the PRJCT .:R chronicles (iMod.:R BUILD UP)

[JLCVDUB]

Either fuel pressure for the low pressure side of the fuel system or oil pressure. The range is too high for boost and you don't need to monitor water pressure.

I'm going to go with this. Although, I wouldn't want an oil pressure gauge somewhere I can't see it. Does it have some sort of sender for cabin reading?

I thought about doing oil temp, but I'd much rather have pressure. I'll still have the wideband, and the gauges I'm getting have capability to ready temp as well, so who knows what I'll do.

[iMod.:R]

Either fuel pressure for the low pressure side of the fuel system or oil pressure. The range is too high for boost and you don't need to monitor water pressure.

You were damn close on your first guess so Mr. zbeasty, you are declared the WINNER of this round!

I'm going to go with this. Although, I wouldn't want an oil pressure gauge somewhere I can't see it. Does it have some sort of sender for cabin reading?

I thought about doing oil temp, but I'd much rather have pressure. I'll still have the wideband, and the gauges I'm getting have capability to ready temp as well, so who knows what I'll do.

Once you git yer' mitts on the car I have a feeling that we'll see steady progress quite quickly. Im very curious about the route you' end up going as well.


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[iMod.:R]

So the answer is that this is the fuel pressure regulator on Howie's (HE Performance) Stage 2 manifold. This is the key, the heart if you will to the entire system. Ultimately we are designing a fueling solution that will allow the car to run 8 RS4 injectors and 4 AEM nozzles (direct port style) for WMI.

The question really is what is the best FIC device to orchestrate all this fueling. TEFF'ster and the good Doctor Simon are both at this same stage as well. Its a hell of a challenge that between the three of us should be sorted in the next few weeks. This intake manifold will quite literally be the main artery in this build to conduct all fueling and therefore, holding 550+ sustainable awhp would likely not be possible without this piece.

Howie, if you are reading this: Your intake manifold is a straight up masterpiece!

The beauty of this beast in overview mode.




The underbelly where you can clearly see the threaded ports for the AEM methanol nozzles.




Close up of the methanol ports.




Fuel railing action!




I learned about this bundle of badass here:

[HE Performance WEBSITE]


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[Dutchmastr9]

this thread bores me now

[iMod.:R]

this thread bores me now

Oh damn, now you too?!!! I can understand. Its a crashing bore to watch a car get mildly modded.

[johnnyR32]

Oh damn, now you too?!!! I can understand. Its a crashing bore to watch a car get mildly modded.

[JLCVDUB]

That manifold gives me three wood. She will be mine during phase three

[Dutchmastr9]

Oh damn, now you too?!!! I can understand. Its a crashing bore to watch a car get mildly modded.

i just like pretty pictures

[zbeasty]

So the answer is that this is the fuel pressure regulator on Howie's (HE Performance) Stage 2 manifold. This is the key, the heart if you will to the entire system. Ultimately we are designing a fueling solution that will allow the car to run 8 RS4 injectors and 4 AEM nozzles (direct port style) for WMI.

Nice manifold but why didn't you go the Stage 3 with the additional plenum volume? Also, 8 RS4 injectors? Unless you're running a combination B7 for direct injection and B5 for indirect injection you'll only be able to run 4 RS4 injectors.

[iMod.:R]

That manifold gives me three wood. She will be mine during phase three

Three wood? Hecka bonertime! LOL!

i just like pretty pictures

Pics only brah, from now on. Instaclam shots with no text is how I'll do it.

Nice manifold but why didn't you go the Stage 3 with the additional plenum volume? Also, 8 RS4 injectors? Unless you're running a combination B7 for direct injection and B5 for indirect injection you'll only be able to run 4 RS4 injectors.

It is my understanding that he stg2 has been run on a 700 whp car, so we'll easily get where we need to be without the stg3 manifold. We've definitely got some ideas in place that will allow us to go with 8 injectors. For now the idea is primary's are RS4s and the secondary set may be as well. We have not gotten to that hurdle just yet but when we do, there is also a back up set of S3 injectors if we are in a bind. For now though, our goal os all RS4s.



