Jypels fully built stroker Twin Turbo B8 S4 - Project

[Jypels]

Hey Guys,

So let me start at the beginning. I Live in Cape Town, South Africa and I own an late 2011 B8 S4 - car has been stage 2+ for a while with ported blower. August 2017 I got the dreaded gearbox malfunction (Gear position sensor went) so gearbox had to come out. Whilst the gearbox was out, my good friend and the only mechanic I would ever get to touch my car said, why don't we do the porting of the heads now (I have been planning to do it for a while before gearbox malfunction) as its super easy to get motor out once gearbox is out.

Now my initial plan was to only mildly port the heads and run a small shot of nitrous and leave it at that, but this soon changed to also cutting the cams to a different profile, then we decided to do a big valve upgrade - going from 33.8mm valves to 35mm valves. Whilst this work was being done, I started talking to Oleg Popov ( One of the craziest oke's I have seen!) He has the big turbo Audi S5 and closely followed his build and the benefits a turbo could provide over the small TVS1320 we are running.

So now I have bitten the bullet aswel, whilst my initial plan was to also follow the same recipe as Oleg and go with a single big turbo, I have since changed my mind and decided on going with 2 slightly smaller turbos. At this current point in time the motor is completely stripped and ready to get iron sleeved, within the next week. Once this is done we will get Custom Forged Pistons ordered from JE and start assembling the bottom end.

Shaun from Deutsche Auto Specialists is doing all of the disassembly and assembly work on the car and motor - He is a good friend and the only guy in Cape Town I trust to work on my Audi :)

So here is the current build list:
82mm JE Pistons (getting custom made)
Iron sleeved block
154mm Forged H-Beam Rods from 2.7T (Big ends being machined to size)
Audi 3.2fsi Crankshaft (Changing from 89mm to 92.8mm stroke)
ARP Headbolts
ARP Rod Bolts
Ported Heads with 35mm (1.2mm oversize) Intake valves (Jay @ Jaytech performance in Cape Town completed work)
Supertech Titanium Valve Springs and retainers
Camshafts getting cut to new profile (van der linde developments in Johannesburg is doing work)
Custom Intake manifold with custom air to water intercooler with 20 Bar core (Reinier @ ElectigEel doing fabrication work)
Custom piping for turbos will be done by ElectigEel
Custom 20 plate AC Chiller to cool down IAT
Custom Triple Pass Racing Radiator (fabricated and built by Bellville radiators in Stikland)
NXexpress meth injection (per port injection)
NXexpress nitrous injection (per port injection)
Precision turbo 40mm waste gates (2 units)
K&N Cold air intakes
Tial Q 50mm blow off valve
Cortex Electronic boost controller
2 x Walbro 450L Fuel Pumps
80mm Hemi TB (Might move to 90mm unit)
Flex Fuel Sensor
Custom exhuast built by Electig Eel
Unichip Q - to control meth and nitrous (Sakkie @ Dynotech doing installation)
1200cc e85 capable Port injectors

Turbos: Bought 2 x GTX3076R 11 blade dual ball bearing billet turbos

I will add pictures as the build progresses and any snags we encounter along the way :)

[P1Racer]

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[whiped]

Awesome build idea. Any idea where you are going to shove everything?

If you are crafty you can stuff the turbos down near the fender liner and run some SMICs B5 style.

[rubicant5x]

subscribed! Are those Precision turbos based on the Borg Warner EFR series?

[Jypels]

Awesome build idea. Any idea where you are going to shove everything?

If you are crafty you can stuff the turbos down near the fender liner and run some SMICs B5 style.

Hey bud, great idea, I didn't even think about that! My Plan was to either put them where the stock cats were or if there is enough space left and right at the back of the engine, we will only know final spacing once the motor is assembled and we can hoist it in the car and see what space we are working with. But your idea might just work perfectly!

[whiped]

The B8 SMIC for the supercharger should give you an idea of the spacing. There is even more space available on the pass side.

That or you can just keep the air to water intercooler similar to how it is stock or how the 4.0TTs do it.

[EIAlfonso]

I was going to post about my new exhaust tips but.....


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[GandalfTheIbis]

Wishing you all the luck in the world with this one. I'll be following.

[NAR Mike]

I was going to post about my new exhaust tips but.....


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hahaha

- - - Updated - - -

can we at least get one pic? plzz

[Thurston]

Random questions


How much do you think all of that will end up costing you?

What awhp / tq do you anticipate seeing?

Did you have any issues and if so how did you solve em w the Alusil cylinder coating audi used?

Really bad A to see a twin turbo build for this platform.

Awesome blossom.

[washyourrhands]

Good Luck with this! Subbed

[RReddington]

GL!

[Brother Owl]

Damn bro sounds bananas, hope everything works out for you

[RWD2quattro]

Oh snap, that's one heck of a challenge. You're paving the way for the rest of us

[JD S4]

What’s the transmission plan?

Awesome idea and build!


Sent from my

[UkuRiSh]

This is awesome build, stock block defiantly hold more then 2.7tt and with forged internals will be a lot more interesting

[HOUs4]

I was going to post about my new exhaust tips but.....


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Haha!

Can't wait to see the build progress. Subscribed.

[AvusPdx]

in

[Jypels]

Random questions


How much do you think all of that will end up costing you?

What awhp / tq do you anticipate seeing?

Did you have any issues and if so how did you solve em w the Alusil cylinder coating audi used?

