Audi A4R4 450HP CBEA (CR) Build

TDIsyncro

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mrchill said:
I met a fellow who was selling a standalone system for CR diesels when I was at PRI. If you are interested...I'll try to find his card. What is your ultimate goal?
Hi Chris. Yeah, I am always interested in options. I have looked at few standalone, but the options have been in the $4K and up range.
Ultimate goal? :confused: Not sure I understand your question..but I will answer what I think it is:
1. development of a turbo controller technology
2. good solid power that will be streetable and raceable in 1/4mile, 1 mile and autocross (three things I like to do). Obviously I would like to set a few records, if possable, but I have heard of some potent R5's out there so... This car will be daily driven in the summer, and produce respectable results at the races.
3. the challange of working on the edge of TDI diesel development and technologies
4. facilitating the next step in TDI performance (Common Rail)
 

TDIsyncro

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shadowmaker said:
Very nice plan. It's going to expand though. I know. :D
God, I hope not!! lol The only other item that will be on board for emergency back up will be 150 shot of nitrous and extra fuel. No guaranties how long the engine will stay together past 450HP.
 

TDIsyncro

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TheoSweden said:
Wow! Great choise of car I think. I've been running in a A4 -98 tdiQ with the same colour for 4 years. I´m sure you can make it ~200kg lighter, then it will be fast for sure.

Good luck from Sweden!
thanks. Dropping 200kg would be very nice. I will be doing corner weights soon, just to see my starting point.
 

Farfromovin

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This is my favorite thread ever. Excellent work, even though it's miles over my head I'll enjoy looking at all the shiny pics and fancy graphs when they get up here. Thanks for the vicarious power fix!
 

jjordan11

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Farfromovin said:
This is my favorite thread ever. Excellent work, even though it's miles over my head I'll enjoy looking at all the shiny pics and fancy graphs when they get up here. Thanks for the vicarious power fix!
+1 I might have to plan a trip to Canada when it comes closer to completion :p. It's just over 1k Miles.
 

TDIsyncro

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Here are some pics of the 16V CR head progress from a couple weeks ago.

Exhaust Ports - OEM Condition - lots of blockage.




Exhaust Ports starting to open up



Intake Ports - OEM Condition - lots of room for improvement



Intake Ports starting to open up





Exhaust Ports - starting work. These are opened up to 1.3"dia now. I will be using our ultrasonic material thickness gauge to determine how much more we can go on the ports that are near completion.



Bill, do you have those new pics yet?
 

87turboquattro

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TDIsyncro said:
Bill, do you have those new pics yet?
i was hoping mrchill would come to get his parts.your head is in the trunk of my passat which is under snow.:eek: and i'm only 1 handed.

as for pics,can you guys see the exhaust port dip under the seat.nice core shift there.this head begs for bigger valves but you can't.seats are real close to the fire ring.my pics should show the scribe mark and what were dealing w/.
 

MarkoP

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That head looks quite a different compared to BKD head.. which suprises me.
How does it compare flow wise to BKD?
 

TDIsyncro

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MarkoP said:
That head looks quite a different compared to BKD head.. which suprises me.
How does it compare flow wise to BKD?
I don't think anybody in NA has flow numbers on BKD or CBEA head. This is the first 16V VW TDI head ported by Bill, and possably in North America.
 

TDIsyncro

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87turboquattro said:
i was hoping mrchill would come to get his parts.your head is in the trunk of my passat which is under snow.:eek: and i'm only 1 handed.

as for pics,can you guys see the exhaust port dip under the seat.nice core shift there.this head begs for bigger valves but you can't.seats are real close to the fire ring.my pics should show the scribe mark and what were dealing w/.
no problem. Perhaps you can get him to put it in my crate with the other parts and ship to Scott Dewitt's. I have a shipment coming up from there very soon.
I thought we went +2mm on the exhaust.
Does it matter to you who I use for flow benching the head? What vacuum should be used in the test?
 

mrchill

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I have 2 BKD's here that I will disassemble and run up. They were my power project engines...though I have had them for 2 years new in the crate and not used them. Once I take one apart I'll let you know how it flows. I suspect there will be tremendous room for improvement. As far as your project, you answered my question nicely. Thanks! Cant wait to see how your head finishes up. Its REALLY bad. What were they thinking with the lack of clearance to the injector? The casting flash is abysmal...I'm having Saturn 16v flashbacks!:eek:

