Race engined, big turbo TTRS build.

[PovertyRS]

Posting this up as Michael Woodford MST was interested in my gay TT



The story starts in autumn 2010.

All my life I had wanted a UrQuattro or a turbocharged 5 cylinder audi, so when they announced the TTRS with a 5 cylinder turbo I had to have it.

So I went ahead and traded in my stage 2 plus, 360hp, 2.0TFSI Cupra K1.

Great car, practical, cheap to run. Loved the car, hated the dealer after support!

I then picked up this beauty, Ibis white, delivery miles, so happy! Dream come true.

 

[PovertyRS]

I'll be honest, coming from a 360bhp front wheel drive hothatch with 360bhp to a 335bhp 4wd coupe, the TTRS did feel kind of boring. The 4wd system makes it too capable, the 255 width tyres giving crazy amounts of grip which basically meant it was a point and squirt car. It wasnt involving enough for me. So straight away I started to mod it.

First mod obviously is a remap.

I got this done by Revo, and it bumped the car up to 400hp on stage 1.

I then added a full turbo back race exhaust from milltek.

Stock

Milltek vs oem

Next I looked at the brakes. The OEM pads were very dusty and didnt last long at all.

I bought some brembo blues for the car.

In hindsight these werent a very good addition as the soon killed the admittely not very good stock rotors.

Next I changed the panel filter.

I then looked at the intercooler. The stock intercooler is tiny so I fitted a forge motorsport unit. I got it fitted at Forge HQ, got a chance to meet the big boss Peter who is a really nice guy and really enthusiastic about his products which was nice to see.

 

[Advikaz]

Lovely mate, how you finding the brembo blues, i have them on my 200 and they seem ok...

 

[PovertyRS]

At this point I will introduce my buddies roadster. We mod our cars together, so he also got the forge intercooler fitted at HQ the same day.

His spec then being identical to mine up at that point.

Both of us not being happy with our brakes, we turned our attention to calipers.

We both settled on a set of rs4/rs5/r8/gallardo 8 pot calipers.

We also bought some new braided brake lines, castrol SRF brake fluid and I bought mintex 1155 pads. A friend machined the "revo" plate for us so the pads would sit on the oem disc properly.

Next up I attended a 30-130 and top speed event at a runway.

This was my best result. 30-130 in 14 secs (on a slight uphill track), and 170mph top speed. Basically the same results as stock GTR on the day. Not bad for a manual 400hp TTRS.

After that it was show season, and the two TTRS attended a few! The TTRS also won a auto X, handling challenge type event at one of the shows, which surprised many as we thought the track would be more suited to a N.A super mini type car. As soon as the TT was on boost it was time to brake again, so a good and shock result.

 

[PovertyRS]

I then replaced the stock intercooler hoses for some uprated forge ones. Another great forge product!

However we then came across a THS intercooler for free, and we were wondering what we could do with it. So, we decided to cram it behind the roadsters engine bay somehow!

And so this is what we came up with. Removed the air conditioning rad, attempted to remove the A/C pump aswell, but thats required due to the way the belts run on the engine. For it to fit we also had to cut the crash bar.

Then we painted the intercooler black for the stealth look.

End results via logging shows that temps are even cooler, and will peak at a certain temp and not increase anymore, but if you ask me whether its worth massacaring your TTRS for the small gain over the forge unit, I would say no. Therefore the coupe wont be going this route, and it did highlight actually how well the forge unit is actually designed, as the temps differences were minimal!

 

[Lal B3N]

What power is it then, still 400ish?

I like them and I understand it will be probably be silly quick but they don't really wow me.

That titanium exhaust doesn't half look epic though!

 

[PovertyRS]

The roadster then got some new wheels, whilst the coupe got race plugs.

New vs old

Full polybush set for both cars

 

[PovertyRS]

Then I decided to ditch the milltek in favour of a scorpion turbo back titanium exhaust.
This exhaust is the most beautiful piece of engineering I have ever got to touch I must say. Work of art!

And the weight saving is awesome too, i could lift the backbox with my two little fingers!

It turns blue after getting hot!

