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    Thread: Big turbo build- take two

    1. Member Doooglasss's Avatar
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      11-18-2011 01:03 AM #1
      Mod list:

      Suspension
      KW Variant 3 coilovers
      H&R front & rear sway bars
      034 track density front strut mounts
      Defcon front control arm inserts
      PowerFlex front control arm bushings
      MadMax lower rear multi-link
      Kmac upper rear multi-link

      Brakes
      Hawk HP+ pads
      Slotted rotors
      ATE SuperBlue Fluid
      Stainless lines

      Drivetrain
      Front Raxles
      Spec billet steel 13 lbs. flywheel
      Clutchnet red pressure plate
      Clutchnet unsprung kevlar pucked disc
      BFI stage 2 motor mount set
      Powerflex polyurethane steering rack bushings
      Diesel Geek Sigma 6 short shifter
      B&M short shifter
      Force Fed Engineering metal shift mount bushings

      Interior
      Hertz Hi-Energy 165K component speakers
      Sundown Audio SD-10-D2
      Audison LS 500.2
      JL Audio 250/1
      Kicker EQ
      Belkin A2DP input
      Apple iPod input
      iPod touch 32gb
      Modshack gadgeTT
      ProSport premium: oil pressure, air/fuel & boost gauges
      OSIR shift ring light
      Euro headlight switch

      Fueling
      Eurodyne Maestro software
      Wideband AWP conversion w/ VVT module
      V8 S4 MAF
      Injector Dynamics ID1000's
      Aeromotive Adj. FPR
      Fuelab 41402 pump
      OBX fuel rail -6AN
      Custom FFE under hood surge tank
      Fragola fittings & braided lines
      2.0T FSI coilpacks & NGK 7 irridium plugs (BKRE7EIX, Stock #2667)

      Motor internals
      IE Rods - 20mm pins/ACL bearings
      JE Pistons - 81mm/8.5:1 CR
      Eurospec main studs
      ARP head studs
      AEB head
      Ferrea valves, springs, retainers

      Forced induction
      Precision 5857 - DBB/4" inlet/v-bands
      Precision 650hp intercooler core
      MadMax Evo DV
      Tial MVS
      OBX intake manifold
      70mm throttle body
      Boost Valve dual stage boost controller
      Magnaflow stragiht through muffler
      EuroJet 4" exhaust tip
      Force Fed Engineering turbo kit:
      -4" turbo inlet pipe
      -2.5" intercooler piping
      -Tubular exhaust manifold
      -3" turbo back exhaust

      Exterior
      Verdict Motorsports antenna delete
      Headlight reflector delete
      smoked turn signals
      badgeless 5 bar grille
      shaved front bumper

      Last night's progress- from empty engine bay to this in about 2 hours thanks to Greg & Vince:





      Tonight:













      Last edited by Doooglasss; 11-06-2012 at 01:28 PM.
      -Doug

    2. Member bklnstunt718's Avatar
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      11-18-2011 02:14 AM #2
      i wanna come by asap! sit on a chair like a little kid... AND WATCH!!!!

    3. Member Doooglasss's Avatar
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      11-18-2011 09:10 AM #3
      Haha Jaymo you know where to find me man! Not to worry we got the majority of the install on video but last nights work it ran out of space somewhere and I didn't notice.

      I'll get a lot more photos up here this weekend of the work leading up to this.


      Hey anybody mind helping me out? I cannot for the life of me remember which knock sensor goes on which side??


      Last edited by Doooglasss; 11-18-2011 at 05:17 PM.
      -Doug

    4. Member 631 Corrado's Avatar
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      11-18-2011 02:59 PM #4
      getttin paid.... getting paid.

    5. Member Tempes_TT's Avatar
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      11-18-2011 04:16 PM #5
      Yeeeah buddy! So excited to see some progress from you man!

      ps. what short shifter kit/shift cable end links do you have?

      Last edited by Tempes_TT; 11-18-2011 at 04:18 PM.
      Quote Originally Posted by DCMS371 View Post
      You do realize women are biologically programmed to ruin men's lives by making them get rid of anything that they might enjoy more than spending time with the woman right?
      Quote Originally Posted by SchmidTT View Post
      Has anyone really been far even as decided to use even go want to do look more like?

    6. Member Doooglasss's Avatar
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      11-18-2011 05:19 PM #6
      Thanks man!

      I have:

      Diesel Geek stigma 6 under the hood (comes with the cable ends)
      Force Fed bushings on the mount
      B&M short shifter (shift rod side)

      It's super notchy and short
      -Doug

    7. 11-18-2011 05:31 PM #7
      looks great, what are your hp goals?

    8. Moderator PLAYED TT's Avatar
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      A German thing, and a not so German thing
      11-18-2011 05:45 PM #8
      The teaser pics look a lot better on a computer. Its about time

    9. Member Doooglasss's Avatar
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      11-19-2011 10:20 AM #9
      Hp goals-- I wanna go fast. Realisticly I want 450fwhp pump and 550fwhp e85. I've never dyno'd AWD so I don't know those numbers yet. Last year I made 410fwhp with a small port head, bad tune and pump gas.

