Ed's 1992 UrS4 "da fridge" - da movie

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vt10vt
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Re: Ed's 1992 UrS4 "da fridge": Fuel system build...

Post by vt10vt »

Hope you guys can get it all sorted tonight/tomorrow, good luck! I'd love to check your car out in person, one of if not my favorite URS4's around.

DuBistS4 wrote:What kinda of Lambda targets are possible with E85?

There's a good discussion in Philip2's project thread about E85 Lambda targets and also in McStiff's thread, I'd check those out for some good reading both on E85 and as builds in general.
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
DuBistS4
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Re: Ed's 1992 UrS4 "da fridge": Fuel system build...

Post by DuBistS4 »

Awsome thanks
'94 UrS4 Red/Black
Vems
Lightly modded head

-Will
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Mcstiff
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Re: Ed's 1992 UrS4 "da fridge": Fuel system build...

Post by Mcstiff »

The caveat for my build is that I am running 10.2:1 compression ratio and being very conservative. My tune would be pretty rich in an AAN.
EDIGREG
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Re: Ed's 1992 UrS4 "da fridge": Fuel system build...

Post by EDIGREG »

Running E85 on the stock fuel system was causing a major drop in fuel pressure, and I wanted to build something that would retain all of the stock lines from the tank to the engine bay. After about 6 months of planning/parts sourcing, I finished up the new system last night. Main components of the system are:

-IE surge tank
-2x 044 fuel pump
-EFI-X fuel rail
-Weldon Racing FPR
-Honeywell digital fuel pressure sensor (input to VEMS)
-One billion AN fittings

This creates two fuel loops - One 044 in the stock tank feeds the surge tank under zero pressure. The stock fuel return line is used to return excess fuel from the surge tank. The second loop consists of two 044 pumps feeding -8AN lines to the fuel rail, regulator, and a return back to the surge tank. Everything is relayed and triggered by the OE fuel pump relay.

This means there will be four 044 pumps in my car at any given time (including a spare). It is an angry hornets nest :)

I also rebuilt the injector/cps harness while I was in there, got rid of the EV6->EV14 adapters.

Will be getting on the dyno to do a full tune soon...600+whp is the goal, we will see how my clutch likes that. :idunno:

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Ed
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loxxrider
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by loxxrider »

I see you have cleaned your expansion tank.
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
E34 530i (maybe rear-mount soon)
roortube
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by roortube »

Nice work Ed! Looking forward to the results!
Rob

Prepping my 91 M5 Dinan for sale to fund 07K and EFR build for my UrQ. May also sell Lotus Elan resto project. PM if interested in either.
EDIGREG
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by EDIGREG »

loxxrider wrote:I see you have cleaned your expansion tank.


hahahha :rofl:
Ed
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loxxrider
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by loxxrider »

Really though, it looks more badass than ever! I can't wait to see the results as well. Maybe we can race next Carlisle :)
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
E34 530i (maybe rear-mount soon)
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chaloux
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by chaloux »

Hnggg so sick. Definitely looking forward to results!
Matt

18 Silverado 1500 work pig, roof rack and tonneau cover
11 Jetta sedan TDI DSG, rear muffler delete
GONE :( 87 4ktq - 4 FOX SNAKES

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85oceanic
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by 85oceanic »

Looks effin baaaadddazzzz. :drool:
-Ben-
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-1985 Audi 4kq: Xona 7164 AAN 488whp- -2009 Audi A4 -
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mushasho
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by mushasho »

Super amazing job.... That's bay is quite a site...

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UglyUr 2.5L 95.5mm Stroker
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da_trem
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by da_trem »

**Almost** to nice to abuse..
95 Audi S6, VEMS, BW S362
00 Volvo S70 T5M
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gtn116
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by gtn116 »

At Carlisle gathered around the car:

"This should make it good for... a couple... hundred more horsepower..."

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mushasho
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by mushasho »

gtn116 wrote:At Carlisle gathered around the car:

"This should make it good for... a couple... hundred more horsepower..."

