fiestaturbo.com

[freak power]

Some of you will remember this

250-bhp-n-a-2-1-zetec-16v-orion-now-gone-audi-s3-is-here-vt97695/

It had to go because of many reasons and was gutted about it but i was told that the engine made 303bhp, not bad for a N/A Silver top Zetec

Ok most of this will be copied and pasted so some of it may not make sense but any who.




I picked up a Audi S3 about 2 years ago and thats were the troubles started



As some of you know my big end went after a oil pump failure some time ago and at the time i was trying to get it sorted with the garage i got it from but no such luck.



Anyway the engine was stripped to find that the crank was damaged beyond repair and there were scores in the bores as well as some pitting? A second hand engine was my first choice but there a bit thin on the ice and if i did find one people were wanting a lot of money for them and had no history for the engine. The second option was try to find a good S3/TT crank? how wrong again as they are like rocking horse poo but i was offered a 1.9TDI crank and was told that they could be used as part of a stroker kit. I handed over £150 for the crank and walked away thinking what am i getting into know lol.



What to do next? build the engine with what i had I did my research and found pete @ Integrated Engineering very helpful and i have now handed over $1600 USD to pete@IE for a stroker kit giving a 2067cc engine and 8.5:1 compression but still safe to 6500+rpms and some performance valves set with inconel exhaust valves



The rest of the engine has been inspected and found to be good, The head will be fully stripped down cleaned and ported by my own hands as this is what i have been doing for many years. It looks like the head can be improved a lot around the exhaust ports as there is a 5-6mm difference in port size of the head and the manifold and some modification will be done to reduce carbon build up, improvement of of flow, knife edging the split ports on the inlet and will be given a light skim and so on.



When the engine is build it will be run in and a down pipe and exhaust system will be fitted at a later date as well as a remap to make the most of the 2.1 engine, when i get the spare cash the rest of the car will be give a look over on chassis modifications and then a big turbo conversion will be considered depending on money?



Picture will come soon of the damage engine and new parts



But for now here is the car in question



Car before ebay intercooler fitted











Ok a little update as i got the camera out today to take some pictures of some of the damage and modifications been done



Lets start with the damage



Main bearings





The modifications to the head as you can see the gasket on the head, the gasket lines up with the ports on the manifold but not on the head so i did a little bit of portering to match them

Before



After





Still have loads of work to do on the head as i will fit new guides and recut the seats as there is a bit of play in the valve guids



Picked up a brand new sump today





Painted my cam cover, boost pipe and inlet in crackle black







Got these some time ago after having to pay a small charges









JE 83mm forged pistons for 2067cc



IE Steel rods



Performance valve kit



Got the engine block and head back from the machine shop and now has a 83mm bore and a nicely skimmed head



Block is painted crackle black witch doesnt look that good in the pictures but it does look good in person and its very high temperature paint



Started to get the bottom end together and ran into a few little problems, with the now 95mm stroke the pistons hit the oil jets so i tried to space the oil jet out of the way with some 2mm spacers but thats just not enough and if i go any more one of the jets will hit the trigger wheel for the CPS so the pistons will need machining witch i will get pics up when done



The trigger wheel was also a problem as the bolt holes didn't match TDi crank ones so i modified the S3 ones to fit but i have now found out that you can use one from a 2.0 8v ABA engine that will bolt on.



With the block back i thought i would cheap the head gasket and all is well with the ALH N/A 2.0 Passat gasket



Spent most of the day lapping all my 20 valves in and rebuilding another head for customer but had to stop with my head as euro car parts gave me the wrong valve steam oil seals



Now for lots of random picture















































I've machined and balanced the pistons as the oil jets hit them, now i don't have any clearance problems



Fitted them and all is well and turns over by hand nicely









ust finished putting the head and bottom end together



Just waiting for my flywheel now from TTV witch is taking the piss with the time



























Had to wait a bit for this as the company that made it are between moving premises.



I would of made it myself but to buy a slug of steel the size i needed was very expensive but at £200 i think its a bargin



But worth it



The steel one













Thats 3.5 kgs



The old Duel Mass Flywheel thats been sat outside in the rain











Thats 10.5 kgs



I hope this will help my 2.1 as the TDI crank was 2 kg more than the S3 crank



The paint job

















The Turbo








Got my GTX3076r and kit from CTS in Canada, also placed a order for some 870cc injectors, supertech valve springs and titanium retainers.
Did a little dummy build of the manifold, looks like i may have to mill the head to clear the down pipe but no biggy
I'll update a little more later on












More to come

[luca]

interesting build

[freak power]

Thanks Luca hows the fiesta ?

[luca]

Still at JKM waiting for me to collect it. In no rush though until the weather warms up quick visit to painters then its all ready.


Your new turbo will give that engine a whopping kick

[freak power]

Still at JKM waiting for me to collect it. In no rush though until the weather warms up quick visit to painters then its all ready.


Your new turbo will give that engine a whopping kick

Wish i waited for the Borg Warner efr turbo's but i'm sure the GTX will still get me over 500bhp

[luca]

Still at JKM waiting for me to collect it. In no rush though until the weather warms up quick visit to painters then its all ready.