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[TLud]

That manifold is something else. Wow. If it works as good as it looks...

I'm curious to see whether you've come up with anything in your build that might yield benefits for those of us sticking with stage 2+ setups.


Sent from my iPhone 4S using Tapatalk

[Dutchmastr9]

Pics only brah, from now on. Instaclam shots with no text is how I'll do it.
.

instaham is my favorite thing right now

[zbeasty]

It is my understanding that he stg2 has been run on a 700 whp car, so we'll easily get where we need to be without the stg3 manifold. We've definitely got some ideas in place that will allow us to go with 8 injectors. For now the idea is primary's are RS4s and the secondary set may be as well. We have not gotten to that hurdle just yet but when we do, there is also a back up set of S3 injectors if we are in a bind. For now though, our goal os all RS4s.
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8 direct injectors? If so you'll need more fuel volume than the Stg 2 HPFP pump can provide. If you plan on running 4 of them as indirect (ie in the 4 additional injector spots on top of the HEP manifold) you'll still need a HP fuel feed as these will just dribble fuel at normal injection pressures. I would have thought the best way would have been to retain the standard injectors in the head and run a larger injector to supplement. That way you get the much better spray pattern from the standard injector but have that additional hit of fuel when you need it.

Feel free to PM me if I'm ruining any surprises you might have in store for everyone else

[JLCVDUB]

He also has the USP low-pressure piece as well. You're going to be using direct injectors in the intake ports? Interesting..

[iMod.:R]

8 direct injectors? If so you'll need more fuel volume than the Stg 2 HPFP pump can provide. If you plan on running 4 of them as indirect (ie in the 4 additional injector spots on top of the HEP manifold) you'll still need a HP fuel feed as these will just dribble fuel at normal injection pressures. I would have thought the best way would have been to retain the standard injectors in the head and run a larger injector to supplement. That way you get the much better spray pattern from the standard injector but have that additional hit of fuel when you need it.

Mark-
The plastic intake manifold will simply not put up with the demands and heat that we will be placing on this car and may in fact fail with the increased boost. We will also be running a secondary "fuel well" to sort of pre-feed the primary injectors. This will be utilizing the new HPFP Upgrade Stg2 pump. The secondary injectors whether they are RS4, S3 or whatever works best will be fed by the USP Low pressure in-tank pump.

As I'm quite sure you know, the Skoda that ran nearly 700hp on the salt flats was also running the HE Performance mani and has had no problems that Howie has ever been made aware of. That is an extreme example of what can be done with this engine. Granted it's a TSI, but its so damn close to the FSI that at this point we have no reason to believe with good mapping that we will encounter any issues.


Check this 1st (1-of-8 vids) video with the Skoda team:


I appreciate your concerns and they are well thought out so thank you. Can you share with us your experience with an 8 injector set up? If you learned something that would save myself or another forum member some R&D $$$ this is a great place (and time) to share!

Best-
Jason

You're going to be using direct injectors in the intake ports? Interesting..

We will be experimenting, but we have all the provisions needed to work out a few scenarios.

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[GASMAN664]

Hey Jason,

Whats the hold up? You guys still working on it in Phoenix? We need pics or something. This is like rehab or something...between you and teff you fed the addiction...now it feels like you're weaning us off!!! We NEEEED more!!!

Plus I can never figure out the guess the part thingies.....maybe if you posted something easier like a door or a tire?

[iMod.:R]

That manifold is something else. Wow. If it works as good as it looks...

I'm curious to see whether you've come up with anything in your build that might yield benefits for those of us sticking with stage 2+ setups.

Yeah the Mani is proven to hold 700hp worth of fueling concerns so it should work a treat for this lowely 600hp .:R, LOL! As far as Stage 2+ items a few of the best parts from that stage are:

-Okada Projects
-HPFP Upgrade (145 bar)
-NEW BSH CAI (out within 2 weeks)
-NEW BSH FMIC (out within 2 weeks)
-NEW BSH Battery Relocation kit (out within 2 weeks)
-N2MB Wot box
-AEM Methanol kit (w/ failsafe device)

Hope these ideas help show you some good options

instaham is my favorite thing right now

InstaHam or InstaClam. Its all the same to me and its my new favo thingy now as well!


