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Thread: S3 PE1820 big turbo build

  1. #201
    Welly's Avatar
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    Quote Originally Posted by MUSH View Post
    Yep top mount is the way forward, you may have even pulled your last head off..!! Lol
    I hope so....
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  3. #202
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    Quote Originally Posted by Dani_B19 View Post
    Very nice, you just use normal flap wheels? Looking into starting mine next, should be fun lol.
    No, not flap wheels, I'll photo the implement used - it's like a flap wheel, but a rotary bit with just a harsh grade sand paper outer.

    I've got a spare TB here so I don't mind messing about with this one. I'll see what it's like and then maybe do a bit more.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  4. #203
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    Cheers welly.
    Driving the most secretive S3 on ASN

  5. #204
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    I use a number of different burrs and emery clothes inc flap wheels
    Was 531bhp 8L S3 thats going to break the 600+ bhp Club then break something else. Lets see what this OD HTAGT3582r can do
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  6. #205
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    Welly you seen this:

    http://www.edition38.com/forums/inde...&#entry3576781

    Good idea like in the thread another started a week or so ago but bloody dear for what it is dont ya think?
    Driving the most secretive S3 on ASN

  7. #206
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    Looks awesome Welly!

    Best of luck dude, REALLY looking forward to seeing the results you get from this!
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    But I know nothing so ignore me.

  8. #207
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    Another milestone on the road to completion yesterday - the head.

    I'm a bit nervous of the 20V heads due to their tightness on the inlet side, so enlisted the help of a friend who has got some reasonable experience with them....

    Tuffty!

    All his work on the head, stem seals and cam seals have all been replaced. The stem seals were a bit weepy and the cam seals were completely shot and leaking. So hopefully no more leakyness now.

    Photos:







    Head is now back with me at home after collecting yesterday.

    Big thanks to Tuffty for doing this - a lot of skill, work and time went into it to complete it. Thanks dude .

    Awaiting oil and coolant line's completion tomorrow and we should be good to go on building back up...
    ------------------------------------------------------------------------------------------
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  9. #208
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    Oh, also trial fitted the TIP to see how it fits - well is the answer....

    Last edited by Welly; 11th April 2011 at 09:02.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  10. #209
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    Quote Originally Posted by Welly View Post
    ... Thanks dude .
    Welcome mate...

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

  11. #210
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    Quote Originally Posted by Dani_B19 View Post
    Welly you seen this:

    http://www.edition38.com/forums/inde...&#entry3576781

    Good idea like in the thread another started a week or so ago but bloody dear for what it is dont ya think?
    Link doesn't work for me mate :-/
    ------------------------------------------------------------------------------------------
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  12. #211
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    Is that a worthwhile bit of maintenance to do when I remove my head, stem and cam seals? Expensive parts?
    Thanks

  13. #212
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    Quote Originally Posted by superkarl View Post
    Is that a worthwhile bit of maintenance to do when I remove my head, stem and cam seals? Expensive parts?
    Thanks
    The head set to buy is around 70 - includes a HG, stem seals, cam seals, chain tensioner seals, inlet manifold gasket, exhaust manifold gasket and a rocker cover gasket. Not bad all in all.

    I would say they are worth changing once the engine gets over 100K - the seals tend to become dry.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  14. #213
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    Turbo hoses are done..... yay!
    Last edited by Welly; 11th April 2011 at 14:28.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  15. #214
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    OK, so had a night on it tonight.

    Initially concerned that the turbo oil return hose was a little short - however it turned out to be fine.

    Many thanks to Bill for grabbing them for me today .

    So... here they are:



    Score. Total cost of 136.96 wasn't the cheapest, however they are made out of PTFA internal braided hose - so should be pretty heat proof.

    I have also heat wrapped (two layer, firstly with exhaust wrap, and then with silver foil tape followed by SS wrap straps) the two pipes that will run underneath the manifold.



    Thats done, it was time to start rebuilding..... Started by fitting the exhaust mani to the head, and then the head to the car. Only mocking at this point.