Really bad A to see a twin turbo build for this platform.

Awesome blossom.

A lot - i have learned to not count up all the cost as that will usually put you off the project. Once I am near completion i will list all costs, but doing it now just might make me sick

In terms of awhp we are aiming for as close to 1000awhp as possible.

The Alusil isn't a problem as the block is getting iron sleeved.

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[Jypels]

This is awesome build, stock block defiantly hold more then 2.7tt and with forged internals will be a lot more interesting

Thanks bud, and thank you for all the advice and help over the last few months. If it wasn't for you I wouldn't even have attempted this build

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[Jypels]

What’s the transmission plan?

Awesome idea and build!


Sent from my

Hey bud, thanks. In terms of transmission we will defnitley be upgrading the clutch packs. As for the rest we are not sure until we push the trans and see where it breaks seeing as no one apart from Oleg has attempted to get anywhere near the power figures we are chasing.

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[Jypels]

Small update:

The turbos have been decided on. We are going with twin GTX3076R dual ball bearing turbos. Will first try the ar.63 housings and then switch to ar.53 if needed.

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[AFR1485]

This sounds awesome and crazy. I’m guessing the SC is coming out?

I can’t wait to see pics of this build


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[Jypels]

This sounds awesome and crazy. I’m guessing the SC is coming out?

I can’t wait to see pics of this build


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Yes the Supercharger is getting removed. Custom intake manifold is getting built by one of the best in the business :)

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[Works2shoot]

Finally. An ACTUAL build thread. If I had to see another wheels / exhaust / tune / suspension "build journal" I was going to go bananas.

Best of luck OP! When it's all said and done we should all provide crowd-source funding to bring the car to the US to race Loe

[schirm]

subscribed! This is sweet.

[TexasDfwS4]

stupid question but, do you have a local tuner to help with the ECU issues you'll have?

[MrFunk]

Good luck! In for updates!

[RWD2quattro]

Small update:
The turbos have been decided on. We are going with twin GTX3076R dual ball bearing turbos. Will first try the ar.63 housings and then switch to ar.53 if needed.
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.63 should be a decent size housing for early spool but you will run out of breath by 6000 rpm You'll need a bigger housing if you want more top end power but your band may shift up by 1k on an .82 a/r.
I currently run an older GT3082R on my Volvo with an .82 a/r housing and it's smooth power delivery to 7500 @ 24psi. Good luck man.

[Jypels]

stupid question but, do you have a local tuner to help with the ECU issues you'll have?

Hi yes indeed, we will also be utilizing a Dastek unichip with Turbo driver, nitrous and meth driver aswell as extra injectors driver. The plan is to remove all the hardlimits from the ecu using software and then let Dynotech in Cape Town do their magic with the unichip. The unichip isnt really a "chip" its more a fully fledged piggy back ecu that can pretty much do anything you want it to. By using the Unichip we will be able to have 5 programmable maps

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[ReDeViL]

In terms of awhp we are aiming for as close to 1000awhp as possible.

holy sh*t.......#%#!!!!

[Tim11Macc]

Paving the path for those with smaller gonads.. hats off to you brother. Can’t wait to see the progress of this

[Aiserock]

You're going to run out of water to cool that beast.

[Jypels]

You're going to run out of water to cool that beast.

We doing a pretty beastly intake manifold with big air to water intercoolers, craig Davis electric water pump, big tripple pass radiator, custom AC chiller, aswell as meth and nitrous injection which should all aid in the cooling. We might also build a custom tank we can fill with ice for the chargecooler circuit, that will be discussed by end next week when I meet up with Reinier (the fabricator)

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[TROTTERS4]

Nice! Time to push this platform the the absolute limit. So many stage 2 DP guys here who act like pioneers when it's just bolt ons LOL.

[Aiserock]

We doing a pretty beastly intake manifold with big air to water intercoolers, craig Davis electric water pump, big tripple pass radiator, custom AC chiller, aswell as meth and nitrous injection which should all aid in the cooling. We might also build a custom tank we can fill with ice for the chargecooler circuit, that will be discussed by end next week when I meet up with Reinier (the fabricator)

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I am very excited to see the progression! Patiently awaiting pics.

[UkuRiSh]

If you do twin turbo I would go with GTX2867R GEN II Turbocharger or EFR 7064! Twin Precision 5858 is to large for this motor any way good luck.

[Jypels]

If you do twin turbo I would go with GTX2867R GEN II Turbocharger or EFR 7064! Twin Precision 5858 is to large for this motor any way good luck.

Hey bud we going with 2 x GTX3076R Gen2 with nitrous on low rpm (from 3000rpm) to help spool them quicker

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[mockedup]

Hey bud, thanks. In terms of transmission we will defnitley be upgrading the clutch packs. As for the rest we are not sure until we push the trans and see where it breaks seeing as no one apart from Oleg has attempted to get anywhere near the power figures we are chasing.

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Oleg made no more power than a crank pulleyed stage 2 on race gas. OP - who will be handling your tuning as this will be the largest hurdle.

[Jypels]

Oleg made no more power than a crank pulleyed stage 2 on race gas. OP - who will be handling your tuning as this will be the largest hurdle.

Oleg is far from done. Remember he is still on his complete stock engine.Also he is currently way past the power figures of dual pulley, have you seen his latest videos? Read my reply with regards to tuning a couple of post up :)

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