Well, i did it niw... HX35 time!

[freekonwheelz1]

I know everyone won't agree with me at the moment but it'll all make sense in the end.

For now, I just bought a holset HX35 turbo off a guy because my K03s took a shit a week or so ago. After doing bookoos of research I still didn't know what I wanted to buy. Then on Craigslist I saw a guy selling an hx40 but he already had a sell lined out but he had a buddy's low miles hx35 he'd be willing to sell me so I met up and the turbo was dusty but good so I bought it. Now I am gonna buy a manifold and have a local shop fab up a downpipe and dump pipe for an external wastegate. For now I plan to run no more than 15 psi boost since I'm on stock internals. I will soon upgrade my internals for more though so I'm not here to hear the whole "shouldn't of bought a big turbo for little boost" arguments.

Now on to the business. Currently I have stock fuel and stock motor. I do have a Borla catback, cat delete, SAI delete, PCV delete (catch can to atmosphere), RA4 clutch kit with single mass flywheel, Eurodyne maestro, and a racetec front mount. For now I'm gonna leave everything as it is.

My goals immediately are to get a 3 inch exhaust with a single Borla muffler made, get a Tial 38mm wastegate, and have a good easy tune for it done. Down the road however, I want to do rods, pistons, and valves, bigger FMIC, deatchwerks injectors and fuel pump for E85, and a 6 speed transmission.

As of right now my only unknowns are what tune I need to run for the turbo currently on my setup, and if a 4 bar Audi fuel pressure regulator will be enough for an E85 setup on this car.


Here is the picture of the turbo just sitting in the engine bay looking pretty.

[csosnowski]

Its actually very efficient to run lower boost levels on a big turbo like that so it won't overshoot the boost target easily if it's being brought up at a slower rate to a lower peak. The holsets spool pretty soon for being so big, is yours divided housing?

I'm planning a holset build myself, I've got an hx35w sitting waiting. These turbo are capable of flowing 60lb/min. You'll need 1100cc or larger injectors and 400lph to run e85. Usually people convert to the return style fuel system as well because of the additional flow requirements for e85.

[MarcRogers]

These are my plans as well. Cheap setup and it's great for power.

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[freekonwheelz1]

Yea, I figured I would need some monster injectors. But since deatchwerks hasn't ever worked on a longitudinal motor they are pretty eager to do an e85 conversion with me. I believe they have 1200cc injectors for the 1.8? I know they have 2 4 digit cc injectors to choose from but I forget the specifics.
Yes, it's the 7 fin divided housing turbo. I'm pretty pumped to get it goin! Luckily I have the return fuel system. So I'll probably just have to run a returnless tune and both fuel lines for supply. Not sure yet on that.

[freekonwheelz1]

These are my plans as well. Cheap setup and it's great for power.

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It's gonna be a fun build! I'll keep it updated over the next month or two with my upgrades! I might do a new post for the engine build and tranny swap. Who knows.

[csosnowski]

Yea, I figured I would need some monster injectors. But since deatchwerks hasn't ever worked on a longitudinal motor they are pretty eager to do an e85 conversion with me. I believe they have 1200cc injectors for the 1.8? I know they have 2 4 digit cc injectors to choose from but I forget the specifics.
Yes, it's the 7 fin divided housing turbo. I'm pretty pumped to get it goin! Luckily I have the return fuel system. So I'll probably just have to run a returnless tune and both fuel lines for supply. Not sure yet on that.

With the return style system you'll really only want to add an afpr of your choice and 1100cc or better of your choice.

I'll have to count my fins but I know that mine has divided housing too. Mine has an internal waste gate which could be helpful or a hindrance dependant on how much I want to try and extract from this thing.

[freekonwheelz1]

With the return style system you'll really only want to add an afpr of your choice and 1100cc or better of your choice.

I'll have to count my fins but I know that mine has divided housing too. Mine has an internal waste gate which could be helpful or a hindrance dependant on how much I want to try and extract from this thing.