    Fitted the oil lines to the turbo and then the coolant lines. Basically I followed my normal rebuild procedure... lol. Torqued the head, fitted turbo, fitted remaining coolant lines, etc etc etc.

    Have finished up the night in this state by close of play tonight...



    Engine bay as is.



    Coolant return pipe coming out of the turbo and winding it's way around the bay to the original coolant K04 return feed.



    Here, Bill has welded the 007P directly the the TIP 76mm joiner. This is purely a space saving measure as it means less hosing in the engine bay.



    Oil return, coolant feed and oil feed pipes visible along the bottom of the head/turbo area.

    So, all in all a good night. Spent a little while standing back admiring it.... lol. (sad...)

    On a side note, the funny story from the evening is as follows.

    Get home, start fitting the oil return line and the gasket falls down somewhere in the engine bay. Arse. It's grey so finding it in a black engine bay is next to impossible.

    Spend an hour or so poking around looking for it. Nowhere to be seen. Stopped briefly as Dane came to pick up the hybrid from my yard, then eventually found it luring down on one of the heat shields.

    Now, we have a new (and bonkers) labradoodle puppy, who has taken to sitting under my car (as she's up in the air). I suspect she has actually eaten some missing bolts that were under there - and aren't now.

    I manage to poke the gasket out from where it was, and it dropped to the deck.

    At which point the puppy promptly saw, and ate it (it was only a paper gasket). Amused I was not. In fact I went absolutely bonkers having spent an hour looking for the damn thing.

    Then had to go to Bill's to get another suitable gasket.

    Bloody dog!
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  16. #215
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    LOL, post from last night now added after some ASN weirdness.....

    Cheers Tuffty
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  17. #216
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    Gotta love the dog,LOL

    Feed it headgaskets, you must have 20 in stock.LOL

  18. #217
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    Must be great working on a turbo that's so much more accesible than a ko4 hey!

  19. #218
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    Quote Originally Posted by Byzan A4 View Post
    Gotta love the dog,LOL

    Feed it headgaskets, you must have 20 in stock.LOL
    I fed it's arse my foot. I was not happy at all, bloody thing. It fell in the pond the other day as well. She is sooo skatty.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  20. #219
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    Quote Originally Posted by superkarl View Post
    Must be great working on a turbo that's so much more accesible than a ko4 hey!
    Yeah, some things still a challenge like actually doing up the oil return flange with the turbo in situ - but still far easier than any K04 work.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  21. #220
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    bolt drain onto turbo 1st then turbo onto mani
    **http://www.facebook.com/Badger5Ltd**

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  22. #221
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    Quote Originally Posted by badger5 View Post
    bolt drain onto turbo 1st then turbo onto mani
    Normally what I would have done - however pipe angle constraints stopped me from being able to....
    Last edited by Welly; 12th April 2011 at 14:32.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  23. #222
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    Quote Originally Posted by Welly View Post
    On a side note, the funny story from the evening is as follows.

    Get home, start fitting the oil return line and the gasket falls down somewhere in the engine bay. Arse. It's grey so finding it in a black engine bay is next to impossible.

    Spend an hour or so poking around looking for it. Nowhere to be seen. Stopped briefly as Dane came to pick up the hybrid from my yard, then eventually found it luring down on one of the heat shields.

    Now, we have a new (and bonkers) labradoodle puppy, who has taken to sitting under my car (as she's up in the air). I suspect she has actually eaten some missing bolts that were under there - and aren't now.

    I manage to poke the gasket out from where it was, and it dropped to the deck.

    At which point the puppy promptly saw, and ate it (it was only a paper gasket). Amused I was not. In fact I went absolutely bonkers having spent an hour looking for the damn thing.

    Then had to go to Bill's to get another suitable gasket.

    Bloody dog!
    Lol! Reminds me of the dog in Gone in 60 Seconds eating the Merc keys!

  24. #223
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    Another long night spent in the garage last night, however it did bear some fruit....

    It's done - a few odds and sods aside at least. Awaiting delivery of a few pipes and fittings, however, the bulk of the work is now completed.

    Usual stuff done last night, timed the engine, fitted the timing belt covers, inlet manifold etc etc etc.

