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REVO stage 3 project on an Audi RS3 – By Dave Massey , ADS Automotive

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This month’s article takes a closer look at the projects that have been going on in the workshop at ADS HQ. Just before Christmas, we completed an exciting REVO Stage 3 project on an Audi RS3 8P chassis, which already boasted 0-62 mph in just 4.3 seconds, with a top speed of 155 (limited) mph!

This car had come onto our workshop running Stage 2, already running approximately 440 bhp and 415 llb torque. Not bad figures and it’s a very quick car on the road bearing in mind all that power and torque is in an Audi A3 chassis, coupled with a very capable 4-wheel drive Haldex system.

SMALL CAR + BIG POWER + 4-WHEEL DRIVE = MENTAL FAST ON THE ROAD!

Screen Shot 2018-03-27 at 21.04.24But our customer wanted more and, with our Stage 3 turbo kit, we had just the thing. It comprises a brand-new BorgWarner turbo, which has been modified into a hybrid and capable of achieving 500+ bhp using high octane pump fuel, see Figure 1.

This kit requires a lot more from the fuel system, so we use the Autotech high pressure fuel pump to meet the increased demands of the injectors. Autotech is the premier manufacturer of fuel pump upgrades for the TFSI engine because our kit offers the highest quality, solid engineering and great value.

Upon installing the pump, notable increases include 5% torque and an additional 10Bar of fuel rail pressure. We also install higher heat range spark plugs, opting for NGK Iridium NGKR7437-9.

Screen Shot 2018-03-27 at 21.04.52The Stage 3 kit demands a full Turbo back exhaust system, at least 3 inches, with high flow race cats. We went for a custom Pipe Werx downpipe, which married up to the existing Milltek Cat Back and secondary cat bypass system, previously fitted for the Stage 2, see Figure 2.

All this extra boost means we need extra cooling and the stock coolers on these cars are notorious for poor heat soak and can affect inlet air temps meaning a loss in power. To remedy this, we lean towards our go-to intercooler supplier, Wagner.

The Intercooler Upgrade Kit from Wagner Tuning for Audi RS3 EVO II with integrated crossmember is a high- performance redesign of the original OEM intercooler designed specifically for the Audi tuning enthusiast. Wagner has increased the intercooler core size and efficiency, as well as improved the end tank design to remove any OEM bottlenecks, resulting in increased flow rating and charge air cooling properties.

The Wagner Tuning Audi RS3 Evo 2 Upgrade Intercooler features: EVO2 535mm x 260mm x 95mm 13,214 cm3 intercooler core, compared to EVO1 535mm x 160mm x 110mm 9.416 cm3 core and OEM 535mm x 160mm x 80mm 6,848cm3 core.

Due to this being a Stage 3 car, we opted for the Evo 2, which as you can see by the specs is more than double the original capacity – more than adequate to cope with the extra boost.

The final piece of the puzzle we left to the magicians at Revo Techik, who have developed their Stage 3 software to achieve in excess of 500 bhp! These boys don’t mess around when it comes to software and spend a huge amount of time testing and developing it before it’s released to the market. Their software was initially designed to run a LOBA turbo but the only difference with our Stage 3 conversion is that we run our own hybrid turbo, designed and built by TDI Turbos on the South coast.

After we had installed all the hardware and loaded REVO Stage 3 software, it was time for some testing on the road while data logging, before we put her on the dyno for final testing.

With REVO software, we can control the amount of ignition timing, AFR and boost, giving us a degree of adjustment and control of the power. It’s always wise after such a big build to gradually increase boost until we know everything runs well and is safe. We always keep a very close eye on ignition timing advance and fuelling, making sure lambda is within specification (under 0.8 lambda under full load) and to ensure there’s no excessive knock correction or ignition timing retardation.

All data on the road was as expected and we were ready for the dyno, after running the base map and making some incremental changes to increase power. Having driven this on the road, I was very optimistic of seeing good numbers and we were all excited to see the end results.

Unsurprisingly, the car had over achieved, giving us a whopping 550 bhp, running 99 octane fuel! After we had finished the work we invited the customer down to go for a drive before the vehicle handover and his smile said it all. Let’s just say he was a very happy boy indeed and had his toy just in time for Christmas.

Another fantastic job done at ADS and more importantly, another very happy customer!

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