 

[PovertyRS]

The roadster then got this prototype ITG intake! Made nice gains!

And we decided the roadster needed a louder exhaust that the milltek race back box.

So we fitted a single exit rear can! Now its really loud, sounds super!

 

[PovertyRS]

At this point it was decided that we would move away from Revo software, and paid a visit to APR.

They wrote a stage 2 map for the car, we were hoping for great things and we werent dissapointed. The power holding that the map provided vs the revo stage 2 map was just crazy. Its pulls and pulls all the way to the redline. The way the power doesnt drop off and it keeps on just pulling leaves you smiling from ear to ear.

Now after the forge intercooler was installed, the car was dynoed at 420hp at stage 2 and between 380-400lbft of torque, I cant remember the exact figure.

I decided I wanted to dyno this new map to see what the car was making now.

The APR map gave me a nice gain, 430hp and 450lbft! The power curve is just beautiful aswell!

So now we are at 430hp and just about reaching the limits of the stock turbo.

I still need more power.

To do this the car requires:

Uprated clutch
Uprated fuelling
Bigger turbo
Internals, because we are going over the 600/650hp threshold

 

[JaredHasNoBrain]

That is stunning! Vid up of the new exhaust?!
Seen below... jesus this thing is a monster lol

And did you keep them wheels? the (i think) rotiform ones.

 

[PovertyRS]

And so the engine build begun!

This is how its started:

And here are some progress pics:


Stripped down head

Port moulds and the ferrea valevtrain

 

[LIL B]

Very nice, indeed.

 

[PovertyRS]

That is stunning! Vid up of the new exhaust?!

I'll see if I can dig one out.

The engine build was done by the geniuses at Race Development. In case anyone is wondering what the port moulds are all about, it helps to aid the redesign of the cylinder head port and flow.

Lovely mate, how you finding the brembo blues, i have them on my 200 and they seem ok...

They were good, but too aggressive for the crappy stock ttrs discs. They just warped them nearly straight away. TTRS front rotors are non directional so one side gets hotter than the other. Think 850 degrees C iirc.

 

[Advikaz]

I'll see if I can dig one out.

The engine build was done by the geniuses at Race Development. In case anyone is wondering what the port moulds are all about, it helps to aid the redesign of the cylinder head port and flow.

I know of a guy with a Grey TTRS who's running 700 odd brake out of one of these. It goes like sh*t off a spade.

 

[PovertyRS]

I know of a guy with a Grey TTRS who's running 700 odd brake out of one of these. It goes like sh*t off a spade.

Do you mean jonnyC with the matte grey one?

 

[PovertyRS]

Rings gapped, parts balanced, ready for assembly. High temp, low friction thermal coating.

Old VS new

 

[Chi]

Awesome mate!!! Subscribed..

 

[PovertyRS]

Progress shot on the cylinder head

 

[Ali]

Superb! The engine is an absolute masterpiece. My favourite bit of the RS3 i drove. Great work!

 

[Munson]

Got to respect anything with 5 cylinders TBH.

 

[Advikaz]

Do you mean jonnyC with the matte grey one?

I certainly do.

 

[PovertyRS]

UK APR development car pulled a 0-60mph in 2.8 secs on road tyres, on a unprepared surface! With a garret GTX3071 turbo and stock clutch.

And Drive/Tuned did a review of the APR US development car in the States.

The 600 HP APR Stage 3 Audi TTRS - TUNED - YouTube

 

[_Tom]

Awesome work and thread. Keep it coming.

 

[PovertyRS]

fuelling side of things in development courtesy of APR.

High pressure fuel pump.

Ive also made some extra progress on the weight saving. These recaro pole positions are 13kg with sidemounts and runners. The OEM seats are about 34kg, so a saving of 21kg per seat.

The titanium exhaust saves 26kg over OEM.

So thats a 68kg saving so far. I have a few more weight saving ideas in my head, so should be able to reduce the weight by about 100kg over stock. Will make the car weigh roughly 1360kg with a quarter tank.

