Finally stage 3 after 4 years!

[Corradovolksb]

I have owned my 2000 S4 since 2012 and its my daily driver. It was really beat up and neglected and I have brought it back from the dead over the past 4 years. The passenger side turbo has been making noise the whole time and now it's time to convert to stage 3 on stock block with 230,000 miles.

Prior mods are

Stage 3 south bend daily clutch
440cc injectors
K&N intake
SSAC twin 2 no cats
EVOMS DV's
Tein springs
18" VMR 703's and Dunlop SP sport 225-40-18
Devils own stage 2 W/M kit
Touareg V8 FSI fuel pump
Stage 2 tune personally tuned


Mods being installed

SRM K24 hybrids
SRM INLETS
SRM V3 intercoolers
SRM by-pipes
JHM rs6 to k04 downpipe flange adapters
85mm Maf housing with hitachi Maf

The engine removal went well and the K03s came off easy. I made sure the waste gates are adjusted correctly and set cracking pressure to 15psi. The SRM K24s installed without too much of a hassle while retaining the stock oil and coolant lines. I deleted the egts and converted the Bosch Maf to the hitachi Maf. The SRM intercoolers installed pretty easily and fit perfect. The engine fired right up and all was good. After checking for leaks and making sure all fluids where topped off I took it for the first drive on WG pressure. With the cracking pressure set to 15psi the boost spikes 17 and tapers to 15. I was super stoked to not hear a whine noise from the turbos like before and instead heard the amazing sound of new turbos. After a few road tests to make sure all is good I stated the tuning process. I had to dial in my fueling after installing the 85mm Maf. Once I got my fuel trims where I wanted them I did a FATS run and pulled a 4.41 it felt great. For comparison I ran a 4.54 on E85 on the K03s. I stated adding boost and I'm currently on 22psi and dropped my FATS to 4.10 I will keep making revisions and start running W/M to see what I can squeeze out of it with these 440cc injectors until I get bigger injectors and upgrade my fuel pump.

I did a time laps of the engine pull. From start to finish took 2.5 hrs

https://youtu.be/vjaWuVToSpo





https://youtu.be/uzeGlqLqMcE

[jaychen]

well done, cheech. now go do something reckless in it

[S4tech2]

Great job, I was in the same boat you were in. It took me around 4 years of saying I was going stage 3 to actually do it.

[vavJETTAw36]

Nice work!! It sounds like you are self tuning??


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[Corradovolksb]

Thanks guys. I'm happy I finally pulled the trigger and did it. I am tuning it myself and mine will be the 4th stage 3 car I have done.

[hibiscusS4]

looks good keep it up

[Monty23]

Looking good, but you forgot to install rods! Mind posting a log of boost response in 3rd gear?

[aysix]

Put a 6 inch straight pipe before that intake. If anyone here knows it should be you!

[Corradovolksb]

I would have liked to do rods but I was on a tight time schedule and only had a few days to do the install. I will do rods down the road at least that's the plan haha. I will post a some logs soon

Your right aysix I need to add that section of pipe before the Maf I was hoping that the velocity stack that I have with the K&N intake would straighten the air enough but it prob still needs the section of pipe to help direct airflow without a strainer over the end of the Maf. good lookin out.

[erykv1]

Put a 6 inch straight pipe before that intake. If anyone here knows it should be you!

I would have liked to do rods but I was on a tight time schedule and only had a few days to do the install. I will do rods down the road at least that's the plan haha. I will post a some logs soon

Your right aysix I need to add that section of pipe before the Maf I was hoping that the velocity stack that I have with the K&N intake would straighten the air enough but it prob still needs the section of pipe to help direct airflow without a strainer over the end of the Maf. good lookin out.

sorry to thread jack, but is there a recommended minimum distance before the MAF housing?

[frankwizzle]

sorry to thread jack, but is there a recommended minimum distance before the MAF housing?

Also does anyone know where to get an 85mm air straightener?

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[JVD]

Also does anyone know where to get an 85mm air straightener?

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http://www.saxonpc.com/

[Corradovolksb]

At least 6 inch is a good recommendation because it allows the air to straighten out before it hits the Maf element and will allow for optimum reading of the air mass.

[christianb5s4]

Awesome stuff, you're so lucky to have that shop to use! Which oil supply and return lines did you end up using? Did you replace the wastegate lines?

[Corradovolksb]

Thanks I do love my shop we have a great facility. I used all stock oil and return lines with the updated 01.5 lines. I cleaned the oil feed and return lines to make sure they where able to flow the correct amount. I didn't replace the WG lines but they where in great shape and pressure tested ok.

[Corradovolksb]

I did a log this morning with 65F ambient temp and My CF's are too high for my liking so I'll be dialing in my timing and adding some meth to my W/M tank since im running water only right now.

