NefMoto

Hello, i have an AJQ Engine with bent rod and decided to do 2.0 Stroker with Forget internals for more powa.
Came up with an idea to make post and get some advices from ppl that done such things.

The car:
Audi A3 8L 1.8T Quattro 1999yr.

Power plan is around 500hp.

Actually got:
- Stock 180hp AJQ Engine.
- BPJ 2.0 TFSI Crank
- BPJ 2.0 TFSI Pistons
- 2.0 TFSI PRISM Rifle Drilled Rods 144mm pin 20mm

My questions are:
1. Will CR:8.5 be ok to be around 500hp? with PB98 Fuel.
2. What turbo i should use (actually got K04-064) (Street Car).
3. Is my BPJ 2.0 TFSI Setup good for that engine ? its 06A Block so does BPJ engine is EA113.
4. I will send Pistons to machine shop and they will make room for 3rd valve and also mill pistons for less cr.

Thanks :)

A k04-064 will produce 350hp on a port injected 1.8t
you can use the BPJ Block with 20v head if available
8.5 is fine

i run a stroked 1.8t with tfsi crank and k04-064 style hybrid with 400hp

in your case, when only the rod is bend i would just swap rods and thats it.
the stroker is not worth the money

Thanks for info, about the turbo k04 i was using it and bent rod, so i think ill do stroker and also switch turbo for bigger thats why stroker is important i guess.

Ok regarding the set-up i think its good for 500hp+- except turbo but thats obvious.

Wondering if BPJ Pistons with one "+" under it will work for 500+ anyone?

On 98 RON for port injected 500hp you need 8.0 CR or lower than that,

If you are using WMI or ethanol then 8.5:1 is ok for that power.
Otherwise for 98 RON, you're going to be done at 400hp at that CR, after that you will hit a brick wall with EGT and late timing on 98 RON.

Hey, thanks for reply, good to know i was wondering that cr 8.5 may be too high for pb98 and 500km.
How about 2.0 TFSI Pistons, will they hold up 500km? i am thinking about stock 2.0TFSI 20mm PIN pistons but Brand New Mahle.
What do You think.

No idea.

If you're building the engine I'd just buy forged pistons, and also get the right CR too.
Don't worry about CR also, lower is always better, except for fuel consumption on normal driving.
500hp 1.8T does nothing off boost anyway...

Also, make sure you upgrade the valves and springs, so you can rev higher.
If you just do the springs and valves you can easily go 8000 rpm on hydrolifters and with this amount of power it will be very useful, especially in 1st and 2nd gear.

Otherwise most likely 1st gear to 2nd shift will be impossible without massive lag, even with flatshift.

Thanks for quick reply!
The catch is that it will be typical Street Car, maybe even everyday use, friends don't recommend forged pistons to everyday drive.
8000rpm good advice!

500hp on this engine is not a street car. It's a drag race only or autobahn car.

It is much slower than the same car with 400hp on the street.

Stay with 064 - its a good option for a daily drive
500hp absolutely useless as a street car dueto massive lag

Yea i know but maybe ill find a Turbo which spools good and will be around 450+ *Garrett Powermax* maybe, 500km is just Theoretical question that engine should last.

Gonna drive on that 064 for sure after i assemble the engine.

I think i am gonna go with New Mahle Pistons (20mm pin as well) as well for this project instead used BPJ one's.

I don't think so. Anything over 400 is pushing it on that engine.
FSI is different because you can use scavenging to improve the spool significantly.

But even EA888 with 500hp is quite laggy. Mostly relies on DSG hiding the lag.

Topic update:

Got few things in road to 500hp
- Custom Wiseco Pistons 2.0tfsi (20mm pins) for 1.8t engine with 8.5cr
- K2 Rods 144mm (20mm pins)
- 2.0 TFSI BPJ Crankshaft EA113
- Engine Block bored for 2.0tfsi crankshaft
- Large Port AEB Cylinderhead
- ADR n/a Camshaft Intake+Exhaust
- Supertech Exhaust valves +1
- RS4 2.7biturbo FCP Valve springs

Next steps DSG and no idea for Turbo maybe G25-660 or G30-660

Am i going in right direction?  ;)
Anything more i should take care of?

I am not sure why you are asking anyone about anything here, since you do it differently anyway.
So just build it, finish it, then realize during tuning that it's not going to work on pump fuel with that high CR, and you end up with a 400hp engine with massive lag or drop a valve due to too high egt.

