Almost ready to do a 'look what I did to the A3' thread.

[h100vw]

A few folk have heard about my plans for the A3.

I bought a JBS 04 turbo and stage 3 kit from JBSautodesigns in the UK. Being an agent for Custom Code software, who are co-located with JBS. I planned to use it to showcase the products and hopefully generate some business for myself at the same time.

I had a front mount intercooler and 3 inch turbo back exhaust made in 2006 by a local firm. aseturbo. They did a sweet job.

It has been a long process and I had the turbo for well over a year before it got anywhere near the car. Other parts in the kit included an ATP manifold (tough to fit that monkey!!!!), S3 injectors, MAF housing, 4BAR FPR, S3 fuel pump, TT airbox lid. Obviously, an ECU upgrade was required too.

In the middle of last year the clutch died so I fitted a ABF flywheel and VR6 clutch kit. Thanks to Matt for the FW.

The manifold and turbo went on over Christmas and I ran it with the std 150hp/1110KW software in the ECU. It immediately felt nippier as Robin will testify.

I had couple of issues getting the MAF sorted and then the injectors were shorter than the std ones. Not one to give in easily, I 'engineered' my way around all those little problems.

Today I finally loaded the software and drove it.

The boost comes in pretty quick and had my boost gauge off the clock!!!!

It is pinking a fair bit and I can see it pulling a lot of timing. Over the next couple of weeks I'll be doing some data logging, to send back to the UK. Where the guys at CC HQ will refine the code and send it back to me to load. I can do further logging to check the results.

I'll add some photos when I get some time. As I am always under pressure to get things done, I didn't take as many as I might have.

Have a great weekend.

http://custom-code.co.uk/

http://jbsautodesigns.co.uk/jbs04.php

http://www.audi-sport.net/vb/forumdisplay.php?f=17

http://www.seatcupra.net/forums/forumdisplay.php?f=127

A few links with CC/JBS information in. For those who might be interested in their product lines.

Gavin

[Jmac]

Sound like she was leaning out too much hey mate, you dont want that pingin hey. Good onya mate im keen to see how you go. Could be keen to talk about your software
Cheers

[gpk_gti]

nice write up gavin....interesting to hear what happens....

is this the first time you have done a CC programme on a stage 3 kit????

[h100vw]

nice write up gavin....interesting to hear what happens....

is this the first time you have done a CC programme on a stage 3 kit????

Yeah mate, no longer a virgin, have reached first base. ;)

Not done many flashes but CC prices have come down recently which might help matters.

Gavin

[h100vw]

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P1031305-1.jpg

New turbo


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P1031297-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P1031296-1.jpg

New and old manifolds.

[h100vw]

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P1271315-1.jpg

Left to right. New S3 injectors, early S3 injectors and std ones.

The new S3 ones were about 12mm shorter so had to reduce the height of the fuel rail mounts on the manifold to make them fit.

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P1031303-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P1031302-1.jpg

Better flow in the ATP manifold, I think so!

I'll take a few more photos of the gear that's fitted when I get a few minutes.

Gavin

[SoVeReIgN]

Watching with interest. :)

[h100vw]

A few more pics.

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P2061318-1.jpg

AGU MAF element grafted into S3 housing.

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P2061319-1.jpg

IGN amp grafted into TT airbox lid. I have a Green Cotton twister that will go on pretty soon.

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/P2061322-1.jpg

Fuel rail mount that had to be shortened to get the injectors to fit.


The car seems to be getting better daily, becoming more driveable and smoother. I still need to do the datalogging and have Custom-Code refine the map for me. Just have to find the time from somewhere.
It'll light up in second as it comes on boost, which is nice! Consumption doesn't seem badly affected. I have been driving through lots of traffic and it did 10 per 100 on the last fill up. On the open road it will use loads less.

Gavin

[Golf Loon]

Looking horn mate.
Keep us posted on the custom mapping. Looks like a flexible way to do it.

[Sleepy]

oooooohhhh does this mean u can help with my 3" MAF set up Gav :)

[h100vw]

A good chance mate

[Water Boy]

Has this beast been on the dyno and pulled some big numbers yet :D

[DubSteve]

Wow thats awesome Gavin hows the program treating the car looks awesome, top work mate:)

[h100vw]

Finally been on a dyno today. It was a bit of a shootout with someother dubs in Adelaide.

Anyway, I was pretty chuffed to pull 165kw at the wheels. Peak boost 27psi, AFR was off the scale at 10 to 1. This is all with the base ma loaded.

I am going to go back in the near future and do some logging on the dyno to refine the map. There should be a fair bit of power still to be had.

Plots to follow when I get home from my mates.

Gavin

http://www.youtube.com/watch?v=wPEH0c3hEbA video of the run

[DVR68U]

165kw very nice must be fun to drive ;) good work
cheers brenton

[h100vw]

http://www.vwwatercooled.com.au/forums/images/imported/2008/05/A3power-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/05/A3boost-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/05/A3AFR-2.jpg

The pictures to go with the words.

Can't wait to get it tuned properly....Fun to drive doesn't cover it..

Gavin

[schwartza3]

good work!
27psi:o i hope the shaft has been upgraded unlike the eurospec e05 that used the regular k03 shaft with upgraded cold side impeller.
can that AFR graph show anything below 10:1?. you'd think that on the base map it'd be running lean :???: even with 380cc/2.75" ID maf and 4bar. 380cc at 4 bar would be more like 420 or thereabouts so i guess thats why its rich, but still your maf is sort of "scaled" to go with the bigger injectors, hmmmmm. vagcom it and see what you lambda readings are, it looks like your afr drops well below 10:1, its just the graph isnt showing it. anyway.......
once you get the map sorted will it be possible for ppl to purchase it and copy your setup without going through the trouble of logging-sending data overseas..etc? for agu cars would you need our ecu's to install the chip-load the map? cheers!