 

[Lal B3N]

Now its getting interesting

 

[tomtombanban]

I love this build.... such a clean looking car too... so many big budget builds like this go to heavy on the race looks... This is a total silent sleeper... Awesome car, awesome colour. Keep it going!

 

[PovertyRS]

Engines all done and finished. Also had some parts superfinished, never got any pics of it, so I'll borrow this pic of my friend jonnyc so people can see what it looks like. Nice and shiny!

Superfinished crank.

Next immediate step right now is strengthning the gearbox.

So its being split open, and the gears will be superfinished also.

The end results will look like this:

Gearbox internals before:

Internals after

What is superfinishing?


In a nutshell superfinishing removes the imperfections off moving parts, meaning less friction and up to 4 times longer component life. Extensively used by F1 and superbike race teams.

Components have been proven withstand 30 percent higher loads for at least three times the life of the non superfinished part so to me it wa worthwhile to spec in this build.

 

[n2x]

I think the TTRS wheels are one of the best looking ones ever. Rotiforms look gay compared to the originals. Epic motors both of them, nonetheless.

 

[PovertyRS]

I certainly do.

Ahh yes jonny is in the same boat as me atm. Both cars are off the road due to waiting for our uprated clutch and flywheels. Jonnys clutch kept slipping at 1.4 bar of boost, so around 530hp, and the turbo on his will probably be run at around 2.1-2.2 bar so its got a hell of alot of potential in it yet. Will be awesome when finished

Awesome work and thread. Keep it coming.

Thanks

I love this build.... such a clean looking car too... so many big budget builds like this go to heavy on the race looks... This is a total silent sleeper... Awesome car, awesome colour. Keep it going!

Its going to look completely stock thats my plan, other than sitting a bit lower on coilovers.

I think the TTRS wheels are one of the best looking ones ever. Rotiforms look gay compared to the originals. Epic motors both of them, nonetheless.

I didnt like to rotiforms either TBH. They got sold. The roadster is possibly going soon for a double clutch coupe TTRS. Then a hybrid turbo will probably be fitted to it, should mean high 10 second 1/4 mile times if setup well.

 

[PovertyRS]

Now onto the APR turbokit. Hello GTX35

Some more pics. The turbo is bigger than my mates meatball head lol.

All put together:

 

[alexr19]

Subscribed! Love this. I will own one

 

[PovertyRS]

Engine Spec:-

RaceDevelopments built
Full race engine build
Balanced and blueprinted
Superfinished crankshaft
Gasflowed race spec cylinder head with valve seat modifications
Bore block
I-beam Rods
Custom oversized pistons, high temp low friction coating
Full Ferrea valvetrain
ARP bolts

Turbokit:-

APR Stage 4
GTX3576R
Cast Inconel manifold
V-band connections
Tial valve


Gearbox:-

Superfinished Internals
Twin plate paddle clutch
Lightweight Single mass flywheel

 

[Jaff.]

So you bought a new car, spent thousands on it, and now its not working.

​could have bought a fiesta st ffs!

 

[Emma.]

Lol that looks bigger then the whole 1*2 engine.

​Great work car looks epic!!

 

[JD]

Fantastic. I recognise the old mk1 TT in this pic - one of Bill Brockbank's mates isn't it?

 

[PovertyRS]

So you bought a new car, spent thousands on it, and now its not working.

​could have bought a fiesta st ffs!

Id rather massage my prostate than buy a fiesta ST :lolup:

 

[Martin.]

I'm sure I took that photo. From Santa Pod? TTOC meet about 3 years ago?

Car looks awesome mate. Some serious cash and effort has gone into it!

 

[Darren S]

Instant reaction? I despise the switch - I've a proper soft-spot for those Leon's and your's looked a beauty. To swap that for a white TT of all things?? Ewwwwwww....

That said, I simply cannot fault your commitment (and pockets) to your ultimate goal. It beats simply tweaking a Scooby or Evo in search of mad performance figures anyway.

Now how's about transplanting all that hard work back into the Leon shell???

D.

 

[ColinG]

This is amazing! TTRS is one of my favourite cars.

why everyone loves those rotiforms though is beyond me?! They are dreadful wheels!! Properly chavtastic!