I consider it a hindrance. First thing I took off when I got it lol I don't see how I could use it since I had to clock the turbo over for it to even seem to fit right! But a tial is affordable soon so before I'm done with the low boost build it'll be on there. Are you considering using the internal wastegate? What manifold are you thinking of using?

[freekonwheelz1]

There is the image by the way guys! First link was trying to insert it on my phones browser lol sorry guys!

It's just sitting in there. I don't even have a manifold yet.

[csosnowski]

I consider it a hindrance. First thing I took off when I got it lol I don't see how I could use it since I had to clock the turbo over for it to even seem to fit right! But a tial is affordable soon so before I'm done with the low boost build it'll be on there. Are you considering using the internal wastegate? What manifold are you thinking of using?

I am planning on using the iwg. The factory clocking of the turbo is almost identical. It simplifies the plumbing too and I don't feel like a dump pipe.

I'll use whatever clone manifold that will fit the t3. Hopefully I'll find a divided housing t3.

[coolgraymemo]

It's just sitting in there. I don't even have a manifold yet.

I would have never guessed it.

[Seerlah]

Usually people convert to the return style fuel system as well because of the additional flow requirements for e85.

You've been out of the b5 game for too long. We have a stock return system. What OP may need is a aftermarket one that can handle more flow (larger port).

[GOODBYNAAIR]

What year is the car that will help with tuning if its an 01 and that clutch will need to be upgraded for 300+ whp if i'm wrong redline will have something to say about it.

By the time you get over 300 + whp you will want rods and with a big turbo like that a built head will not be a bad idea so you can see high rpms.

[freekonwheelz1]

I am planning on using the iwg. The factory clocking of the turbo is almost identical. It simplifies the plumbing too and I don't feel like a dump pipe.

I'll use whatever clone manifold that will fit the t3. Hopefully I'll find a divided housing t3.

crazy. i couldnt think of an easy way to have it sit in there without clocking it first. im going tial external and just making the dump pipe go straight down for the time being.

What year is the car that will help with tuning if its an 01 and that clutch will need to be upgraded for 300+ whp if i'm wrong redline will have something to say about it.

By the time you get over 300 + whp you will want rods and with a big turbo like that a built head will not be a bad idea so you can see high rpms.

i have an 2001. the clutch kit is supposed to be good for 300 awhp right now. if i put the RS4 clutch kit in there i should be able to handle 400 awhp all day which is the end goal, but for now im gonna work my way up to there slowly. ill need rods before i get past 300 and valves and springs before i get to 400 so i have a few other things to handle before that. i figure ill do turbo first, obviously, then do e85 conversion sometime after, and then piece by piece buy the internals until im ready to tear it down and build it for 400 awhp. sometime in between the e85 and internals i want to do brakes though. go fast parts are fun, but i want to be able to stop 400 awhp before i make 400 awhp.

[freekonwheelz1]

I would have never guessed it.

everyone i show that picture to says "damn, so its already running??" so i felt like clarifying for less observant folks.

[Rodgman15]

Welcome to the club!

[ray4624]

^^^oh damn!

[demonmk2]

have you ever drove or ridden in an A4 with a hx35?

[freekonwheelz1]

Welcome to the club!

that manifold though... i am unsure what manifold to run. i know itll have to be a side or top mount though lol

have you ever drove or ridden in an A4 with a hx35?

nope. no one in oklahoma goes past just exhaust and a tune. some volkswagen modders but no one seriously modding audis here i guess. or they are just good at hiding.

[csosnowski]

You've been out of the b5 game for too long. We have a stock return system. What OP may need is a aftermarket one that can handle more flow (larger port).

Oh snap I didn't even realize I was posting in the b5 forum hahaha. My forum reader just showed this thread in recent activity. I still have that clutch/fw from you in my garage!

Op already has return style so he's good for e85 with that respect.