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ROFL!!!!
UglyUr 2.5L 95.5mm Stroker
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Hank
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by Hank »

LOL, :lol: That is exactly what people did when I said it. hehe
EDIGREG
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by EDIGREG »

LOL :rofl:

Thanks for the comments all...hopefully on the rollers this week
Ed
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JustinB_20vt
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by JustinB_20vt »

just awesome ... cant wait to see what this thing put's down
Justin aka banget3k
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//urS6 - Tasty plate of mods with a pinch of salt
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pilihp2
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by pilihp2 »

Damn that's a purdy bay. Excited for numbers.
-Phil
87 5ktq - 20vt
91 v8 5spd - Why?
05 S4 - Gone and very much so forgotten
14 TDI Touareg

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PRY4SNO
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by PRY4SNO »

Such a clean install.

Mad props, sir.

Satisfy the mob, provide dyno plots please!
Find me on Instagram @pry4sno

|| 2010 Golf Sportwagen TDI /// #farmenwagen
|| 2002 Dodge Ram 2500 24vt 4x4 #bertancummins
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar
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85oceanic
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by 85oceanic »

I know I just said this Ed, but man, your car is effing badass. I love it. Looking forward to numbers too!
-Ben-
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-1985 Audi 4kq: Xona 7164 AAN 488whp- -2009 Audi A4 -
highlander69
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by highlander69 »

Looks great Ed.

I don't care what the numbers are :D .............love the clean engine bay :drool:

Cheers,

Craig
EDIGREG
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by EDIGREG »

Thanks all! Dyno on Friday :twisted:

It's incredible how this new system provides stable and consistent fuel pressure. Even with base pressure matching the old setup, it is uber rich everywhere but idle - goes to show just how much the old setup was struggling. You can compensate for this with pulse width to a degree (which is exactly what I was doing), but that only gets you so far (around 400whp with E85, and that is only if you taper boost off hard over 6k RPMs).
Ed
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EDIGREG
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Re: Ed's 1992 UrS4 "da fridge": Fuel system done...

Post by EDIGREG »

Did the first tuning pass on the dyno last night, big thanks to Aaron who was the dyno operator while I tuned the car. Currently at 545whp/495wtq @ 32psi. We ran out of time so this was only fuel and open loop boost, no timing adjustments or boost PI controller tuning. There is still a bit of fuel to be pulled out up top and after ignition is properly tuned I'm confident we will easily be into the 600whp range at ~35psi. Should be able to get back on for some more tuning in the coming weeks.

The new fuel system is performing incredibly - the injectors need close to no gain because fuel pressure is so stable (a major change from before where we were compensating for dropping fuel pressure with pulse width). Started out uber rich @ around 400whp on spring pressure, all was going well until my o2 sensor stopped working suddenly. Fortunately we were able to borrow a spare and continue tuning. Didn't even touch 50% duty cycle on these monster injectors. Fuel pressure is the orange line.


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Didn't get to do much boost tuning so I'll need to increase n75 DC after torque peak to get it to actually hold boost. :P

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[youtube]http://www.youtube.com/watch?v=OGWQRpO5uUU[/youtube]


We also installed the Mustang motor mounts before getting on the dyno - not an easy endeavor, required a lot of cutting to get them to fit but they are performing very well - the motor barely moves at all now. I need to build a heat shield for the turbo side but they aren't really exposed to crazy heat in the C4 chassis like they are in the smaller chassis cars. My motor mounts were in BAD shape... driver's side was hanging by one bolt before Carlisle (we swapped in a good OE mount), and the passenger side was destroyed as well. Hopefully these hold up to the beating. Shifter feels nice and tight too. Filling my trans mounts with Poly and then everything should be pretty darn solid.

FWIW, I noticed no increased NVH with the poly mustang mounts, still nice and smooth.
Ed
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Hank
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Re: Ed's 1992 UrS4 "da fridge": dyno tuning

Post by Hank »

Freaking sounds fantastic!
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85oceanic
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Re: Ed's 1992 UrS4 "da fridge": dyno tuning

Post by 85oceanic »

Awesome stuff Ed!
-Ben-
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-1985 Audi 4kq: Xona 7164 AAN 488whp- -2009 Audi A4 -
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