Better set the fuel system up for ethanol directly if you're going to use those pistons.

I dont want ethanol in my car and no access to it, i can modify pistons to lower cr like 8.0 should i do that then ? Or use plate ?

I don't know why you didn't just buy the correct ones directly.
Plate at 250+ hp/liter not very good idea imo.

G25-660 full boost will be 4500+ rpm.
No way to reach full boost until 3rd gear without launch control.

1st and 2nd gear car will be much slower than something with 400hp unless using launch with antilag.
Third gear will be about equal to a 400hp car, and it will be faster in 4th gear and up.

Undrivable in the city, only good for drag race and autobahn.

Ok i got Your point that it will be one bit Lag untill power comes.
So no Plate thats what i thought.
CR 8.0:1 <- worth a try
G25-660 a bit too big, how about GT3076 ? i will try to adapt smallest turbo for around 500hp+-
Btw. i have bought Wiseco Pistons + K2 Rods + 2.0 already Bored Block for very nice price thats why :)

Anything with a GT30 turbine will spool after 4000 rpm.
If you fit too small AR you will just have massive surge.

Maybe EFR 6758 for drivable car.
Or G25-550 is probably also similar.

Anything bigger is drag strip/autobahn bruiser only.

try custom turbo like gtx3067r gen2
only possible make aftermarket and small turbine housing
67 compressor wheel max 450-480hp
better spool like 3071or 3076  and top end i think good enough
and gtx30 wheel better low rpm than G25-G30
g25-550 good low rpm but very small compressor wheel and max hp approx 440

Yea 4000rpm is quite laggy GTX30 is best i guess
DSG gearbox will get rid of lag at gear changes :)

Thanks for reply!, thats what i was thinking of GTX3071 GEN2 or something similar i dont want hybrids :S

As I said before, anything with a GT30 turbine will spool at 4000+ rpm.
Including all the GTX turbos, they still use a GT30 turbine. If you want to use an older turbo (GT style) then you will need to go to the GT28 turbine to have sub 4000 rpm spool.
I see no reason to use one of those. G25-550 or the small EFR are reasonable choices, they will give you a roughly 3500-3600rpm full boost.

There is no magic fairydust here, as was said before many times.
You can make a 420hp decently drivable car or you can make a 500hp lagmonster.
Choice is yours, but in city driving the 420 hp variant will be always much faster, in every situation except for starting from full launch control at light.

This realization comes pretty hard to people, that bigger turbo on tiny engine is not always better, it really depends what the car is used for.
If you want to sit at every traffic light in launch control like a retard then go ahead and fit a GTX3071, but why not use a better more modern turbo such as the EFR7163 in that case? On the 1.8T you will have full boost at 4300-4400 rpm on this turbo. And this is in higher gears. In the 1st gear you will not reach the full boost without launch control, in the 2nd gear maybe at the very end, but probably also not. Same goes for the GTX3071 Gen2.
The car will make full boost starting with 3rd gear... 3rd gear 4300 rpm is over 100km/h so the car is useless in city.

With the smaller 400-420hp turbos you will have full boost already in 2nd gear at 5000rpm or so, even without launch control.

I remember over 10 years ago doing a test with a friend on an old airfield.
He had a 700hp 2.2T Audi S4 and I had my 480hp RS4.
We started both in 3rd gear at low rpm. By the time he got on boost, I was in 5th gear and half the airfield away from him ;)
With rolling launch or starting at high rpm no chance for the RS4 of course. But this is not what happens in city driving.

So it is kinda funny how you say 4000 rpm is laggy but you're trying to choose turbos that will give you max boost at 4500 rpm in high gears. Make up your mind what you want, then get turbo for power target.
I think for 400-420 hp you can also get away with the 8.5 pistons, so you don't have to bodge anything.
But if you want to make a dragstrip car or for autobahn then you can easily go to 7163 or G25-660 and 8.0 or even 7.5 or so CR (tbh I'd do 8.0 + WMI), and have lots of fun at high speed. Driving in city it will be like N/A.

In the end with the modern cars you have to think that a 3.0 BTD or 35d bmw also makes 400hp with just a remap, and everything is full of those, and they have nearly no lag (and are boring as hell). Your car is lighter, so it will be faster, but if it has a huge ass turbo on it, then the diesel will be at the next lights by the time you spool lol.