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Thread: Bobby Singh's Audi A4 3.0 TDI Project car

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  1. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #61
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    October 2018

    Santa Pod trip

    Well finally made it to Santa pod yesterday. Waited for 4 hours for the track to dry out, the queue was unbelieve considering it was a non event day.
    Was hoping for more runs but someone fell off a bike




    Audi A4 3.0TDI 500hp / 980nm Santa pod 11.9 @ 116mph - YouTube

    Done 11.9 which I'm happy about, but I think there is more to be had, why?:

    1) 20mph head wind
    2) Car hooped (then bogged down) for some reason (maybe too much boost at take off) - see incar clip
    3) Gear change from 1 to 2 took 1.1second, Rest took ~300ms
    4) In the past my 60ft was around 1.7s but this time 1.9

    Better gearbox software will help for sure (come on xHP)

    Still pretty decent for a true daily driver - drove there and back, no smoke, just diesel and air etc


    Cheers
    Bobby
     
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  2. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #62
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    Bought a Dragy gps device for measuring performance not had much of a chance to play with different RPM take off's but managed this so far:



    This is with full weight etc

    Its pretty clear the amount of torque reduction between gear changes - but still pulling just over 0.5g at 60mph.

    Here is a JD "450hp" stage 3 for comparison whats clear is that the 8hp gearbox changes are more seamless:



    Cheers
    Bobby
     
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  3. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #63
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    February 2019

    More information for others that may experience this.
    For a while know I've been getting a vibration under my seat, had the wheels balanced but didn't help.
    In the end I took a look at the prop shaft and could see oscillation marks on the rubber.



    I bought a replacement center support bearing


    https://rover.ebay.com/rover/0/0/0?m...2F222775149133

    I tried for many hours to split the center joint but gave up. Took it to Prop Shaft services in Heathrow who tried for a few hours and also gave up.

    In the end got a replacement shaft (used), new one is 1.2k.

    Hammer time

    Off course got to find out why this damm thing wouldn't split:

    Cut the prop shaft:



    Joint exposed:



    CV puller:



    Applied plenty force that the bar started to bend:



    Out came the angle grinder:





    As you can see no tapering on the spline so they really want you to spend the 1.2k


    Cheers
    Bobby
     
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  4. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #64
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    June 2019

    Haven't had much of a chance to work on my own car recently.
    Changed the front and rear pads and discs.
    Decided on EBC yellow stuff front and rear pads.
    Front disc managed to source some EBC and rear's from ATE.







    Air box mod done - OEM+ look



    (Before everyone starts drilling their air boxes take some pressure measurements as 99% of the owns won't need this)

    I'm also working on something special in the background
    More details to follow in the next couple of months (I hope)

    Cheers
    Bobby
     
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  5. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #65
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    More incredible work. You are seriously dedicated! Or mad.
    Current- A6 C8 40 tdi quattro s line Daytona Grey
    Gone-S3 sportback, A6 C7 biturbo saloon,A4 B 8.5 avant, A6 C6 3.0 tdi Quattro saloon, A6 C5 2.8 Q Avant
     
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  6. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #66
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    Makes zero sense so gotta be mad
     
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  7. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #67
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    July 2019

    Been four years since the last car detail - special thanks to my cousin @tEaMspb for all his effort:











    For a car with over 150k on the clock he done a great job.

    Cheers
    Bobby
     
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  8. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #68
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    January 2020

    Been a while since I've done much with the car.
    Some maybe aware but I bought a used engine last year with ojective to rebuild it. As I mentioned earlier in this thread the PCP are extermely high and main task I wanted to address is compression ratio. With such high pressures the heads have started to lift when using the power for prolong periods causing coolant issues. The car has 160k on it and still being driven and still performs well.

    Here are some pictures of the replacement engine:





    Nice to see cross bore drilling:



    Heads cleaned & flattened



    Valves reseated



    12.9 head bolts sourced and modified to suit the Audi V6 engines



    Piston work







    CAD drawings are complete with CNC profile set.
    If all goes to plan lowered compression ratio will add scope for more power while remaining within PCP.





    Bigger CP3 pump

    The new pump will take some doing to mount and line up correctly but should be possible - approx 20% more fuel than the current R90



    To be continued...

    Cheers
    Bobby
     
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  9. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #69
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    March 2020

    Some progress on the replacement engine.

    Pistons all cleaned up:



    Machined:







    Piston installed with fresh rings:



    New guides, new chains, new gears etc



    Heads installed with upgraded head bolts



    Next task is to get the larger cp3 mounted for a mock up

    Cheers
    Bobby
     
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  10. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #70
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    May 2020

    Not much to report slow progress however new custom injectors arrived and decided to go with cast manifolds. I've not had any issues with the stainless manifolds as I run low egt's, but I rather not risk the turbo if I push things a little further.







    Part numbers for the manifolds are:

    059253034P
    059253033P
    059131789N

    As you can see they fit the stock 2260 Y collector perfectly



    Cheers
    Bobby
     
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