.

When i get to the heads i will hit you up for some knowledge! Good luck with your build, i will be following this!

**britishturbo** · 09-30-2012 05:48 PM

Originally Posted by haggard69er

When i get to the heads i will hit you up for some knowledge! Good luck with your build, i will be following this!

Thanks, I'm sitting in an airport right now on my way home... I was helping a customer in Tuscon with their 5-Axis and doing some tuning... We were getting this turbo quad running (Megasquirt :-)) and tuning it on the dyno, plus working on a turbo gsxr1000 engined quad too... that one's sick lol. Can't wait to get home and work ont he Audi some more.

Hit me up anytime on heads.

**Cobra Commander** · 09-30-2012 06:45 PM

Very nice work...subscribed for more.

**britishturbo** · 09-30-2012 07:53 PM

Well since my flight has been delayed I've been sat here bored in Atlanta airport... so I started on some intake manifold design work...
Here's what I have roughed out as a concept so far...

**britishturbo** · 10-02-2012 05:31 PM

Worked on my downpipe tonight

**britishturbo** · 10-02-2012 05:38 PM

Not the best welding ever... but it will do

**britishturbo** · 10-02-2012 05:39 PM

**S4 00 2.7** · 10-02-2012 07:47 PM

Looking good. My welding also needs work, actually mine is terrible.

**britishturbo** · 10-03-2012 11:14 PM

Worked on my gauges tonight.

**Monty23** · 10-04-2012 05:05 AM

45 psig, I like where this is going

**britishturbo** · 10-04-2012 06:33 AM

Originally Posted by Monty23

45 psig, I like where this is going

I hate getting 30psig gauges and then having to replace them when I need 30+... so I'll just start with the range I plan on needing :-)

**lo-lyfe** · 10-04-2012 07:42 AM

Originally Posted by britishturbo

Not the best welding ever... but it will do

Better than my welds, which look like a little kid had been playing with Play-Doh.

**britishturbo** · 10-04-2012 07:50 AM

Originally Posted by lo-lyfe

Better than my welds, which look like a little kid had been playing with Play-Doh.

If I wouldn't insist on welding in the dark while crouched on the floor it would probably help haha ;-)
I was more concerned about good penetration than looks, and I only have a MIG at home not a TIG so that's about as good as I can get it lol

**rockcandy** · 10-04-2012 08:02 AM

Originally Posted by britishturbo

You show those awesome manifolds amd then post this? What is wrong with you? Haha. You have to redo this, im sorry:)

**britishturbo** · 10-04-2012 08:08 AM

Originally Posted by rockcandy

You show those awesome manifolds amd then post this? What is wrong with you? Haha. You have to redo this, im sorry:)

Haha yeah I know... I'm not a big fan of the downpipe I have at this stage, but I plan on reworking it once I have it all working and proved out.
The sharp angle isn't ideal but it will still flow plenty for stage 1 of the project... ;-)

Once the downpipe is all in place and I knwo the angle work and everything then I can see what angles and bend radius I need to do it right.

**britishturbo** · 10-04-2012 04:15 PM

Intercooler piping mock up:

Blow off valve should work here:

**Limey** · 10-04-2012 05:50 PM

Originally Posted by britishturbo

Intercooler piping mock up:

Blow off valve should work here:

Awesome build so far, can't wait for future updates. Your pics arent working for me, just red X's poping up

**Austonwerner4** · 10-04-2012 06:03 PM

I think they work for everyone else

**Spooled1.8** · 10-04-2012 06:19 PM

Awesome build, excited to see updates!

**michael66899** · 10-04-2012 06:24 PM

Blow through MAF?

Loving it all so far, best of luck!

**britishturbo** · 10-04-2012 06:35 PM

Originally Posted by michael66899

Blow through MAF?

Loving it all so far, best of luck!

Indeed :-)
I love a real Blow Off Valve, so we'll see how Blow Through goes :-)

Worst case I'll convert to Speed Density ;-)

**britishturbo** · 10-05-2012 12:54 PM

My plan for the weekend is to try and move the car under it's own power. Hopefully all goes to plan :-)

**michael66899** · 10-05-2012 02:56 PM

Originally Posted by britishturbo

Indeed :-)
I love a real Blow Off Valve, so we'll see how Blow Through goes :-)

Worst case I'll convert to Speed Density ;-)

Indeed, good stuff man can't wait to see this car all finished up.

I might have missed it somewhere but are you doing all the tuning?

**britishturbo** · 10-05-2012 03:48 PM

Originally Posted by michael66899

Indeed, good stuff man can't wait to see this car all finished up.

I might have missed it somewhere but are you doing all the tuning?

Yes I do all my own tuning. Friend of mine just flew me to Arizona to help him with some tuning the weekend ;-)

**britishturbo** · 10-05-2012 03:49 PM

Front mount heat exchanger. Should work nicely :-)

**britishturbo** · 10-05-2012 03:50 PM

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

**britishturbo** · 10-07-2012 01:18 PM

Today's update. Got coolant in the system and fixed some leaks.
Installed the intercooler and piping. Not 100% happy with the intercooler piping just yet though.
Tomorrow I'll extend the MAF cable and it should be ready for a quick road test. Then this week I'll install the fuel system and intercooler heat exchanger and pump/hoses.
Then it's tuning time :-)