3.2 vr6 turbo random info

The Snail
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3.2 vr6 turbo random info

Post by The Snail »

Howsit guys

Just did a turbo conversion on my 3.2 vr6, thought i'd add some random info / observations for anyone that is interested.

Setup:

3.2 vr6 24v bmj
9:1 cr / forged pistons and rods
Chinese gt3582r, with a big twin scroll kkk 1.0 A/R exhaust housing, rebuilt and balanced. Running 0.5 bar boost.
76mm DP and exhaust with 63mm stock resonator box chilling in the middle (havent had time to replace it yet) :-X
Ebay cast exhaust manifold
38mm external wastegate
bosch 044 fuel pump,rising rate adjustable fpr and surge tank (with return line)
Stock 280cc injectors @ 4bar]
Stock intake manifold
Stock MAF
DCPR8 spark plugs
100% methonal injection for some extra safety for now.
External EGT gauge.
Everything else still stock, including stock ecu tune.

Okay, starting from the beginning.....

I basically bolted on a turbo kit that i made, all the above specs but with stock motor and stock c/r. Ran 0.5bar, car pulled insanely hard, ran around 14 degrees advance, 12.5 afr. Would have easily eaten a stock A45 AMG. ;D
I was impatient, waited to long for head spacer plate to arrive, hence why i drove the car, excitement got the better of me lol Long story short, ended up cracking a piston on cylinder 1. No surprise there.

I have since put in wossner pistons and forged rods.

Did the first 500km break in, in stock NA mode.

The car is now boosting again, exact same setup as before but with lower compression ratio.
The drivability of the car is fine, besides for part throttle boosting obviously, thats sometimes a bit jerky.
The logs are rather interesting too.

Car makes 0.5 bar boost just under 4k rpm in 3rd, barely any boost in 1st gear, but when its in boost it breathes so nicely ;D So im really happy with the turbo choice!
The car is running between 18 and 24 degrees advance with low timing pull with 100% methonal injection.
Hits maf limit on stock maf @ 0.5bar, just above 290 g/s.
So far only running on the LAMFA map, requesting 0.899 lambda and its meeting the requested fueling under load. Part throttle fueling obviously crap. Injection timing sitting around 14 ms.
EGT's hit 920 degrees celcius with a 5th gear pull to redline.

Running the car without methonal injection is a different story. (in high gear mainly, >= 4th gear)
EGT's still dont go above 920 degrees, but it obviously starts requesting other fueling strategies, and dumping fuel.
Timing advance is hard to say as it jumps around a lot, i would say around 18 degrees but with scary 8.5 pull.

Busy building the intake manifold now, as soon as its done i will pop the 550cc injectors in and begin the mapping.
Will try give as much info as i can regarding mistakes and observations and tips for anyone that might need it.

Loving the car, pulls really hard!!! ;D
Will be doing a base dyno asap!

Anyways vids below:

Stock motor, without wmi.
https://www.youtube.com/watch?v=twyCjSYNutU

Built motor, 100% methonal injection... 0 to 170 km/h
https://www.youtube.com/watch?v=cDoyOHwmAq0

Built motor, 100% methonal injection...4th gear
https://www.youtube.com/watch?v=4q2GzJk6UpA
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
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Abnormal
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Re: 3.2 vr6 turbo random info

Post by Abnormal »

Nice
\Oo) \ _w_ / (oO/
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Re: 3.2 vr6 turbo random info

Post by mk3vr6golf »

Hi there

Thank you for all the info thus far, absolutely love your build :drool:
Keep them vids coming!
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smoke.machine
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Re: 3.2 vr6 turbo random info

Post by smoke.machine »

Pulls nicely
Current: 9n3 1.9 TDI Pd100...cupra lip..Pgti rear apron
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vwdubnam
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Re: 3.2 vr6 turbo random info

Post by vwdubnam »

Nicely done. Post some pics

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Re: 3.2 vr6 turbo random info

Post by AshT5 »

So awesome damn!! Please post some pictures


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Re: 3.2 vr6 turbo random info

Post by Pynoxim »

It's so stock looking that if it didn't have that ridiculous exhaust, you wouldn't know that it was actually quite a beast. It's one of those brown A3's with some of the most horrible A-Line wheels you've ever seen, but that all adds to its character :D The engine bay however, that's a work of art, especially for a guy who does all his work (Welding, Fitting Rods, Heads, etc) in a garage that is only large enough to fit the car, you can hardly walk next to it. This dude is truly gifted when it comes to making his cars faster than everyone elses.
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amstel18
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Re: 3.2 vr6 turbo random info

Post by amstel18 »

any pics of the conversion or the car?
Current:
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The Snail
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Re: 3.2 vr6 turbo random info

Post by The Snail »

LOOOOOL Thanks for those kind words Pynoxim, so romantic! :hug:

I will definitely get some pics up later for you guys! Will try be more exact on parts, prices and the shops where i got the stuff from if you guys want!
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
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vwdubnam
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Re: RE: Re: 3.2 vr6 turbo random info

Post by vwdubnam »

The Snail wrote:LOOOOOL Thanks for those kind words Pynoxim, so romantic! :hug:

I will definitely get some pics up later for you guys! Will try be more exact on parts, prices and the shops where i got the stuff from if you guys want!
That would be cool.