[99gti]

Very nice numbers Gavin! Well done!

[Jmac]

Gavin you 110% have me impressed mate. Give some people a fright that and have them talkin.
Great stuff mate and the i love that rasp on Youtube, thats the cats pyjamas man.
Hat off to you mate
Jmac;)

[h100vw]

schwartza3, I have replied in my business section to keep this thread close to topic. My answer got carried away!! see below

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?p=161817#post161817

Jmac and 99gti thanks for your kind words.

[schwartza3]

i cant post in the business section so i'll have to ask you here.
i've just looked at CC prices, 246 pounds is about $500au, what map does this apply for? a k03/k04 flash they already have? once you start customizing the map to suit your setup how is this charged? from what i understand you a probably using the their base k04 map and getting it altered to suit your setup?? it seems that CC should be able to make big turbo files for agu? sort of like revo does for dbw US cars.
if someone installed a gt28 for example, run it on a k04 map, do some logging, send it off to you, you send it to CC then they should be able to adjust the map to suit that particular setup?
what blocks need be logged for agu? cheers!

[h100vw]

i cant post in the business section so i'll have to ask you here.
i've just looked at CC prices, 246 pounds is about $500au, what map does this apply for? a k03/k04 flash they already have? once you start customizing the map to suit your setup how is this charged? from what i understand you a probably using the their base k04 map and getting it altered to suit your setup?? it seems that CC should be able to make big turbo files for agu? sort of like revo does for dbw US cars.
if someone installed a gt28 for example, run it on a k04 map, do some logging, send it off to you, you send it to CC then they should be able to adjust the map to suit that particular setup?
what blocks need be logged for agu? cheers!

That map will be a Phase 1 for your car. 'Off the shelf" if you like.

You can't do direct comparisons on pricing like you have based purely on exchange rates. No-one else in the game does. I can't see Guy Harding doing flashes which are effectively the same money as the states.

Before I make any statements about how much it would cost to map and car for you. I think we need to talk about where you are headed.

Essentially, you are right though. Log, adjust, reflash. Much easier if you have something on file which you can use as a starting point.

You need to do some external logging with the AGU as the ECU doesn't have a built in MAP sensor.

PM will be sent with my number.

Gavin

[schwartza3]

cool
i understand that the price is for uk customers, just wanted to ask how is the customizing of the map charged compared to the base price as the map needs to be refined.
obviously the base price will have a markup to start off with. pm recieved :)

[h100vw]

http://www.audi-sport.net/vb/showthread.php?p=604090&posted=1#post604090

I didn't want to type it all in again. If you have a 02J gearbox please read this.

Gavin

[Tim]

clutch forks bending and breaking is a common failure in 02As as well ive heard.

[h100vw]

clutch forks bending and breaking is a common failure in 02As as well ive heard.

Yeah, just found that out after talking to jmac, wish I'd heard that 2 weeks ago...... Would have saved me a day.

Live and learn

[DVR68U]

at least you caught it before it broke :)
cheers brenton

[h100vw]

at least you caught it before it broke :)
cheers brenton

Yeah Brenton, something about thankful and small mercies. :)

[DVR68U]

hey gavin in my mk2 vr6 i have the cable clutch conversion, and the bracket that holds the cable on the box ( where the mk1 gbox mount is) was bent back 15mm by someone. this was causing it to hit on the shifter when you tried to go into 2nd. i bent it back and now my clutch pedal is super far out and the clutch slips.?? but i can get 2nd . its in the postion the bracket is supposed to be. its like the cable is to short, or maybe the clutch forks are bent ? the vr6 clutch on a cable mech is very heavy lol
what do you guys recon
cheers brenton

[h100vw]

I don't think the cable conversion was supposed to handle the clutch you need with a VR engine.

The hydraulic is much better.

Gavin

[h100vw]

I have been busy this evening after getting in from work. The other week I got my data logger working finally. I had been trying to use the coilpack trigger to feed the logger for engine speed. I have seen this done and done it myself but couldn't get a reliable reading.

Everyone was telling me to use the tach output from the ECU. Anyway after a gave up and did that it worked first time.........

I took some logs about 2 weeks ago and got the new software in the week. C-C have been mega busy.

Kev says to do some logging and reduce the boost with the actuator. I asked how much, he says drop it to 22PSI, I said that didn't seem like much fun as I have enjoyed 27 since I first loaded the trial map.

His response was that bent rods aren't that much fun either :)

So I loaded it up and took a few pictures. I have started it up and driven around the block. I'll try and do some logging this weekend and see how it has improved.

http://www.vwwatercooled.com.au/forums/images/imported/2008/09/P9261801-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/09/P9261802-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/09/P9261803-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/09/P9261804-1.jpg

Cheers

Gavin

[Jmac]

Hmm very interesting Gav!!!!!! :biggrin:

[h100vw]

I added a dodgy switch into the loom tonight, one I pulled from a old Cessna. You can see it near the leatherman.

When you do the flash you have to reboot it and it was a pain in the a$$ to unplug it from the power to do it.

It worked a treat, I'll have to do it for the other 2 bench leads I have as well.

Gavin