My MK1 3.2 TT Turbo

[V6RUL]

car crazy said:

Can the Dsg handle 500hp without disintergrating, thats more than double the power of a standard 3.2. Thats got to be some amazingly quick car.
I used to be on the TT forum they have weekends at places like donnington park, and you can buy performance parts for your TT. Even had a parade lap of 120 TT's when i was there.

The engine is capable of 800bhp at the crank on pump gas and the DSG has had the clamping pressures maxed out and the load shedding feature has been removed. If the box goes terminal then it will be swapped out for a manual conversion but i want to see what the potential of the DSG is. Ive already had 537 bhp crank power through it and it was fine. Its time to up the anti.

There are lots of weekends out for the TT Forum and at some venues there are organised sponsers there selling there wares, but you are very much mistaken if there is anything there for me, as these peeps only supply for the mass 1.8 market. The majority of my parts would have never gone near a 1.8 TT as my build is more radical.
If youve read the build thread you will see the complexity of the build, there are more similarities with the R32 boys who go FI but they havn't used a charge cooler or SSP clutches.
Steve

[vrooom]

Im normally not fan of TT, but that is awesome build. Enjoyed reading though it.

[V6RUL]

vrooom said:

Im normally not fan of TT, but that is awesome build. Enjoyed reading though it.

Cheers, this is not a normal build that is done every day, esp the way im doing it, so i thought it would be better to share.
The next 4 weeks should be interesting, when we get it out on the road and do some running.
Steve

[V6RUL]

Well..
The ECUs are in customs at London.
Unitronic have had some brilliant results on their test bed engine running Stage 3+ components.
Destruction testing and then producing the final version of the files took a little longer than expected due to the complexity of the changes required and Canadas public holiday system.
The software includes a tune facility that Autograph will utilise to tweak certain parameters once some logging has been done on da mota.
Two valves and bronze guides in the cylinder head have been replaced and compression testing has shown good seals.
Due to various and speculative reasons the block has had all oil seals replaced and was bored by 1mm to ensure a 100% good starting point. This takes the CC of the 3.2 to 3.3 now, which is within the tuning parameters of the Unitronic files.
The crank has been checked for balance/trueness and has been polished. It was found to be within tolerance.
6 x 85mm Wossner pistons [coated skirts] and rings have now been introduced to plug the gap in the block.
6 new spark plugs have been installed utilising the spec of Unitronics test engine.
6 new ID1000 Mitsy fuel injectors have been installed to match the potential of the engine.
The TT is now running a turbo hybrid of Garret and ATP..GT35/T04z with the antisurge compressor housing.
A larger wastegate has been installed to allow better control of the boost.
A stainless flexible hose has been installed between wastegate blow off side and the exhaust to allow for expansion.
Ceramic coating of the DP and WG hotside will be done when possible.

Brake master cylinder has been replaced due to perished seals on the old unit.
A new DMF has been installed as the OEM one had 15mm of play in it and 1-2mm is new.

Results from Unitronic have shown that the test bed engine is producing 740 bhp at 16 psi.
The gearbox ECU will have some OEM features removed or maxed to allow for the most torque we can get through the box.
The clutch is able to run 600 lb/ft so..if the box goes terminal, it will either be replaced or a manual conversion installed.

Unfortunately the dents/dings won't be pulled before i pick her up so the wrap will be scheduled for when i next go offshore..
I may have to pay if i want my wheels changing to the Rederwerks one-eleven S as ive had my freebie rims.

Steve

[JC2012]

One epic build! - If you dont mind me asking whats your cost to date? Im sure they cant be small but it would be interesting to know!

[V6RUL]

PMd

[JC2012]

Very impressive !

[djtimodj]

JC2012 said:

One epic build! - If you dont mind me asking whats your cost to date? Im sure they cant be small but it would be interesting to know!

Can you PM the approx build cost mate as I have built a TT 350z with forged bottom end etc and would love to compair! lol..

Also I cant seem to PM but you profile says your North west UK? Im on the north west too! Would be a ggod race once you cars built! ;-)

[V6RUL]

What is a TT 350z ?
I will PM ya.
Steve

[stabbed rat]

V6RUL said:

What is a TT 350z ?
I will PM ya.
Steve

In case he hasn't told you yet, I would guess at twin turbo 350Z but could be proved wrong

[V6RUL]

I thought it was a TT that i hadn't heard of before..
Sorry Tim.
Steve

[minimatt1967]

Mental, that is all.

[djtimodj]

Yeah sorry for the confustion mate, I ment I have a Twin Turbo (TT) Nissan 350z! lol.. If you local mate, North west I would love to pop along to a local audi TT meet and check this beast out! PM me if you can ...

[V6RUL]

I should be at Awesome Gti on Sun 29th July and a local meet at the Sandpiper on Sep 1st..
here is a link to the NW meets..
http://www.tt-forum.co.uk/forum/viewtopic.php?f=3&...
Steve

[big dub]

V6RUL said:

I should be at Awesome Gti on Sun 31st July
Steve

Cool, will look out for you, I'll be there with Peak V.A.G Club.

[V6RUL]

Come say hello if ya see me.
The TT won't be wrapped this time round as prep and wrap time are about a week or so and ive ran out of time to get that sorted.
Steve

[monthefish]

V6RUL said:

Enjoy..

Just a question on that particular turbo.

Which 'hole' is for what?

My guess is

1. Exhaust gas inlet (square hole at back opening towards the box)
2. Exhaust gas outlet (hole you can't see pointing toward top right of pic)
3. Cold air inlet (large opening at front pointing towards bottom left of pic
4. Cold air outlet (hole pointing towards ceiling)

[RobCrezz]

monthefish said:

Just a question on that particular turbo.

Which 'hole' is for what?

My guess is

1. Exhaust gas inlet (square hole at back opening towards the box)
2. Exhaust gas outlet (hole you can't see pointing toward top right of pic)
3. Cold air inlet (large opening at front pointing towards bottom left of pic
4. Cold air outlet (hole pointing towards ceiling)

Your guess is correct.

Big hole at the front towards the bottom left you can see the compressor side of the turbo and on the other side you would see the turbine(hot side). Some turbos have an internal wastegate which would also be next to the turbine, but this turbo doesnt have an internal wastegate so it would have an external wastegate a little way down plumbed into the exhaust.

[V6RUL]

Yep..your correct on the turbo connections and external wastegate connection.
The turbo is now a hybrid with at least 1 additional feature as seen here with the anti surge compressor..

Steve

Edited by V6RUL on Saturday 20th August 22:35

[V6RUL]

Here are some pics from the last few weeks of the rebuild and new bits and bobs that have been fitted..

A view after cleaning and the rebore of 1mm..




Balanced and polished crank..


New caps,shells, rods and rings..




Crank installed with R36 big end bearings and new ARPs..




Pistons, gasket and studs fitted..


Head rebuilt and pressure tested..


Head on the block..


Chains on..


Injectors..OEM..630cc [for sale]..new 1000cc babies..


Turbo compressor wheel side..


Turbo Hot side..


There will be further progress to post up very soon.
Steve