.

[iMod.:R]

Hey Jason,

Whats the hold up? You guys still working on it in Phoenix? We need pics or something. This is like rehab or something...between you and teff you fed the addiction...now it feels like you're weaning us off!!! We NEEEED more!!!

Plus I can never figure out the guess the part thingies.....maybe if you posted something easier like a door or a tire?

Sorry my friend, I had to skirt back to California for a week for a new job so thats why updates have slowed down. I saw the final prototype this morning for the BSH CAI and its is very, very tidy. Who would have thunk that a cold air intake could actually add a sense of symmetry to the engine bay? Yet it has, and imagine this. It operates consistently at 15 degrees below typical CAI AITs.

Once the tooling is prepared for this piece I will be sharing pics as I am sure "BSH-R" on the forums will as well since he is the guinea pig enjoying the final prototype as I write this....



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[zbeasty]

Mark-
The plastic intake manifold will simply not put up with the demands and heat that we will be placing on this car and may in fact fail with the increased boost. We will also be running a secondary "fuel well" to sort of pre-feed the primary injectors. This will be utilizing the new HPFP Upgrade Stg2 pump. The secondary injectors whether they are RS4, S3 or whatever works best will be fed by the USP Low pressure in-tank pump.

As I'm quite sure you know, the Skoda that ran nearly 700hp on the salt flats was also running the HE Performance mani and has had no problems that Howie has ever been made aware of. That is an extreme example of what can be done with this engine. Granted it's a TSI, but its so damn close to the FSI that at this point we have no reason to believe with good mapping that we will encounter any issues.

I appreciate your concerns and they are well thought out so thank you. Can you share with us your experience with an 8 injector set up? If you learned something that would save myself or another forum member some R&D $$$ this is a great place (and time) to share!

Best-
Jason




We will be experimenting, but we have all the provisions needed to work out a few scenarios.

.

Hi Jason

No question on the need to run the HEP manifold for the amount of boost you will be running to pull the numbers you are after. I'm sure the standard manifold would cry enough after a very short period of time. My question is the secondary set of injectors. The USP pump will not supply fuel at high enough pressure to get either the RS4 or S3 injectors working effectively. The USP pump will deliver a max of 10bar (if not less) whereas these injectors are designed to run at least 10 times that pressure. I'd say you'll have to look at something like a low pressure Bosch Motorsport injector for the secondary set like any of these:

http://www.bosch-motorsport.com/cont.../html/2659.htm

If you want to run a single set of high pressure you could also speak to Bosch about these:

http://www.bosch-motorsport.com/en-U...2776067211.pdf

It looks like they can tailor a set to requirements. Would just need to know the flow rates.

I haven't done an 8 injector set up for mine yet but do have a fair idea as to the limitations of the standard equipment. I would have thought that there would be more injector upgrade options available by now with a lot of car companies moving to DI to meet emissions standards. Now it seems they are looking at hybrid DI/IDI options to get the best of both worlds. You'll be a step ahead of the game when your car is completed.

[AAC Welder]

I'm excited to see more updates soon. I'm particularly excited to see what system is used to control the secondary injectors as this is something I'm going to want to install. Heck, I'd install the secondary injectors just for their intake cleaning properties, even if I didn't install a big turbo right away.


I can see it now. I justify the expense of installing a HEP manifold and all the equipment for the secondary injectors just so I can prolong the life of the engine. A week after the install, I will justify a big turbo install in order to utilize all the new fueling capacity... This is going to be fun.

[sup_lado]

instaham is my favorite thing right now

[iMod.:R]

Hi Jason

No question on the need to run the HEP manifold for the amount of boost you will be running to pull the numbers you are after. I'm sure the standard manifold would cry enough after a very short period of time. My question is the secondary set of injectors. The USP pump will not supply fuel at high enough pressure to get either the RS4 or S3 injectors working effectively. The USP pump will deliver a max of 10bar (if not less) whereas these injectors are designed to run at least 10 times that pressure. I'd say you'll have to look at something like a low pressure Bosch Motorsport injector for the secondary set like any of these:

http://www.bosch-motorsport.com/cont.../html/2659.htm

If you want to run a single set of high pressure you could also speak to Bosch about these:

http://www.bosch-motorsport.com/en-U...2776067211.pdf

It looks like they can tailor a set to requirements. Would just need to know the flow rates.

