3.0L Single Turbo Build Diary (and seeking advice)

[tsbpenguin]

Hey all!

Figured some people might be interested in following my build, and this will be a good place for me to consolidate all my questions.

Car is a German spec 01 A6 2.7t 6mt. Guy bought it in Germany while he was stationed there in the military and had it shipped back. It has about 170k miles and is completely stock, it was sitting in his garage for 5 years so I'm currently diagnosing a non-start issue.

Picked up a set of OZ Racing Formula HLT 18x9's (pictured below).

Attachment 62592

Attachment 62593

So far for the build I've acquired:
BEL 2.7t block, bored for 3.0
Polished 3.0 crank
Eurospec girdle
JE Custom pistons
IE rods
2.8 heads/cams - fully refreshed
All necessary gaskets/seals/etc
XS Power single turbo conversion kit


Parts I'm undecided on:
Turbo
Fuel pumps/rails/injectors
P&P stock intake manifold vs something else
Possibly upgrade valvetrain on 2.8 heads
Clutch/flywheel setup

Basically my end goal is 750awhp on e85. It will split daily driving duty with my other vehicle so it needs to be fairly reliable. My initial thought for turbo was gt4088r, but I know the Precision turbos are fairly popular so I'm just looking for opinions on different sizing for this motor. I'd like to see fairly good spool by 3k so I'm not looking to go huge, dont need the potential for 1000, just something perfectly sized for 750.

As for valvetrain, I'd hate to disassemble the nicely refreshed heads and replace perfectly good heads, but I also really like the idea of 8k+ redline. Talk me into/out of it.

For fueling, I know the dual bosch 044 w/ surge tank will be the most popular option, but I'm curious if anyone is partial to other options like dual walboro 400s, or some other tandem. With rails I dont really know where to start. Injectors, I assume I'll need at least 1000cc ev14s or similar. Would that be sufficient for e85 at higher fuel pressure, or do I need to go even bigger?

Intake manifold, I find it hard to justify the coin for the rs4 manifold. Can similar results be achieved with a thorough port and polish? Are there any good aftermarket tubular style manifolds for a reasonable price? What about a 2.8 intake manifold? How does it compare to the 2.7t's?

Any other thoughts, opinions, advice, or input is greatly appreciated. Excited to get rocking on this sucker!

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[3.0L_Noggy_B5]

Best of luck to ya! I’m pumped to see this.


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[tsbpenguin]

Bump, still looking for input on turbo, fueling, valvetrain, etc.

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[m_haiser]

totally unrelated but does the tsb in tsbpenguin stand for technical service bulletin?

[tsbpenguin]

Ha no but that's more entertaining than the real answer, so let's go with that.

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[julex]

You need to decide between 750awhp and "3k spool" either but not both.
If you choose 3k spool then it means fairly small turbos, no 750whp in most likeliness and 8k+ rpm redline is a moot point because the turbos won't breather at this point anyway.
If you choose large turbo then no 3k spool but 750awhp easy, you can red line as far as you want because turbos will flow.

So that's for your turbo choices .

I will follow this thread to see how much fabrication/PITA it will be .

[tsbpenguin]

Lol yeah I'm not saying i want full boost by 3k, i know that's utterly unrealistic. I'm just saying I dont want to be waiting around til 5k to see boost. I figure if I'm planning to run 35psi+ it should be within the realm of possibility to see 20+psi by 3500. I was told the gt4088r would likely only be good for about 600 wheel so I'm just trying to figure out the balance of being able to hit 750 without going so big that the car isn't streetable.

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[tsbpenguin]

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Got my single turbo conversion kit today. Gonna port out some exhaust manifolds then send it all off for ceramic coating.

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[m_haiser]

curious to see the reliability of a power level like that. these blocks as far as I know don't handle that power well but maybe the issue has been recognized and resolved. Not to nay say, just curious.

[tsbpenguin]

Well I've got the BEL version of the block which has beefed up main journals plus I'll be running the girdle for extra rigidity. Block failure is pretty rare unless you're dealing with a lot of detonation, which is all about the tune.

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