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Re: 3.2 vr6 turbo random info

Post by UzziB »

Sweeett :drool:
If you aint first, your last !!!


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The Snail
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Re: 3.2 vr6 turbo random info

Post by The Snail »

Okay the prices that I can remember, lots of items still left out probably:

Exhaust manifold (ebay) + 2x lambda bungs
-R2000
6x bosch ev14 550cc injectors (4x gumtree, two new @ R800 each from diesel electric)
-R4300
intercooler (flat four racing)
-R1700
intercooler piping (63mm)
(10x 90 degree SS bends @ R140 each, 6m straight 63mm SS pipe @ R800 from NDE)
Silicon couplings (between R140 and R220) (flat four racing)
-R2600
wastegate 38mm (flat four racing)
-R1700
bosch 044 fuel pump (diesel electric)
-R2600
fuel lines (flat four racing)
-R700
FPR with gauge (flat four racing)
-R2000
surge tank (DIY, 4x 8mm SS fittings @ R80 each) (flat four racing)
-R320
DV (OEM, 710N)
-R450
headgasket (Alert engine parts)
-R800
GT3582r turbo with 0.63 ar exhaust housing (Mr turbo)
-R4900
Fitted kkk 1.ar exhaust housing and rebuild, balancing and welded VBAND flange onto exhaust housing (Oom Kallie @ KB turbochargers)
-R2500
Headbolts(Alert engine parts)
-R500
Exhaust manifold and turbo housing skimming (Oom Kallie @ KB turbochargers)
R350
1.8T IAT sensor (Pynoxim)
coffee
Turbo oil and water lines, go through pics to see what i used (flat four racing)
-approx R2000
WMI kit (Pynoxim)
-R2700
Various turbo, exhaust manifold studs (flat four racing)
-R400
New fuel filter for return system
-R150
Injector adapters, Denso to ev14 (Mr turbo)
- Around R500
2x silencers (Mr turbo)
R1200
76mm SS pipe for exhaust, 6 meter length (NDE)
-R900
76mm SS bends for DP / exhaust (4x) (NDE)
-R640
2x Vbands for exhaust and turbo (flat four racing)
-R900 (R450 each)
Flex pipe for DP (profit exhausts)
-R450
EGT gauge (flat for racing)
-R1800
9:1 c/r Wossner forged pistons
- R13500
Forged rods
- R9000
King rod bearings
- R600
Head recon (Motor masters <--- Really awsome work from them, and well priced, definitely recommended)
-R2500
Honing was done by motor engineer Kevin - 0721589234
-R350
Intake manifold flanges i had made up at work luckily! Had to buy 1m 100mm pipe though (profit exhausts)
R500
Lots of other loose odds and ends like hose clamps, vacuum pipes, oil, oil filter, coolant etc etc
-approx. R3000

Flywheel / clutch kit....So far i have a quote from formula friction, to cut a flywheel and balance is R6500. As for the clutch, i have no idea. Struggling with that, but i came across a site that says the pressure plate for the mkv gti, s3 etc is the same size? if so then that should make life much much easier!!!

SOFTWARE - MAP definitions
-R2500

Still need to learn to semi tune it now! But the mpps cable isnt wanting to write to my ecu. Pynoxim coming around later with another cable, hopefully it will work!

Let me know what i missed out :/

I tried to do the build as cheap as possible, bought a tig welding kit and used the money i saved paying a fabricator to pay for it. Best thing i could have done! Saved a lot! Just taken ages to figure out how to weld but its finally getting there! I think! :troll:
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
The Snail
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Posts: 82
Registered for: 11 years 4 months
Car Make: vw
Car Model: MK4 GTi

Re: 3.2 vr6 turbo random info

Post by The Snail »

Jeepers creepers, adding all those figures together almost made me sh.t my pants. No wonder i have no money. Already over R70k, excluding a clutch kit, nevermind all the parts i had to replace too. Prop, lambda, MAF, valve cover etc etc. Its fine, id do it again xD
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
The Snail
Cadet
Posts: 82
Registered for: 11 years 4 months
Car Make: vw
Car Model: MK4 GTi

Re: 3.2 vr6 turbo random info

Post by The Snail »

Here is my tow truck

ImageIMG_20160324_084604 by Nicholas Tolken, on Flickr



ImageIMG_20160621_103302 by Nicholas Tolken, on Flickr
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
The Snail
Cadet
Posts: 82
Registered for: 11 years 4 months
Car Make: vw
Car Model: MK4 GTi

Re: 3.2 vr6 turbo random info

Post by The Snail »

All the goodies and turbo!