I haven't done an 8 injector set up for mine yet but do have a fair idea as to the limitations of the standard equipment. I would have thought that there would be more injector upgrade options available by now with a lot of car companies moving to DI to meet emissions standards. Now it seems they are looking at hybrid DI/IDI options to get the best of both worlds. You'll be a step ahead of the game when your car is completed.

I do know that there s one guy out there I have been in contact with whom is altering the spray pattern of the RS4s to deal with the black smoke WOT issue. I hope his solution is ready soon as an option to all of us. Not at liberty to divulge who exactly this person is, but their claims of development are real and he and his people are more than well equipped to handle the task of building these.

As far as the secondary pump is concerned your points are being brought up at the right time and we (BSH and myself) will talk about all of this on Tuesday. I saw a few preliminary sketches of how the fueling system will work and they have got some ideas that go above and beyond my area of expertise. I'll find out and post about it once I have a clearer understanding for how they are planning to tackle this. The thought process right now is that the USP will still feed the system.

Watch this space...

I'm excited to see more updates soon. I'm particularly excited to see what system is used to control the secondary injectors as this is something I'm going to want to install. Heck, I'd install the secondary injectors just for their intake cleaning properties, even if I didn't install a big turbo right away.


I can see it now. I justify the expense of installing a HEP manifold and all the equipment for the secondary injectors just so I can prolong the life of the engine. A week after the install, I will justify a big turbo install in order to utilize all the new fueling capacity... This is going to be fun.

I think you should probably blame ol' TEFF for this high horsepower quest we are all on. Its his fault, LOL! (just kiddin' TEFF, you're the homie for sure!)

and another because 3 is the magic number according to De La Soul...



.

[xht20]

Hehe

I think i also know that guy who wants to modify the S3/R injectors

[iMod.:R]

Hehe

I think i also know that guy who wants to modify the S3/R injectors

You would know MR. Resources!

[iMod.:R]

More HEP which may as well stand for Hella Engine Porn!

On the reality tip, I can't stop looking at this thing.












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[iMod.:R]

One more thing about this beauty...

If this mani was a girly-girl at the club I'd dance with her and then toss a slumber party on her later that night.

[NeverOEM]

it's pretty freakin sexy.

[iMod.:R]

it's pretty freakin sexy.

Dead on accurate in your assessment my good man.

[Dutchmastr9]

Oh dats purty

[iMod.:R]

Oh dats purty

G'yeah!

[iMod.:R]

So today is another good day. The ECU was pulled off and is headed to a software writer who has already privately tuned Golf Rs overseas and yanked some VERY impressive numbers as Stage 1. They just need to pull the protocol off a US Golf R and I am quite sure big things are on the horizon for our community. As per normal during all this R&D, I am under NDA much like Dutch was during his time with the guys at 42DD.

Most everything is due to be unveiled at Wuste so we are in a mad rush to get this car built. Well, they are I am just salivating at the prospect of not driving an underpowered sh!tty rental car.



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[iMod.:R]

....and lucky post #666





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[Dutchmastr9]

at least you have a car. i was carless

[iMod.:R]

at least you have a car. i was carless

Yeah, if you call a "Toyota Corolla S" a car. No idea what the S designation is for because this little bitch can't get out of it's own way. It's really quite pathetic. I am totally ready to be driving the R again.

Manifold is supposed to be built in the next few days as well as exhaust. So hopefully it will all be done on time for Wuste.

[Dutchmastr9]

Yeah, if you call a "Toyota Corolla S" a car. No idea what the S designation is for because this little bitch can't get out of it's own way. It's really quite pathetic. I am totally ready to be driving the R again.

Manifold is supposed to be built in the next few days as well as exhaust. So hopefully it will all be done on time for Wuste.

the S obviously stands for suck