I found some pretty good ebay top mount psi mani knockoffs, those angle the turbo too so the exhaust routing would be a little easier. There's also some bottom mount cast knockoffs too. I think the key with the cast eBay knockoffs is to brace the turbo so there isn't that cantilever force being exerted on a weak casting.

I have been out of the b5 game awhile, still building my wife's b5 Avant engine/car:










Not a holset on hers because I wanted something with a small hot side for in town and off idle torque.



Pic from a couple winters ago.

[freekonwheelz1]

Oh snap I didn't even realize I was posting in the b5 forum hahaha. My forum reader just showed this thread in recent activity. I still have that clutch/fw from you in my garage!

Op already has return style so he's good for e85 with that respect.

I found some pretty good ebay top mount psi mani knockoffs, those angle the turbo too so the exhaust routing would be a little easier. There's also some bottom mount cast knockoffs too. I think the key with the cast eBay knockoffs is to brace the turbo so there isn't that cantilever force being exerted on a weak casting.

I have been out of the b5 game awhile, still building my wife's b5 Avant engine/car:










Not a holset on hers because I wanted something with a small hot side for in town and off idle torque.



Pic from a couple winters ago.

AEB motor?

[freekonwheelz1]

i know my fuel lines can handle the flow of a decent build (which is what i consider mine to be) so for 1200cc or less and 400 lph or less fueling and i should be more than fine on the fuel lines. at least i think im right lol please, correct me if i am wrong on that.

[ray4624]

AEB motor?

i believe the 2000 is an 058 block with small port head.

[csosnowski]

AEB motor?

Yes AEB. 058 bottom, ebay rods, goetze rings, glyco bearings, sealed power im shaft bearings, polished crank, std displacement, new oil pump/pickup etc. AEB head with supertech exhaust valves ti retainers, hd double springs etc.

Should be a blast when I find time to finish lol.

[csosnowski]

i believe the 2000 is an 058 block with small port head.

Correct, ATW is the engine code. Basically AEB bottom and AWM head for 2000, 2001 moved to 06A bottom and same head called it AWM.

[freekonwheelz1]

Welcome to the club!

what oil restrictor are you running, if any? ive read some guys running the hx35 with no restrictor and some running a really small restrictor. the K03s restrictor fit into the holset housing (checked thread pitches before i went ramming it in) and with an O ring it fits perfect. could i just get away with running that restrictor? then i can run the factory oil feed line specs. found a nice fully braided oil line for my motor for $30 and its the factory banjo on one side and the factory threaded on the other.

[Rodgman15]

Use an o-ring for sure, with no restrictor. That's what I was told by Tim @ Tim's Turbos, and that guy knows his shit. Here's what he told me:

ME: "How do you know when to run an oil restrictor? I've stumbled across talk of them on the forums, but could never figure out when it was actually necessary."

TIM: "Oil restrictors are more of band-aid. If you have a proper oil return line, you usually don't need one. Try to run tube not AN fittings for the return. if you you are not smoking you don't need one. Start out with a 4an. if you need to restrict it more move to a 3AN. that usually fixes it. That will still keep the flow up with out burning out the brg;s."

[freekonwheelz1]

Use an o-ring for sure, with no restrictor. That's what I was told by Tim @ Tim's Turbos, and that guy knows his shit. Here's what he told me:

ME: "How do you know when to run an oil restrictor? I've stumbled across talk of them on the forums, but could never figure out when it was actually necessary."

TIM: "Oil restrictors are more of band-aid. If you have a proper oil return line, you usually don't need one. Try to run tube not AN fittings for the return. if you you are not smoking you don't need one. Start out with a 4an. if you need to restrict it more move to a 3AN. that usually fixes it. That will still keep the flow up with out burning out the brg;s."

thats what i was thinking. journal bearing turbos are supposed to have more not less so i figured i was fine but not for sure. makes life even easier now that i dont have to find the right restrictor and fittings to make it work!