      Time to go finish this mechanically speaking. Eurodyne support is trying to help me out reading my ECU but all efforts on my part keep failing. I hate this cars communication system- I even ran a wire straight from the ECU to my OBD2 port and zero luck.
      -Doug

    10. Moderator PLAYED TT's Avatar
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      11-19-2011 11:21 AM #10
      Good luck Doug. Keep us updated.

    11. Member Doooglasss's Avatar
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      11-20-2011 07:38 PM #11
      Well finishing off today all the mechanics are together. Due to the new intake manifold putting the TB in a different location than stock I'll need new piping so I decided to change it up entirely. Going to change to a passenger side throttle body I'm pretty sure. Will mean shorter piping and less heat soak in comparison to the last setup.

      Motors all together... missing IC piping and a catch can and obviously wiring:



      Cars on the ground:




      Need to order some items for the fuel system. I picked up an adjustable regulator but I'm going to return all that garbage- keeping it stock with the RMR FPR drop in to -6an.

      Also the ongoing saga of being unable to flash my car continues. I'm going to see if a dealer can bench flash it just to get me up and running then I can troubleshoot from there.
      -Doug

    12. Member
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      11-20-2011 08:39 PM #12
      hmmm, curious how this leads to less heat soak...please explain

    13. Member Doooglasss's Avatar
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      11-21-2011 08:06 AM #13
      Quote Originally Posted by jwalker1.8 View Post
      hmmm, curious how this leads to less heat soak...please explain
      My old IC piping setup literally ran from the turbo to under the exhaust manifold and wrapped around the passenger side of my car. The new idea I have for a setup won't run under the exhaust manifold and will be maybe 2 feet shorter.

      Old setup:

      -Doug

    14. Member
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      11-21-2011 09:04 AM #14
      yes, old setup was recipe for heat...

    15. Member Doooglasss's Avatar
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      11-29-2011 06:25 PM #15
      New part for the day. I don't want to deal with an adjustable FPR.



      Going out to install this and try to figure the ECU communication situation out-- total nightmare. About to buy a TT with a stock wideband
      -Doug

    16. Member 631 Corrado's Avatar
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      11-29-2011 06:42 PM #16
      your welcome.lol. (12pk) i told you that **** was dope

    17. Member l88m22vette's Avatar
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      11-29-2011 07:40 PM #17
      Quote Originally Posted by DougLoBue View Post
      Going out to install this and try to figure the ECU communication situation out-- total nightmare. About to buy a TT with a stock wideband
      How far have you gotten?
      Audi TT mk1 FAQ zero Porsche wheels given

    18. Member Doooglasss's Avatar
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      11-29-2011 09:34 PM #18
      Here's the deal...

      I have a 2001 AMU TT, stock NB 02

      Last year I did a WB swap by using an OEM mk4 harness and unpinning the 02 wires and re-connecting them to my stock harness. I also removed my SAI relay and MAF sensor wiring. My car was running Unitronic at the time off a mk4 AWP WB ECU and the ECU was mailed to them to be flashed. When revisions were made my ECU was installed in a later model mk4 VW because my car could not read or flash the ECU. I had no problem running Vag-Com though.

      Though this time I always had this code, car ran great just couldn't flash the ECU:

      18058 - Powertrain Data Bus: Missing Message from Instrument Cluster
      P1650 - 35-00 - -

      People say this comes when swapping from NB to WB. I'm starting to think the ECU's communicate differently. Digging into AWP vs. AMU wiring diagrams I have found that the AWP has the CAN-BUS connected to the Instrument Cluster specifically the Green connector pin's 18 & 19. The AWP maintains the K line also though- which is the single wire old school diagnostic communications system.

      On my AMU car I have found the CAN lines to run from the ECU,AWD,ABS and possibly other locations but not to the cluster. I decided to install pins and twisted CANBUS wiring from the cluster to the existing CANBUS circuit and I still receive the same code.

      Still can't read the ECU with Eurodyne Flash but I can vag-com it no problem.

      I will be digging through the wiring diagrams and comparing the CANBUS more extensivly. I did read a huge article today that describes most CANBUS communications to have a control unit. I don't know if 2003 VW setups are so old school that they don't have this.

      http://marco.guardigli.it/2010/10/hacking-your-car.html

      I haven't attempted to run wires to the OBD2 port yet for can-bus. After a beer I'll go out and try that one next.
      -Doug

    19. Member Doooglasss's Avatar
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      12-02-2011 09:45 AM #19
      ECU update:

      A couple of days ago I headed down to FFE and tried my ECU & cable read on a MK4 VW- I had the exact same results. Shipped both to Chris @ Eurodyne and hopefully it's an issue with the ECU that can be resolved. If not I'll buy another.
      -Doug

    20. Moderator PLAYED TT's Avatar
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      12-02-2011 10:10 AM #20
      I'm glad your finally willing to scrap that damn ecu.