ImageIMG_20160808_174437 by Nicholas Tolken, on Flickr

ImageIMG_20160808_174455 by Nicholas Tolken, on Flickr

ImageIMG_20160805_191307 by Nicholas Tolken, on Flickr

GT3582 vs GT2860

ImageIMG-20160808-WA0043 by Nicholas Tolken, on Flickr

ImageIMG-20160808-WA0040 by Nicholas Tolken, on Flickr

ImageIMG-20160808-WA0054 by Nicholas Tolken, on Flickr

The waterline fitting that faces towards the block, needs to actually be a 45 or 90 degree fitting. My water pipe is now rubbing up against the block, it wont last.

ImageIMG-20160808-WA0036 by Nicholas Tolken, on Flickr

Vband welded straight onto turbo

ImageIMG-20160808-WA0046 by Nicholas Tolken, on Flickr

This is the kkk 1.ar housing i put on, stock 0.63ar housing on the right. HUUUUGE difference!

ImageIMG_20160727_100150 by Nicholas Tolken, on Flickr
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
The Snail
Cadet
Posts: 82
Registered for: 11 years 4 months
Car Make: vw
Car Model: MK4 GTi

Re: 3.2 vr6 turbo random info

Post by The Snail »

I really apologize for the poor quality pics, my phone wasn't camera friendly at the time!

Out with the old!

ImageIMG-20160809-WA0004 by Nicholas Tolken, on Flickr

In with the new!

ImageIMG-20160809-WA0010 by Nicholas Tolken, on Flickr

ImageIMG_20160813_135615 by Nicholas Tolken, on Flickr

ImageIMG_20160813_143021 by Nicholas Tolken, on Flickr

mini surge tank that i made to replace the charcoal canister

ImageIMG_20160811_094109 by Nicholas Tolken, on Flickr

Oil return line, I just drilled a hole and fitted this fitting with a nut, HAS TO BE A 45 degree fitting if its a long one, if you use the short fitting and weld it onto the sump then you can use a straight fitting, otherwise the transfer box is directly in the way.

ImageIMG_20160910_173035 by Nicholas Tolken, on Flickr

ImageIMG_20160813_210856 by Nicholas Tolken, on Flickr

Ebay exhaust manifold

ImageIMG_20160507_161127 by Nicholas Tolken, on Flickr

Fitting the lambda bungs

ImageIMG_20160507_164601 by Nicholas Tolken, on Flickr

ImageIMG_20160507_190430 by Nicholas Tolken, on Flickr

Making the 100mm MAF housing

ImageIMG_20160522_174423 by Nicholas Tolken, on Flickr

ImageIMG_20160702_193633 by Nicholas Tolken, on Flickr

Stock injector vs siemens deka 630cc. You can see the siemens injector is longer from O-ring to O-ring, so those length injectors wont work as there is no space under the stock manifold, unless ofcourse you have a after market intake manifold.

ImageIMG_20160216_230123 by Nicholas Tolken, on Flickr

The shorter bosch ev14 550cc injectors, i sold the 630cc's. Ignore the spacer cups, they coming off.

ImageIMG_20160902_131446 by Nicholas Tolken, on Flickr
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
The Snail
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Posts: 82
Registered for: 11 years 4 months
Car Make: vw
Car Model: MK4 GTi

Re: 3.2 vr6 turbo random info

Post by The Snail »

Intercooler and boost pipes!

I went with a smaller intercooler with larger core, better flow, easier fit, and we all know only a quarter is used to cool the air, the other 3 quarters is generally ice cold. I still dont understand why people use such massive coolers but anyway :driving: (63mm piping all the way through)

ImageIMG_20160507_195005 by Nicholas Tolken, on Flickr

ImageIMG_20160821_181140 by Nicholas Tolken, on Flickr

ImageIMG_20160902_163352 by Nicholas Tolken, on Flickr

ImageIMG_20160821_155240 by Nicholas Tolken, on Flickr

ImageIMG_20160902_163448 by Nicholas Tolken, on Flickr

ImageIMG_20160902_163823 by Nicholas Tolken, on Flickr

ImageIMG_20160905_104607 by Nicholas Tolken, on Flickr

ImageIMG_20160905_104616 by Nicholas Tolken, on Flickr
Last edited by The Snail on Sat Jan 07, 2017 10:00 am, edited 1 time in total.
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
The Snail
Cadet
Posts: 82
Registered for: 11 years 4 months
Car Make: vw
Car Model: MK4 GTi

Re: 3.2 vr6 turbo random info

Post by The Snail »

DP and exhaust 76mm, with stock 63mm resonator (Still to be replaced). Mr turbo silencers.

