NefMoto

I believe that after some research this could be the most powerful 4 cyl FSI engine in the world without nitrous, I've spent a big chunk the last 3 years on this Sadicupra project, it was very hard and bitter sometimes but I never gave up, This are uncorrected numbers, a write up will be made but for now this is it, this was tune by myself in-house. I would like to thank all my customers because without the opportunity to tune your vehicles I would have never been able to finish this. More and better things to come! along with time slips and other projects from us at Mabotech.

ENGINE
Fully ported CNC and flowbenched head with full +1mm supertech valvetrain and seat angles job
RS4 injectors +12% flow mod and s3 angled pattern at LDD facilities.
Custom +165FRV + stage 2 hpfpupgrade pump
Custom dual intank fuel pump, walbro E85 450lph + stock LPFP externally powered RS3 controller with upgraded ground.
Schrick camshafts 246/252
wossner 9.25:1 +1.5mm (84mm) dished custom pistons, upgraded pins, all coats, modified oil grooves.
Temp controlled torque plated, main caps and transmision plate honed. .044 clearance.
Brian Crower BC625+ H Beam Rods (balanced and swinged)
Full ARP bolts set + aviation complements
Complete ACL + ceramic calico coated bearings set
1.8t oil pump conversion (customized)
IE oil housing plate adapter to 1.8t oil filter housing.
4¨ custom maf with straightener
custom +6L intake manifold RMR parts
titanium Wrapped FFE tubular race manifold t3 44mm wg
GTX3582r 1.06ar Custom non ported compressor housing welded cast 4" bend, Coated + ported turbine housing Tial wastegate with 1.5bar spring.
balanced, knife edge, lighten crankshaft with clutch and pulley + welded IE oil pump sprocket
Fluidampr pulley + ARP bolts
2.85¨ ID throttle body +.6¨
3¨ cast bends, welded discharge and throttle pipes
3¨ custom down/mid pipes and GHL modified R32 catback
4¨ custom intake tubing with 6¨ Canahflow intake cone and modified CAI volant box
TR1245-28 intercooler, stealth thermal transfer black paint coating
Cortex EBC 4port
Rear pcv reroute + front pcv recirc to breather to exhaust.
2row custom aluminum radiator, eliminating the sandwiched intercooler space + giving 3¨ more bay space.
shorai 36ah 4.8lbs lithium iron battery with direct copper cables.

m2nb launch, no lift shift.
brake boost (eurodyne)
boost by speed cortex.

Custom watermeth system with 3 injectors
alkycontrol high pressure pump
coolingmist injectors 12cm pre turbo and 14cm pre tb

(Not installed) 10lbs NX nitrous system with auto purge and fail safe. 75hp wet shot. + throttle controller

Drivetrain

Quaife LSD with peloquins washers kit and ARP bolts
r32 SS shift forks 1st to 4th.
Repsol LSD specialized oil
full forge short shift kit
full solid metal bushings kit
ECS bleeder valve
USP clutch cable
motul 600 brake fluid
SPEC stage 5 clutch kit with 9lbs aluminum flywheel and ARP bolts
Spaced slave cylinder
IE shim diamond and ARP bolts
IE bracket bushings
mk4 6spd metal bracket reinforced*
1500hp solid axles and custom CV joints.

I'm missing some stuff but feel free to ask anything.

Sae Corrected numbers are: 837.15whp and 724.79lb/ft
so with 12% transmission loss is around 937.61hp or 699.18Kw and 811.76lb/ft or 1100.6nm.

How does that intercooler fit its 4.5in thick, you guys must have way more room than us.
How did you make 900hp without added injectors? What octane fuel? That turbo must be
working very hard, those power levels seem out of reach of that turbo.

Really nice project!!
I understand it took a lot of time for such a project.
You use a set of extra injectors in the intake manifold right?

Johan

Thought the tfsi record is in greece right now...

Audi A4 DTM FROM GREECE !

some of the specks :
Engine specs:
-Precision 6466 Turbo
-S3 Injectors
-Wossner piston and rods
-CatCams Stage 3 Camshaft
-Precision PW66 External
-80mm Exhaust
-50mm blowoff valve
-48mm Exhaust Manifold
-Boulekos Stage 3 intake manifold
-TT RS Intank Fuel pump
-Bosch 044 extra Fuel pump
-Aeromotive fuel pressure regulator
-AEM methanol kit
-Clutchmasters fx725 twin disc
-Ultratech additional injector ECU
-Custom Intercooler
REVLIMIT CUSTOM SOFTWARE

Power: 900Hp
Torque: 830Nm

(https://s16.postimg.org/4y0j6frxh/dyno_6466_fill_200x168.jpg) (https://postimg.org/image/sozwojs4h/)image hosting 10mb limit (https://postimage.org/)

I replaced the front bumper support bar, cut the lower portion of the radiator support, put a radiator that bolts right nest to the condenser, custom pipes and moved some AC lines and lower coolant hoses.

turbo is not antisurge which allows more flow top end, I have a big pre-turbo meth injector and I think I'm overspining the turbo at least 5-10%, so I'm literally out of turbo by a lot, If I want to take this further I will DEF need a bigger turbo.

Exactly my car is 37hp more powerful than this one while being almost 300nm higher on torque my corrected numbers are: 837.15whp and 724.79lb/ft so 937.61hp or 699.18Kw and 811.76lb/ft or 1100.6nm

You do use extra injectors in intakemanifold right??
Don't believe this kind of numbers with FSI.
I run 600 hp on only FSI and it was quite some work..

Yea I'm on the same page, no one has the added injectors listed.
I dont see how the power is possible without. I guess the a4s 6466 will make the power claimed.
I'm still not convinced the turbo will flow 930hp. Everybody has them maxed around 750, and most
make that seem like top of the world.