    21. Member
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      12-02-2011 12:39 PM #21
      So why was an adj. FPR an issue?

    22. 12-02-2011 01:09 PM #22
      ^^^ I'm curious too ^^^

    23. Member Doooglasss's Avatar
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      12-02-2011 01:17 PM #23
      I wasn't interested in having another adjustment. I'll be running 3bar and the stock FPR seems reliable enough.

      I would have spent $300 on an adjustable and all the crap that comes with it just to have set it to 3bar or $70 to use the stock FPR and it came with most of the fittings I'll need.
      -Doug

    24. Member
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      12-02-2011 05:07 PM #24
      Quote Originally Posted by DougLoBue View Post
      I wasn't interested in having another adjustment. I'll be running 3bar and the stock FPR seems reliable enough.

      I would have spent $300 on an adjustable and all the crap that comes with it just to have set it to 3bar or $70 to use the stock FPR and it came with most of the fittings I'll need.
      Put a gauge on that OEM FPR and you'll see that they aren't very precise, aka it won't be right @ 43.5 psi.

    25. Member Doooglasss's Avatar
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      12-02-2011 05:20 PM #25
      How off have you seen them be?
      -Doug

    26. Member MKllllvr28's Avatar
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      12-02-2011 06:14 PM #26
      Mine's off by 4 psi. I run the rmr adapter.

    27. Member Doooglasss's Avatar
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      12-05-2011 10:54 AM #27
      So an interesting event occurred today:

      I shipped the ECU out from my job to Eurodyne in Canada. My company provides nuclear power products internationally and government defense products to the US. Canadian customs rang up my boss today asking why they were receiving a package for Eurodyne with an invoice for a nuclear valve going to Korea. Seems like paperwork got mixed up and I've become the start of a running office joke.

      Guess my Canadian bound packages I'll pay full price for in the future...
      -Doug

    28. 12-05-2011 11:24 AM #28
      Quote Originally Posted by DougLoBue View Post
      So an interesting event occurred today:

      I shipped the ECU out from my job to Eurodyne in Canada. My company provides nuclear power products internationally and government defense products to the US. Canadian customs rang up my boss today asking why they were receiving a package for Eurodyne with an invoice for a nuclear valve going to Korea. Seems like paperwork got mixed up and I've become the start of a running office joke.

      Guess my Canadian bound packages I'll pay full price for in the future...

    29. Moderator PLAYED TT's Avatar
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      12-05-2011 12:15 PM #29
      Quote Originally Posted by DougLoBue View Post
      So an interesting event occurred today:

      I shipped the ECU out from my job to Eurodyne in Canada. My company provides nuclear power products internationally and government defense products to the US. Canadian customs rang up my boss today asking why they were receiving a package for Eurodyne with an invoice for a nuclear valve going to Korea. Seems like paperwork got mixed up and I've become the start of a running office joke.

      Guess my Canadian bound packages I'll pay full price for in the future...
      Oh boy haha. That must have been a fun time explaining that one to the customs

    30. Member MKllllvr28's Avatar
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      12-05-2011 03:12 PM #30
      Sounds like terrorism to me....

    31. Member Doooglasss's Avatar
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      12-05-2011 06:53 PM #31
      haha yea it was an adventure. Still hasn't made it there yet even though it was schedueled for delivery today.

      Today got another cluster in the mail. My old one's gas gauge didn't work and it was really super special in the winter- wouldn't function for about 5 minutes. Just crossed my mind how do I change the milage amount on the cluster?

      Aside from this ordered some other toys for inside the car including an A2DP setup.



      Last edited by Doooglasss; 12-05-2011 at 07:06 PM.
      -Doug

    32. Member Doooglasss's Avatar
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      12-08-2011 09:44 AM #32
      While the ECU is out here's some photos from the motor work from a few months back.

      ARP Main studs and IE rods






      JE Pistons and fresh walls and decked block









      AEB head, dipped, decked, new valve guides and seats cut






      Last edited by Doooglasss; 12-08-2011 at 09:48 AM.
      -Doug

    33. Member Doooglasss's Avatar
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      12-08-2011 01:55 PM #33
      Cable and ECU are on their way back to me!

      ECU checks out, cable needed some repair- a big thanks goes out to Eurodyne's Chris Tapp

      Now to try and squeeze my car into Force Fed for some intercooler piping and hopefully after that I can finally drive this thing...
      -Doug

    34. Moderator PLAYED TT's Avatar
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      12-08-2011 01:58 PM #34
      Quote Originally Posted by DougLoBue View Post
      Then after that I will definately drive this thing...and love every second of it
      FTFY

    35. Member RabbitGTDguy's Avatar
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      12-09-2011 06:21 AM #35
      Quote Originally Posted by DougLoBue View Post
      Cable and ECU are on their way back to me!

      ECU checks out, cable needed some repair- a big thanks goes out to Eurodyne's Chris Tapp

      Now to try and squeeze my car into Force Fed for some intercooler piping and hopefully after that I can finally drive this thing...
      Lookin good! Can't wait to hear how it goes!

      Joe

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