Audi A4R4 450HP CBEA (CR) Build

TDIsyncro

Veteran Member
Joined
Nov 14, 2005
Location
Saskatoon, SK
TDI
Audi/TDI x 2
Been stuck waiting on tool and die shop to make me the custom endmills for doing the reliefs. They screwed the measurements up twice and finally after almost 2 months, I picked them up on the way home from work today. Last time I'll ever deal with them to say the least. I should be able to cut the reliefs over lunch on a couple of days next week at work.


that is great to hear Matt.:) If you have time for that turbo housing too it would be appreciated.
 

TDIsyncro

Veteran Member
Joined
Nov 14, 2005
Location
Saskatoon, SK
TDI
Audi/TDI x 2
Been stuck waiting on tool and die shop to make me the custom endmills for doing the reliefs. They screwed the measurements up twice and finally after almost 2 months, I picked them up on the way home from work today. Last time I'll ever deal with them to say the least. I should be able to cut the reliefs over lunch on a couple of days next week at work.


Matt,

I was wondering how you made out on the pistons this week?
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
TDI
Ibiza '99 90HP
All this effort for valve pockets? I would just mark the center by marking it trough the valve guide, then center this on a lathe and you can make any dept/radius/size you want, at least that how I did the 8v pistons, takes an afternoon and some medium effort, noth 3 months =)
 

TDIsyncro

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Joined
Nov 14, 2005
Location
Saskatoon, SK
TDI
Audi/TDI x 2
Looking forward to seeing it all together! :)
thanks.

I was looking a bit more at the head tonight..(sorry..pics tomorrow). I have to check on the thickness of the ceramic coat. it is a bit thicker than I imagined. may have to skim the piston tops to compensate for the reduction in clearance x 2 since piston tops will also get this coating.
 

Alcaid

Veteran Member
Joined
Sep 5, 2006
Location
Norway
TDI
See signature
Have you landed on a decision on what ECU to control this monster? OEM or 3rd party?

(I've been following this project since the start but don't remember any decisions being made, only discussions back and forth between the options)

Also any decisions on compressor bypass and turbine bypass methods/equipment?
 

TDIsyncro

Veteran Member
Joined
Nov 14, 2005
Location
Saskatoon, SK
TDI
Audi/TDI x 2
Have you landed on a decision on what ECU to control this monster? OEM or 3rd party?

(I've been following this project since the start but don't remember any decisions being made, only discussions back and forth between the options)

Also any decisions on compressor bypass and turbine bypass methods/equipment?
yes, I am using a Skynam. There are some picture on it a bit further back in the project. As for compressor and turbine bypasses..yes, I have most of that stuff here. You will have to be patient until it is built and tested. :p My first set-up is going to be OEM head, fuel system and turbo on race block, otherwise there are too many variables to make the engein run properly for break in and tuning process. It will be a long journey for full race set-up changing one or two pieces at a time.
 

Whitbread

Vendor , w/Business number
Joined
Jan 21, 2007
Location
Johannesburg, MI
TDI
Several
All this effort for valve pockets? I would just mark the center by marking it trough the valve guide, then center this on a lathe and you can make any dept/radius/size you want, at least that how I did the 8v pistons, takes an afternoon and some medium effort, noth 3 months =)
When all you have is pistons and a cad drawing, don't that option. Once I finished bored the wristpin hole in the jig, it only took 1.5 hours to do all 4 pistons.





Stayed after work to finish them. Just need the sharp edges taken off. Worked from 7-8, then worked on the pistons and a few other small projects, just left work 30 mins ago haha. I'm scheduled to go in for surgery on my left wrist in 4 hours, joy :rolleyes:.
 

Whitbread

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Joined
Jan 21, 2007
Location
Johannesburg, MI
TDI
Several
All this effort for valve pockets? I would just mark the center by marking it trough the valve guide, then center this on a lathe and you can make any dept/radius/size you want, at least that how I did the 8v pistons, takes an afternoon and some medium effort, noth 3 months =)
When all you have is pistons and a cad drawing, don't that option. Once I finished bored the wristpin hole in the jig, it only took 1.5 hours to do all 4 pistons.





Stayed after work to finish them. Just need the sharp edges taken off. Worked from 7-8, then worked on the pistons and a few other small projects, just left work 30 mins ago haha. I'm scheduled to go in for surgery on my left wrist in 4 hours, joy :rolleyes:.
 

TDIsyncro

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Nov 14, 2005
Location
Saskatoon, SK
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Audi/TDI x 2
It is a ray of sunshine for me to see the pistons. :)
I am glad we are at this point. Please ship them over to Kevin. I have talked to him about doing the radiusing for me and getting the ceramic coating on too. I think I will also have .010" milled of the piston tops to compensate for the ceramic coat of .004 to .005 on both the head face and piston top.



This picture shows the sharp edges that need to be removed.



If we look at this piston model from a year or two ago one can see the radiusing I am talking about.


Hope surgery went well and your wrist is on the mend soon.
 

Whitbread

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Jan 21, 2007
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Johannesburg, MI
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They were picked up by fedex this morning and on the way to ohio, he'll have them tomorrow as per your directions. Hand is well, but I still can't hold a die grinder or anything that vibrates.
 