[freekonwheelz1]

so what basefile should i start on when its all said and done? im thinking the AWP stage 3 371cc file is a good file to datalog on until i do the e85 with built motor. then ill step up to a better file.

[Rodgman15]

Literally no clue, I don't know what works yet. I'm using Maestro on an AEB so tuning is limited for me. I built my motor and got everything together first and would have it going now, but I fried my clutch and need to fix that first.

[Avant Nate]

Isn't there a 1000cc awp file? I would start there.

[freekonwheelz1]

Isn't there a 1000cc awp file? I would start there.

im planning on running stock fuel until the fall when deatchwerks has some down time to look at my pump housing to get me a pump for it (they have never made a pump for the longitudinal motors i guess) but i figure 1400cc injectors with somewhere around a 400 lph pump should be more than enough for e85 and 420 hp when im ready. i can always just run a low duty cycle until im built enough for the power. their 1400 cc injectors will cost me the same as their 1100 cc so id rather go to big and turn it down instead of to small have to buy bigger again.

[freekonwheelz1]

Literally no clue, I don't know what works yet. I'm using Maestro on an AEB so tuning is limited for me. I built my motor and got everything together first and would have it going now, but I fried my clutch and need to fix that first.

the double edged part of the AEB... great flowing heads with not as many options... ive read so much on how they are the greatest motor with the weakest sensors and electronics. i just want an AEB head and intake lol

[ray4624]

dont even bother installing the turbo until you are ready for clutch, proper tune, injectors etc.
Just find a cheap ko3 and run it for now.
It will save you headaches in the long run.

[vrmm]

I ran my 7 blade at 22psi with stock internals for a few months till I stopped being lazy and lifted my engine up to swap out the rods. Obviously drove the shit out of it. That was with 630cc's at the time. I don't believe I ever even bothered with stock injectors. Actually scratch that! I did with stock injectors. Right after I put my Hx35 on for the first time. I believe I ran it at 12psi and I got owned by like 48 stock subarus and a corvette in those few days. It was quite frustrating. And embarrassing since my open dump made it seem like I actually had power. It got old really quick!

I'm very unenthusiastically trying to sell my bosch 630cc's with connectors but without tophats for 100 bones shipped if you're interested.

Definitely brace a cast manifold if you get one! Mine cracked like crazy.

The one solid thing that I will always recommend to any big turbo dewd is to get a full face cerametallic stage 4 ringer racing clutch. It is amazing and takes an incredible amount of abuse. It's as light or slightly lighter than the stock clutch, makes 0 noise/doesn't rattle, and is easy as stock to take off with. I've never had it slip or start smelling even after multiple 7k launches in a row at 30ish psi(granted I only make 23psi or so in 1st). I'm in the 50-70 or so launch realm with it and maybe 25k or so. Each time I've blown up 3rd gear in my tranny I've checked it and it looks great. I know people talk highly of rs4 clutch but it's organic is it not? I just wouldn't trust it personally. It's like Hillary.

[MetalMan]

when deatchwerks has some down time to look at my pump housing to get me a pump for it (they have never made a pump for the longitudinal motors i guess)

I run a Deatschwerks DW200 in my A4 on E85. Fits just fine with a few O-rings around the body of the pump (to space it properly inside the stock fuel pump basket). Had an older DW300 before too in my old car.
It needs the Ford Mustang 85-97 kit to have the proper-fitting sock I believe:
http://www.deatschwerks.com/products...01-1014-detail

[tar]

Its only 100 for that pump setup?? Ordering

[Avant Nate]

I have an walbro e85 450, drops in a stock basket like a 255. Super easy.

[Rodgman15]

Also going to be using a Walbro 450

[Seerlah]

In regards to no oil restrictor, other cars also don't run at 100+psi oil pressure. My gauge maxes at 100psi, and just says HI on some cold start ups.

[Rodgman15]

In regards to no oil restrictor, other cars also don't run at 100+psi oil pressure. My gauge maxes at 100psi, and just says HI on some cold start ups.

Valid point!