[ba] 80tq Update: 516 wheel hp, 450 wheel TQ

JShadzi at aol.com JShadzi at aol.com
Wed Mar 2 22:40:43 EST 2005

Hello everyone, its been a while since my last post Nov 2004, just an update for any of you that are interested in this ongoing project.

The latest since the 455wheel HP run last fall is a bigger 034EFI T3/T62 turbo with flow for about 700HP at a PR of over 3.2.  We hit the rollers earlier this week, the result was 516whp and 450.6 wheel TQ.  Boost comes on at 5krpm and hits with an ungodly force all the way to 7500rpm (depending on where the revlimiter is).  Acceleration is mindboggling, in 4th and 5th is slips the SPEC Stage 3 mercilessly, so a clutch upgrade will be in the future.

The Dyno Plot, no corrections at sea level, ATP Dyno where all my dyno plots are done (for consistency):

The power is courtesey of an 034EFI T3/T61 turbo with large .82 AR turbine housing.  Still running a 3" DP and exhaust with 3" Borla muffler, still running stock 3B IM and throttle body (yes, no Porsche logos here).

Turbine Shot of Turbo:

Compressor Shot of Turbo:

516whp Dyno Run Video:

I also found the limit of the largest of the external CIS pumps, the CIS3 pump (as fit in the 80/90 B3 quattro).  At full boost pressure (30psi), fuel presure would peak and then begin to drop rapidly, causing the lean condition towards redline (that you can see on the dyno chart).  Since I'm already running only 3 BAR fuel pressure (no point in turning up the pressure, lowering it with larger injectors could be an option if higher pressures were being run) with #75 injectors. I will be adding a second pump in parallel to alleviate the condition.  I'll also be using a high flow aftermarket fuel filter, but you can gather the stock Bosch fuel filter is good for at least 600HP assuming its not the restricting factor.  

Anyhoo, see the fuel pressure drop here!:

Some things we now know pretty well:

-CIS3 fuel pump good to about 475whp running 3BAR.
-SPEC Stage 3 holds up to about 425whp (rated at 550 crank HP).
-205 series RA1's on a 2900lb quattro with about 600 crank HP provide absolutely no traction in any gear.
-3B intake manifold and throttle body, unmodified, can support well over 500 wheel HP, with no power drop past 7krpm.
-Being able to tune your fuel, ignition, coil dwell times, etc, etc is essential for making power at these levels (ie: 034EFI Stage IIc ECU)
-Eagle connecting rods support well over 500whp, as well as the stock Audi block with 83mm JE pistons and ARP head, rod and main studs.  Copper headgasket with 0-ringed block seems totally unstressed by this sort of power.
-Bosch copper 7A plugs handily take the abuse of almost 300HP/Liter, so do the stock 7A plug wires.
-75lb injectors running 40psi base pressure run at almost 95% duty cycle at 516whp, aggrivated by dropping fuel pressure.
-About how Hans Stuck felt accelerating in an S1.
-Lastly, I5 20v's flat out, unabatedly kick ass.

Future plans are to add a second CIS3 fuel pump and go back, I anticipate another 30-50whp just by correcting the a/f ratio with the proper amount of fuel.  3-5 more PSI boost should bring output close if not past 600whp.

More about the car at: http://www.80tq.com/20vtMotor.html

All for now, comments and jeers welcome as always.


Javad Shadzi

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