ImageIMG_20160809_213454 by Nicholas Tolken, on Flickr

ImageIMG_20160903_183537 by Nicholas Tolken, on Flickr

ImageIMG_20160903_183454 by Nicholas Tolken, on Flickr

ImageIMG_20160527_090526 by Nicholas Tolken, on Flickr
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
The Snail
Cadet
Posts: 82
Registered for: 11 years 4 months
Car Make: vw
Car Model: MK4 GTi

Re: 3.2 vr6 turbo random info

Post by The Snail »

Stock piston and rod vs forged piston and rod (bought from KS motorsport)

ImageIMG_20161028_152324 by Nicholas Tolken, on Flickr

I luckily saw a crack on one of the rod caps! I sent the rod back to karl, which he then told me it wasnt a crack, but a scratch. He told me to stop being a drama queen. He wasted my time for about 6 weeks, with continuous lies, ignoring me and rudeness. I took the rod to get crack tested, so i could take him to court to get a refund. About 2 weeks after telling him that I will be taking him to court, i received a message the one evening telling me to come fetch my replacement rod. So that was a surprise, during this whole time i actually ordered another set of forged rods as this is my daily car and couldnt borrow other cars anymore. So now im sitting with a spare set of rods, pm me if interested! Anyways ive spent over R50k on items from him already, and to still receive the service that i did from him was shocking. I will never promote his company again.

ImageIMG_20161209_192623 by Nicholas Tolken, on Flickr

ImageIMG_20161214_094405 by Nicholas Tolken, on Flickr

Sexy new reconditioned head! :hurray:

ImageIMG_20161011_175700 by Nicholas Tolken, on Flickr

Here you can see the return fitting i welded onto the fuel rail:

ImageIMG_20161012_075124 by Nicholas Tolken, on Flickr

Also some confusion that i had when installing the new pistons, all the pistons had arrows facing in the same direction. Being a VR motor this is impossible, So i messaged wossner and they told me that the arrows must either face the exhaust or the intake. That didn't exactly help at all. So anyways i checked the valve clearances on top of the pistons and they were all the same. So i just installed all the pistons with half the arrows on the pistons facing opposite to each other. 1400km and still running beautifully.

ImageIMG_20161215_225240 by Nicholas Tolken, on Flickr
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
The Snail
Cadet
Posts: 82
Registered for: 11 years 4 months
Car Make: vw
Car Model: MK4 GTi

Re: 3.2 vr6 turbo random info

Post by The Snail »

Aaaand finally this is the intake manifold im busy making, will hopefully be finished today!

ImageIMG_20161221_152112 by Nicholas Tolken, on Flickr

ImageIMG_20170104_141129 by Nicholas Tolken, on Flickr

ImageIMG_20170104_160232 by Nicholas Tolken, on Flickr

ImageIMG_20170106_200027 by Nicholas Tolken, on Flickr

ImageIMG_20161221_171105 by Nicholas Tolken, on Flickr

ImageIMG_20161221_171020 by Nicholas Tolken, on Flickr
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
User avatar
dcmk4
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Re: 3.2 vr6 turbo random info

Post by dcmk4 »

This little beauty flies :hurray:
'14 Golf Mk7 GTI
THANAS STG/// ECU&DSG
Littco L380x
All the ponies
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ZiF_k
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Re: 3.2 vr6 turbo random info

Post by ZiF_k »

Nice work bud!

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Kid_Rocc
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Re: 3.2 vr6 turbo random info

Post by Kid_Rocc »

Epic build bru, such a sleeper

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THANAS
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Re: 3.2 vr6 turbo random info

Post by THANAS »

The sound this thing makes....Insane!
The Snail
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Re: 3.2 vr6 turbo random info

Post by The Snail »

Shot okes! Finally figured out how to write maps to the ecu, with the help of thanas and pynoxim, flipping boffens! So hopefully by the end of today the new intake mani and injectors will be on! :D
ex. Golf 4 GTi AGU/AUQ

t3/t4 50 trim .48ar
260kW and 390nm
Eurodyne maestro software

Audi 3.2 vr6 Turbo
323Kw and 660nm @ 0.7 bar
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