After they engine is all built up I have no doubt that it will be the best it can be. Watching and waiting.......
 

shizzler

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Awesome thread. Thank you for waiting until you had things mostly sorted out before starting it. Now start building, or at least show us some more TDI porn. :p
 

87turboquattro

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shizzler said:
Awesome thread. Thank you for waiting until you had things mostly sorted out before starting it. Now start building, or at least show us some more TDI porn. :p
if someone would get the head out of my trunk,i'd get some more porn,i mean pics of it.:D
 

dvst8r

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So does a Bosch cp3 from a cummins/duramax fit easily? That would be my logical choice as they are cheap and plentiful, and support 600hp+ of fuel.
 

TDIsyncro

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dvst8r said:
So does a Bosch cp3 from a cummins/duramax fit easily? That would be my logical choice as they are cheap and plentiful, and support 600hp+ of fuel.
It is not a bolt on, but the most logical solution and a fairly straightforward fit. Rotation direction will be correct as well. Issam is designing/making the bracket for it along with the dry sump system. I do not have a CBEA acc bracket, which I need to go along with the set-up.

Issam, what are the stainless studs you are talking about?
 

TDIsyncro

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shizzler said:
Awesome thread. Thank you for waiting until you had things mostly sorted out before starting it. Now start building, or at least show us some more TDI porn. :p
we are stumbling on somestuff here still, but things should break in the next 3 months and you will see a lot of progress after that. so sorry..a bit of waiting will stilll be needed.
 

TDIMeister

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TDIsyncro said:
Looks to me like there's room to increase the diameter of the intake valves by some amount still? I mean, not that I'm suggesting it, but we've seen valves enlarged to the point that it the seat hole was cut into the glow plug hole... :)
 

87turboquattro

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TDIMeister said:
Looks to me like there's room to increase the diameter of the intake valves by some amount still? I mean, not that I'm suggesting it, but we've seen valves enlarged to the point that it the seat hole was cut into the glow plug hole... :)
but its the fire ring i'm worried about.valves are close to the cylinder wall.new pics will show this better.
 

TDIMeister

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Oh I see. I'll be interested to see those pics. Hope your recovery is going well.
 

mrchill

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The fire ring is one area thats close. The deal killer is the injector mount boss area.
 

TDIMeister

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Forgive me that I'm dense; I can imagine that wall-thicknesses in the areas of interest in the head are quite small. The cylinder getting in the way is crystal clear. But I fail to see how the injector mount boss as you describe it -- and as I try to envision what you're referring to -- would be a limitation to accommodate slightly larger valves? Are larger valve seats pressed in, or the same ones used and just made thinner?

tdisyncro has access to an ultrasonic thickness gauge and was going to check the ports anyway. Maybe it would be good to also check this area of the head as well?
 

TDIsyncro

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I am not sure how the injector pocket effect valve size, unless the port wall thickness is shared with the injector boss, and it can't be blended properly with a large dia valve hole. Is that what you mean Chris.

To answer your question Dave, the existing valve seat is cut larger.
 

dvst8r

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I am curious as to your custom injectors.

I know of someone that has machined vw injector bodies to accept cummins nozzles, and has quite a wild set of custom injectors. It also sounds like (haven't actually talked to anyone) that nicktane can have a a pretty big set made.

Then there is also the route of going to someone like a DDP, or a JL Machine, or ect... and you could have new nozzles EDMed, then flowed and balanced via Extrude Hone.

Just kinda curious as to the direction you took, more then the specific size of the nozzles you had made.
 

shortysclimbin

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On the piston side of things find yourself some pistons from an Audi TT CR with engine Code CBBBB The CR ratio is already 16.5:1 on those. This should allow you to cut your valve relief pockets bigger for your cam and be done with it.

Have fun with her, its always fun to build things from scratch.
 

TDIMeister

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Wow, thanks for the tip, Kyle! I hope it drives home the point of the importance to limit PCP by reducing the CR if you want to build an insane setup and want the engine to survive. :)

I recall tdisyncro saying that replacing the pistons are not in the cards, but this gives something to think about, especially if oversize pistons are also available...
 
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