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Well done Burt, it takes a real man…
Agreed!
Have you driven it yet sean?
No, still a few bits to do. Wireing and stuff for a few extra features Plus I have to sort out these ballast resistors for the new super tanker sized low impediance injectors. Then I have to figure out how to rescale my existing map to work with the new injectors, then fingers crossed it will start!!
The two of us will be working on it again tonight.
Sean…
This a great piece of work. The contrast between the earlier, almost finished, pics and the latest is amazing. The amount of extra work you’ve had to do. . that takes real patience . . and determination. Well done. Hope it fires up first time!
Hi Sean, can i ask what was the reason that you have mounted your turbo with the exhaust side exiting to the left, which is opposite to your original install and if i remember correctly opposite to Proalloy’s install ?
I can see so many changes when i look at the before and after shots, you have put so much extra work in on changing the set up - every pipe route seems to be different now !! I have my fingers crossed that it produces the ultimate Audi 20v Install…
Thanks guys!!
Chris I have been meaning to call you for a chat for a while, will call soon I promise.
OK why so many changes. The main issue was I wanted to run an external wastegate and the manifold that Wayne at Pro allyoy has used has meant he has had to make a huge amount of modifications to the rear subframe, including extra bracing etc. None of this is allowed under LOT regs.
So I had to go for one of the compact style manifolds with a built in external waste gate take off. This take off is cast as part of the manifold and it is on the exhaust side of the turbo (as I have it installed now) so that was one factor. The other majaor factor is that the compressor housing of the turbo hits the rear subframe if I mount it the other way around, which would mean loads of mods to the subframe, which as I mentioned isn’t allowed.
So yes, every pipe run had to change, the airbox had to be re-made, the chargecooler is completly new and different, etc etc etc.
Wayne and I spent tonight doing a bit of wireing, so I now have a variable boost rotary switch. This is mainly so that I can turn the boost down in wet conditions. I have a map switch, so I can switch between the three maps that the emerald can store, plus I have a full throttle gear change.
I am using the full throttle gear change as a way to limit lag between gear changes.
Lag between gear changes happens because as you depress the clutch, you also come off the throttle. This closes the throttle butterfly and the boost is then dumped out via the dump valve, plus as the throttle is closed, no air is passing through the engine, so the exhaust wheel of the turbo slows down. Then when you come off the clutch and back on the throttle, there is an amount of ‘time’ for the turbo to get back up to speed and to then fill the pipework with charge air at full boost pressure. This ‘time’ is lag. Now we are not talking a very big amount of time here, but its time none the less.
With the emeralds full throttle gearchange, basically, when I change gear, I will press the clutch, but leave my foot planted on the throttle. I have a pressure switch in my clutch line that when it sees any pressure (when the clutch is pressed) it tells the ECU to cut the revs to a pre set amount (as I will be changing at about 7,500, I will probably make this pre set amount about 6,000rpm), so the revs will drop to 6k while i change gear, but most importantly, as the throttle is still wide open, no boost will have been ‘dumped’ and the engine will still be flowing loads of air, thus keeping the turbo spinning, so as soon as I come off the clutch, the revs kick back in and off we go!!! lol
Well that is the theory anyway lol…
We also fitted a new large sized clutch master cylinder.
Also wired in the ballast resistors and installed those behind the dash. This meant rewiring the injector feed wires etc etc.
We then rescaled the map for the new sized injectors and hit the button and she pretty much fired up straight away, so we were well chuffed with that. It is running a tad lean, so it wasn’t great cold, but it started and ran OK, and that was what we wanted to make sure of, ready for mapping.
Tomorrow, will see the dash go back in, the seats back in, the roof back on, a few jobs in the back, then the rear body work back on etc etc
Sounds awesome, i have read the post twice and yet i still don’t fully understand how the full throttle gear change works…I will leave that for you to explain to me when we chat next…keep up the good work, as us audi boys are looking forward to your ongoing race development for futher improvements in our own cars…If the dollar gets any lower i’ll have to order the bits and put them to one side !!!
Full throttle change sounds strange…what happens when you want to heel-n-toe for a corner ?
Do you not automatically get 6000 revs because the clutch is in and you are on the throttle ?
Sean called this morning en- route to Emerald for the mapping session…
He said he was travelling down the M6 without his trousers…?
I would guess that in all the excitement he forgot to dress this morning…
WTF
He said he was travelling down the M6 without his trousers…?
Hope Burt has taken his false teeth out
He said he was travelling down the M6 without his trousers…?
Hope Burt has taken his false teeth out
spoke to sean about 20mins ago, mapping went really well
I cant wait to drive it now
sean should be posting soon,he is on his way to
plans motorsport as we speak
burt
is he fully clothed now?
burt… why don’t you bring it to Bedford on saturday when he’s in the states?
is he fully clothed now?
burt… why don’t you bring it to Bedford on saturday when he’s in the states?
should be fully clothed
car is at plans all week
burt
Mapping went well, 319.9BHP as expected!!!
Lots to tell, will post up when I get a free half hour
O.k, so before you mapped it so that the power output was 319.9 bhp what did it really put out?
Well lets put it this way, Dave had all of his straps on it holding it down, I was sitting in it, trying to hold it down and it just wheelspan out of the rollers.
And all that was only at 21psi boost and it will run to 30!!
The tyres got up to over 90 degrees!!!
So you couldn’t get a reading then?
Full boost for your day at Donnington I hope.
Well lets put it this way, Dave had all of his straps on it holding it down, I was sitting in it, trying to hold it down and it just wheelspan out of the rollers.
And all that was only at 21psi boost and it will run to 30!!
The tyres got up to over 90 degrees!!!
mmmuuuuhwahahaha ! You are gloriously mad, Sean!
Great stuff!
Awsome work guys, cant wait to see it running.
But S/C Hondas are better
*Runs away and hides *