time to upgrade fuel pump. HKS BOV fixed, O2S1 fixed

[sTTanford]

yay, done with finals! MAN what a long quarter.

rewarded myself by spending the day getting dirty. replaced the first O2 sensor (which had gotten bent and died when i had my DP to close to the frame), and remounted the bung so the sensor is away from the frame.

you can see where it had hit. the sensor didnt actually do all that to the lining, we punched it in with an air hammer as a temporary fix to keep the sensor from banging around. didn't do the trick obviously.

the adjustment bolt on my HKS SSeq stripped itself (weak construction) so i had to retap it with a bigger, coarser tap. upped from M6-2 (i think) to M8-1.25. pic:



spent the evening at ATP on the dyno too. still no luck on the MAF. the 4" intake is just too big (we had made all the software adjustments possible, but still no luck). three options are:
1) drop down to a 3" MAF (leave it 4" into the tubro, i guess)
2) add a flow accelerator (either passive or active)
3) modify circuitry of MAF. this is what i'm gonna try and do first. basically, i'm just gonna TRY and make it so the signal never drops below a certain signal.

Anybody have one of those $40 VW MAFs extra? Sean? wanna help me out? =)

Also found out the limiting factor for power is the fuel pump. regardless of what size injectors, 360, 475, or 550cc, and regardless of rail pressure (3~5 bars), i always leaned out around the same RPM, at the same rate too. pretty good indication that the fuel pump cant deliver. boys at APR obviously did their homework. was guessing fuel pump needed upgrading, since the APR kit came with one.

anyway, my max power seems to be around 270whp, which is 330hp at the crank, using 18% tranny correction. for FWD ppl, that crank hp would yield 290whp at 12% loss. i'm guessing APR decided it was too close for comfort and upped the pump. so any TT aiming for 270+whp, you need a way to pump more fuel.

anyway, plans are almost set for the pump upgrade. it'll be inline, proly be where the OEM fuel filter is (back by the tank, near right rear wheel), and i'll put a microfilter up in the engine compartment near the rail, before the check valve. i'll post pics of the pump soon. but here is a hint: it is VAG, and used on a CIS engine. any guesses? =)

oh yah. i'm kinda wavering whether i shud drop to a small A/R turbine housing. the GT30R is awesome, i can't rave enough about it. but the .63 A/R housing i have right now is just too big. might try .58 (if we can get one with the right flange) or .48 sometime soon.

man i want a 2.0L. anyone wanna donate $6K to my cause? =)

[AxeYrCat]

[sTTanford]

passive = much easier, but its effects will be present, regardless of whether i'm at idle

active = anything from an electric fan (hehe, reminds me of e-turbos, lol), to an actuator that opens/closes the entrance to a nozzle, etc.
basically i figured i could try and have it "disengage" when not at idle so it doesnt hinder flow as much... dunno. shrug =P

u done with finals yet? if anybody on this forum feels your pain, it is ME! winter break is near my friend.

[A34eva]

Thermodynamics final for me tomorrow afternoon. I wish my engine bay looked like yours...

[Qu!cksilva]

or is the motor the restriction now?

Gotta tip my hat to you...helluva job you did...

M,

[hoTTub]

is any good..... Would you like that one?

Also, as far as the fuel pump, you are exactly right about the limits of the factory pump.

If you are using a CIS pump, it has to be from an early DUB, something like a Rabbit or Cabriolet or maybe and early A2 GTI 16V?

[sTTanford]

a large volume plenum and longer runners, polished innerads, and port-matched to my head, if i have the time. seconadary injector bungs too. havent decided whether or not to add a port-injection system for nitrous yet...

hard to decided what to do. the port-matching part is what i need to settle. the guys at ATP and Tomas want to do an engine swap. maybe a 2.1L balanced to 8kRPMs. but it aint cheap. and there aren't heads that will flow efficiently past 7kRPMs available. if i knew what head would go on, were i to get the 2.1L, i could decided how to machine my runners for my intake manifold (cuz i'm gonna have to make one, whether i get the engine or not).

the other thing is fuel management. secondary injector bungs are great and all, but are worthless without EFI management. for a few hundred more than a nice Rebic controller, i could go standalone (in the works on another car up at Tomas). i'll post the details of the one we're thinking about eventually.

all that ends up to a hefty 4-figure bill... =(

my to do list will proly be (chronologically):
-MAF mod,
-fuel pump upgrade,
-.48 AR turbine housing
-IC Misters
-oil cooler
-Gauge Pak! =)
-new manifold
-stand alone (stand-alone is MAP-sensor based. woohooo!!! i can't wait to throw my MAF into the fire)

that'll put me at the limits of the 1.8T i think. the rest is just tuning. i'm not sure if i'll be able to match billyT's efforts (420whp?) or not, whether or not i use the bottle. we'll see. i still havent much of a chance to focus on efficiencies and see where i need to adjust. but it took him 60K miles to finally get his setup tuned that well... so 400+whp is a while away methinks. for now, i just wanna hit 300whp.

[AxeYrCat]

but, yes, at last, finals are complete! woo hoo!

how much do you have to go?

[sTTanford]

if u cant guarantee the functionality of the MAF, i'm not sure i wanna pay too much for it =) if u just wanna donate it, or send it for cheap, then sure, send away.

i just want another one to tear into. having a second one to work one will give me the peace of mind i need to try out whatever ideas i get, rather than hesitating in fear of busting my MAF.

email me?

[sTTanford]

until my Masters work is done. u?