TDIsyncro

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Nov 14, 2005
Location
Saskatoon, SK
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Audi/TDI x 2
They were picked up by fedex this morning and on the way to ohio, he'll have them tomorrow as per your directions. Hand is well, but I still can't hold a die grinder or anything that vibrates.
good news on both counts! make sure you do not rush back into using your hand too much. it takes a fair bit of time with physio and stuff before you can stress it or it will not heal good. speaking from personal experiance here. :rolleyes:
 

Lord_Verminaard

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Joined
Jan 23, 2003
Location
Columbus, OH
TDI
2005 NB TDI
Good to hear, I have carpal tunnel in both hands as well, seeing as how I work in IT my hands are pretty much my life. Hope everything turns out ok.

Brendan
 

cmrn

Well-known member
Joined
Mar 30, 2010
Location
Arizona
TDI
2010 Golf TDI
New years update? Ive been following this build for quite some time. Very exciting.

Sent from my SPH-D710 using Tapatalk 2
 

TDIsyncro

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Nov 14, 2005
Location
Saskatoon, SK
TDI
Audi/TDI x 2
ok. project update. Not very good news. This project is dragging me down..I cant seem to get things done right for me. Next project is going to have work done by vendors completely unrelated to the TDI group..wondering if it would go better.

The pistons still have some very thin sharp sections of metal around the valve reliefs, unlike what I was asking for (shown in a previous post) and the ceramic coating has spider webbing cracks in it quit a few area. Some of it is flaking off. The shop has agreed to take them back and do a better job so I am not going to flame them, but it is poor quality control. Opinions on what you see are welcome.

This will cost anouther 2 months, no doubt. insert fbomb here.













 

TheoSweden

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Jun 10, 2006
Location
Uppsala, Sweden
TDI
A3Q,A4Q, Passat Biturbo TDI
Not fun for you! :( I know american quality often is very poor but on important things like this!? Who can do a work like this and even let you see it? I realy hope you find some good companys to deal with beccause this project is the most intresting over here I think!

Theo
 

kooyajerms

grocery getter
Joined
May 5, 2004
Location
Pomona, Southern California
TDI
97 B4V (mine), 11 x5 35d (hers) 04 V10 (that one you want), 2014 Q7 (mom's) 74 Shasta 1400
I coulda rattle canned the damn thing better than that Louis. Wow. That's horrible.

Sorry bud.
 

Frankencar

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May 15, 2007
Location
Dixon, California
TDI
1991 GTI +TDI, Lifted 98 NB TDI, Corrado TDI Swap, 15 Golf TDI, a dozen TDI motors etc...
HOLY COW! That's some of the nastiest looking work I have seen! :( So much for radiusing, and that coating is going to give me nightmares! :eek: I really hope things turn around for you soon as this is by fat the most interesting TDI build I can find on the net right now. ;)
 

v8 coupe

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Sep 3, 2008
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bloomington, mn
TDI
09 rabbit 2.5L Gas
Those look horrible. I wouldn't run anything that looked like that. I have been using several different places for work like this all do drag engines they seem to be uneffected by the tdi pistons. I had them do the first round of pistons for me.

The edges do need some more radiusing I would say.
 

mk3pd

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Nov 14, 2006
Location
Norway
TDI
Passat Quattro :)
In my opinion,in order to get you going
Just glass blast (or whatever it is called in English) the piston tops to get rid of that crap.
The coating is not going to do anything anyways.
Then use a hand file and fine grit paper and remove those sharp edges.

You will have a thin layer of soot which isolate just as good if not better than that silly coating.
They didn't even bother to clean the pistons before coating,you can still see the 1-4 sharpie marks under the coating.
 

Fix_Until_Broke

Top Post Dawg
Joined
Aug 8, 2004
Location
Menomonee Falls, Wisconsin, USA
TDI
03 Jetta
I was happy with my Swain-Tech coating. Looks nice anyway - it could all be melted off by now for all I know, but seemed like the right thing to do at the time.

I wonder if "glass blasting" would help the piston strength by putting compressive stresses in the surface of the material? This is done on steel/iron parts to improve fatigue life, but not sure about aluminum.

Selfishly, I hope you get this project running to see what can be done with this engine platform. Good Luck - Hang in there!

 

NoJoke

Veteran Member
Joined
Apr 11, 2003
I feel your pain! I know what it's like with these hurdles. Do yourself a favor since you have some lead time and get yourself good set of head studs and I mean tougher than ARP2000's. Don't know if fire ringing will prevent lift but what do I know I'm just a rookie.
 

TDIsyncro

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Joined
Nov 14, 2005
Location
Saskatoon, SK
TDI
Audi/TDI x 2
Thanks for all the support guys. I need it right now. I am so tired of every step going wrong. To think I waited 10 months to get this. I am not going to re-list all the problems but i am now thinking i am going to tale Geir's advice and just take care of them myself. There is an industrial shop in Saskatoon that can glass bead them for me.
Those swaintech pistons looks very nice..especially compared to mine.
 

Spiegelmann

Active member
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Nov 26, 2009
Location
Russia, Moscow
TDI
Rover 25 2.0 Tcie
what method of coating use swaintech? my pistons with microarc oxidation coating and the coating itself is very strenght and can`t be removed by scratching. Maybe you should try it
 

storx

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Joined
Jan 16, 2006
Location
Earth!!
TDI
2009 Jetta CR140, 2010 Corvette Z06
I feel you brother.. i had a set of piston ceramic coated on a gasser years ago and shortly after i found ceramic coating was 50% gone after 6 months of driving on it.. was pretty pissed off cause didnt know if it could end up in the internals of the engine somewhere..
Since then i never thought about doing it again.. cause it just money i threw down the drain..
 
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