Your new turbo will give that engine a whopping kick

Wish i waited for the Borg Warner efr turbo's but i'm sure the GTX will still get me over 500bhp

Easily mate if the head is specced for it. A friend has the gt3076 and tht hits just 490ish /500ft
so the GTX should see it easy.

[freak power]

I ported the head but its still a small port, it would make 500 easy with a large port, i will need higher boost with the small port

[heeman10]

I will own up right now - I skim read about twelve words and just looked at the pics, but picked out "500bhp"! What are you doing about transmission dude? It all looks lovely!

[freak power]

I will own up right now - I skim read about twelve words and just looked at the pics, but picked out "500bhp"! What are you doing about transmission dude? It all looks lovely!

It will need a new clutch at some point so nothing right now as there are a few S3's with 400+ and still running standard transmissions and clutches

[heeman10]

Another 100bhp on top of that is a fair difference Massive

[freak power]

Another 100bhp on top of that is a fair difference Massive

I don't plan to max out the turbo just yet i want to run it on low boost to start with

[jonyb4]

very interesting build, that head looks very weird with 20valves, first ive seen from that angle

[freak power]

very interesting build, that head looks very weird with 20valves, first ive seen from that angle

Great flowing heads even when ported, And mines just a small port head ! On early models they made a large port head which is better flowing.

I will post a picture as i have one coming as the one in the picture above will have its limitations

[SEG1]

Impressive build mate.

i use to own a s3 wicked little car. regret selling it

[Excursion]

Your headwork always impresses me, interesting build! The transmission won't take 500 lb/ft, I think you need to replace the standard front diff at the very least (bolts are weak as is the diff itself).

I had an S3, I'm sure you'll sort it but it was the worst handling sports car I ever owned. It was a 225 with Quattro GmbH suspension and it under steered badly. I think they can be made to handle with various mods - check out Audi Sport for some guides.

[freak power]

Thank you Excursion. I'll have to wait and see about the diff.

Mines not that bad when it comes to handling as mine oversteers with the help of the performance haldex controller and careful setting up

[Excursion]

Thank you Excursion. I'll have to wait and see about the diff.

Mines not that bad when it comes to handling as mine oversteers with the help of the performance haldex controller and careful setting up

Yeah I think the basics are there, just the standard set up is very conservative. This was as a result of the first TTs which were claimed to be 'dangerous' but were actually set up like a real drivers car. The rear ARBs got reduced in size after that so after market roll bars especially give very good gains. I think the 19mm rear works best - from memory.

[freak power]

Got some R32 ARB and coilovers to fit yet

[SEG1]

just a question about the stroker kit why did you go for the 1.9tdi crank instead of the 2.0tfsi one?

[freak power]

just a question about the stroker kit why did you go for the 1.9tdi crank instead of the 2.0tfsi one?

It was a cheaper option to the 2.0 crank and there are loads of 1.9 cranks about unlike the 2.0 ones

[SEG1]

ok good to know

[freak power]

Well the time has come and seeing we have a long weekend i thought it would be good idea to fit my AEB large port head and GTX

A few small issues but the main problem is the the clearance between the turbo and bulk head but hope to sort that out with a modified dog bone bust

here are a few pics of the last few days

[jonyb4]

thats a weird head design

whats the chain for on the rear of the cams, excuse my ignorance

[freak power]

Its to link the 2 cams as it only runs one pulley

[jonyb4]

oh!

thats complicated

[freak power]

oh!

thats complicated

It is but a good design as not many other manufactories have tried to copy the design, if they did they didn't work for them and failed.

They have massive flow figures and with the right spec they can reach 750+bhp

[Fraggle]

Absolute beast...Much respect for pushing on with it...Got any vids of it in action?...Savage motor

[jonyb4]

jesus, im supprised int hat case why we dont see these engines in over cars like kit cars or the like

whats the name of them engines? Eg. C20let

[freak power]

jesus, im supprised int hat case why we dont see these engines in over cars like kit cars or the like

whats the name of them engines? Eg. C20let

So many different names . most commonly known name is BAM but that was found in many TT's and some S3

Mine was a APY but now has a BAM block and AEB head.

1.8 20v Turbo is all i know it as but mine is no longer a 1.8

[freak power]

Finished fitting my WMI with the tank and the pump in the boot

Just need to sort out the timing as i must be out half a tooth but thats easy for me as its got a adjustable cam pulley
















Video isn't great as its on its first start up and the tappets haven't filled with oil yet but i must say when its turned of i love hearing the turbo still spinning

[SEG1]

it all looks factory mate.lovely work
this s3 will be mental!

[jonyb4]

love it mate, very sneaky looking quite standard apart from the huge charge carrier

loving the wastegate, is it using a screamer?

[freak power]

No screamer

just dumps back into the down pipe

[jonyb4]

ah, would ruin the sleeper effect

[DAGET]

Incredible, what a great project. I had to do a standard turbo swap on a standard 1.8t A4 and that was complicatd enough pipework wise. Impressive!