Port injected engine != TFSI/GDI.

The DTM one has "-Ultratech additional injector ECU" listed.
I also carefully say that if they run ethanol, it is possible to make more power on the same airflow because of the different AFR. More fuel in the mix means less needed airflow for HP. Aside from knock control offcourse. I mean I was not considering BTU or octane of different fuels

??? Sorry man, but
(http://s2.quickmeme.com/img/15/15dab75a183faa78bb95546dfa0eb19e17b70a36601cd92603f438df1fa81d2a.jpg)

Lower air-fuel ratio at peak power gives more hp per cfm. So it is possible to get higher HP when you max out the turbo's airflow. Say you make your peak power at lambda 0.8, your afr on e85 is 7.8AFR. On petrol this would be 11.8AFR. More air that has to come from the turbo. It will not be as simple like that, I also have no experience with E85. But its a theoretical approach taken from a compressor calculator sheet I have.
The GTX3582r maxxes out at 75lbs/min or something, that gives around 700hp at 11.8AFR but gives 900hp at 9AFR. Garrett formulates it as Wa=Hp*A/F*BSFC/60 to help choose the right compressor for your HP goal.

9:1 AFR will make the car not go anywhere and quite possibly even misfire, WTF are you talking about??? If you go by what any turbo calculator out there says, the most power you'll make is at 1:1 AFR because the more fuel you burn, the more energy you have. same as 20:1 producing 0 HP, when in fact 20:1 AFR can still burn and produce "some" horsepower.

Dude, dont freak out and read carefully what I wrote. Ethanol has a different afr for stoich. I know that most power will be made at leaner mixtures but then E85 is still more fuel to air than same lambda with petrol. I'm not claiming this is all true but I try to come up with a possible explanation for higher hp numbers in stead of flaming people right away.

Tijn is right, on E85 you can add more fuel to same amount of air and make more hp with same airflow.

TijnCU:

if we disregard all you have said about AFR it would still be silly to talk about E85 since one thing that has been questioned in this thread is the fuelling capacity in a TFSI engine without extra injectors.

You do realise that E85 has a lower calorific value than standard petroleum? As in, 33% less? So to make the same power, you need 33% more fuel.

Yes, that is my point, I did not think the Fsi stock fuel system could support more then 700ish on the big side.

True story.

Sure, I'm aware of the lower btu of ethanol. But the fact remains that you make more power on e85 with a turbo engine as long as you can get the fuel in. You put all this power gain towards octane?

I noted that the a4 dtm had an extra injector ecu listed in the mods, so maybe the owners can elaborate about fueling.

If you disagree with my theory its fine but then you basically say the power claims for this 75lbs/min turbo are total bullshit. (But you rather tell the small guy he's bullshit?)

Here is some more math since it is sunday and it rains outside  ;D

Thermal energy of Gas = 19,000 BTU/lb
Thermal energy of E85 = 13,475 BTU/lb

Lets assume a consumption of air @ 100lbs/hr

100lbs/hr / 14.7 AFR = 6.802 lbs/hr of gasoline @ 19,000 BTU/lb = 129,238 BTU @ Lambda of 1
100lbs/hr / 9.76 AFR = 10.246 lbs/hr of E85 @ 13,475 BTU/lb = 138,065 BTU @ Lambda of 1

So you can see that the final thermal energy output is greater even though E85 has less energy per volume due to the fact that we are using more of it per pound of air.

Sigh...

Ethanol chemical formula is C2H6O. It already has an oxygen atom attached to it. Gasoline does not, as it consists of hydrocarbons (CxHx).
This oxygen atom means when running E85 is a little like running nitrous built into the fuel. Not as dramatic of an effect, but nonetheless.
Add to it the fact that E85 upon evaporation supercools the intake charge, resulting in intake air temperatures of down to subzero at the intake valves, strongly compressing the incoming air.

This is why you make more power on E85.

The very basics with tuning engines is that OXYGEN makes power (even though chemically this is not quite correct).
Provided you have enough fuel supply, it is the amount of OXYGEN that dictates the power you can make.

The second component is ignition angle efficiency, which dictates how much power you extract from the fuel-air mix.
Due to E85 being extremely knock resistant and running very low EGT due to the cooling effect, you can basically run close to 100% efficiency (MBT) all the time.

Well, your chemical explanation is perfectly in line with my analysis that there is less added oxygen required for the same power output right? The stoich AFR and my btu calculation tells this as well. If we do not consider overall efficiency differences there will be about 6,5% more energy generated from a stoich burning E85 mixture on the same amount of external "air".

But the original question I tried to answer was (and remains) is it possible to make 900hp on a gtx3582r?

I am quite sure the dyno numbers on this are out of touch with reality.
The compressor just does not flow enough.

Independent dyno testing on something less happy than an out of cal dynojet will confirm, I'm sure.

Turbo is has a custom 9 blade turbine wheel, turbo is 105% maxed out, juggling overspinning but the bearing system is super tough.
I have 3 huge +1500cc meth injectors supplementing part of that fuel.

I agree completely i m sick and tired of all these cars claiming these super inflated numbers some of these goons i ll pay to have the car shipped to USA to be put on a dyno thats trust worthy of .

Seems common in a lot of countries where tuning isn't as mature as other places. There were guys in Lebanon shouting 470WHP with meth from a turbo rated to 420PS (414BHP) on 102RON where most folk are getting 410-430BHP  ::) Their defense is usually "it's because we can tune this ECUs better than you guys".

I swear to god the biggest reason I want a dyno is to break hearts.

Admirable.