[wbrunner23]

http://www.saxonpc.com/

That's what I'm using 4" intake w/ saxon PC air straightener & homemade heat shield:

[christianb5s4]

Thanks I do love my shop we have a great facility. I used all stock oil and return lines with the updated 01.5 lines. I cleaned the oil feed and return lines to make sure they where able to flow the correct amount. I didn't replace the WG lines but they where in great shape and pressure tested ok.

Thanks for that, those are my plans as well. Although I'll be running Cinesnow's wastegate lines more than likely. Stoked to see some video, car must rip!

[uponone nogaro]

Looks good congrats

[CJ_]

Awesome! can't wait to see this thing rip!

[Corradovolksb]

Thanks guys.

I took some video yesterday so I'll do some editing and post them up.

[Corradovolksb]

I did some fats runs yesterday and both runs where really consistent at 4.11 and 4.15 I had to pull some timing due to high CFs and not having any methinol to add to my W/M tank so that killed my fats time a little but I'm still happy with how it's running so far it's a lot more fun to drive than with the K03s .

https://youtu.be/uzeGlqLqMcE

[CJ_]

Looks good man!

[Corradovolksb]

Did some 2nd to 3rd gear pulls today

[Tumbler510]

dyno?
:)

[Corradovolksb]

It might be awhile since it's already hitting over 100 degrees here in Phoenix but I will for sure get it on the Dyno when I can. I'm estimating I'm at around 400 according to my logs.

[Robsa6]

Its nice and smooth too. Nice project!

[Corradovolksb]

Thank you. I gave it a wash today and decided to take a few pics.

[hibiscusS4]

Looks great!

[Corradovolksb]

Looks great!

Thank you.

[christianb5s4]

I lost track of the DIY I found on it, but how do you like the B6/7 S4 brakes?

[Corradovolksb]

It's straight bolt on. I used B8 calipers, carriers and lines with b6/b7 s4 rotors. I really like them a lot. They have great stopping power for a single piston caliper and really good pedal feel with the stock master cylinder. I have done some high speed braking and have not had any issues. I would recommend doing them if you can find a good used setup.

[christianb5s4]

That's good info, so you can definitely feel a difference over the stock HP2 calipers?

[hibiscusS4]

It's straight bolt on. I used B8 calipers, carriers and lines with b6/b7 s4 rotors. I really like them a lot. They have great stopping power for a single piston caliper and really good pedal feel with the stock master cylinder. I have done some high speed braking and have not had any issues. I would recommend doing them if you can find a good used setup.

Ive been debating doing those when the time comes its proboly worth it in clearance alone.

[aysix]

4.1 fats on 91 sound about right for phoenix. That E game shall get you below 3, especially spraying water.

[Corradovolksb]

That's good info, so you can definitely feel a difference over the stock HP2 calipers?

Yes it's a noticeable difference. My buddy has a tial 650 car with the stock hp2's with slotted rotors and I can slow down way faster then he can without brake fade.


I would recommend this upgrade to anyone thinking about doing it. I was all about doing an 18z or Ttrs upgrade until I came across this B8 setup it's way better than I would have expected and a lot less money when it's time to replace rotors and pads. I will say that the TTRS brakes do stop better due to rotor size and clamping force of the calipers but that is to be expected.

[Corradovolksb]

A buddy and I did some 3rd gear pulls on the highway yesterday. The traffic was pretty bad or we would have done some higher gear runs. A little background on my buddy's car. It's an 01 sport with 58k. He has had it for 9 years had had some really bad luck in the past with shops screwing him over. He started modding it with k04s and stage 3- then he wanted to upgrade to bigger turbos and had the first shop attempt to build him one. They went bankrupt before it was finished and that left his car in shambles. He took it to another shop and had them build him a 2.8L bottom end and install the Tial650R turbo kit this was 6years ago. He ran out of money and never got it tuned so it sat for 6years. He asked me to get it running for him and tune it so I agreed and spent some time getting it back on the road. It turns out that the shop the built the motor over torqued the Tbelt roller nut and the stud broke within a few days of him having it back. It was a huge bummer but I pulled the motor and installed 2.8 heads and ssac exhaust manifolds and got it back on the road. After doing a few tune revisions I found out the prior shop installed an unknown clutch that can't hold more than 22psi on 91oct so the clutch is the next thing we will do.

http://youtu.be/0ONI4ozk0Zw

[Drehmoment]

With the right clutch and 30psi plus the 650 car will be a beast. Tial's like boost and lots of it.

So you installed the SSAC manifold/header ? Any concerns with cracking ?

[Corradovolksb]

We are planning on 30psi and E85 once the new clutch is broken in. We'll see how it goes. Yes against my better judgement but my buddy wanted to give them a shot. I have heard about them cracking so well see how they do.

[Jism]

Dont you need some sort of engine rebuild at 230.xxx miles when going stage 3?