    So, will finish up tonight, and then it's ready to roll up to Bill's at the weekend - which is nice.

    Photos:







    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  25. #224
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  26. #225
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    This weekend? Im so there, let me know when and I'll pop over.

    Good work man!

  27. #226
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    Quote Originally Posted by Dane View Post
    This weekend? Im so there, let me know when and I'll pop over.

    Good work man!
    I'm only bringing her up there for some work on Monday dude - she is lacking a downpipe currently....
    ------------------------------------------------------------------------------------------
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    Quote Originally Posted by Prawn View Post
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  28. #227
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    Well done, you certainly move fast, your oil will still be warm from your hybrid..lol

  29. #228
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    Quote Originally Posted by s3dave View Post
    Well done, you certainly move fast, your oil will still be warm from your hybrid..lol
    lol, it's new oil..... :P
    ------------------------------------------------------------------------------------------
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    Quote Originally Posted by Prawn View Post
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  30. #229
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    Nice work Welly, you do get things done quickly.
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  31. #230
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    Quote Originally Posted by Westle View Post
    Nice work Welly, you do get things done quickly.
    The missus is off for a week, so had to capitalise on having a WHOLE week to get on with no aggro.... lol
    ------------------------------------------------------------------------------------------
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    Quote Originally Posted by Prawn View Post
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  32. #231
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    Quote Originally Posted by Welly View Post
    The missus is off for a week, so had to capitalise on having a WHOLE week to get on with no aggro.... lol
    apart from the dog

  33. #232
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    Quote Originally Posted by Dane View Post
    apart from the dog
    Yeah, the dog....
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  34. #233
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    I only see my gf at the weekends so I have loads of time during the week for late night mechanics

    It's just a shame my mechanical skills aren't as good as yours!
    8P A3 TDI - 220bhp - 335lbft
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  35. #234
    Welly's Avatar
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    Quote Originally Posted by Westle View Post
    I only see my gf at the weekends so I have loads of time during the week for late night mechanics

    It's just a shame my mechanical skills aren't as good as yours!
    It doesn't work yet..... lol. Rumours of my skills are greatly exaggerated.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
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  36. #235
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    Nice work buddy and liking your sticker.

    Welly 2 questions, whats the name of the turbine housing outlet flange, and I thought you was running a catch can, cant see it in your pics tho. What one have you got if you have that is.
    For sale

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  37. #236
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    Quote Originally Posted by S3 Nattie View Post
    Welly 2 questions, whats the name of the turbine housing outlet flange, and I thought you was running a catch can, cant see it in your pics tho. What one have you got if you have that is.
    The name of it? Ummmmm, pass. It's just a boggo IHI outlet to be honest dude - I don't know if it has a specific name.

    Secondly, I was running a catch can, however ended up binning ti as it was a pain during the cold weather. It was metal, and thus got cold at night, combined with a warm engine just caused condensation and I ended up emptying water out of it most of the time.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  38. #237
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    I wasnt to sure if there was a name for the outlet either, thats why I asked. I was just thinking if you was having a custom downpipe made up what would they called the flange thats all as its a pretty strange flange.

    Did you upgrade your breather hoses to Forge ones then, any links for the can you did have mate.
    For sale

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    Autogauge boost gauge
    Chrome Audi Number plate surrounds

    PM for info.

  39. #238
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    Quote Originally Posted by S3 Nattie View Post
    I wasnt to sure if there was a name for the outlet either, thats why I asked. I was just thinking if you was having a custom downpipe made up what would they called the flange thats all as its a pretty strange flange.

    Did you upgrade your breather hoses to Forge ones then, any links for the can you did have mate.
    It Flangetastic..... Turbo Flange SUBARU Liberty Legacy IHI VF38 VF44 VF45 | eBay UK

    Just made my own out of silicone hosing mate TBH.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




  40. #239
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    I suppose you would just called it a subaru/IHI flange then lol.

    Cheers for that welly
    For sale

    3" Downpipe and de cat (will be going on ebay soon)
    Autogauge boost gauge
    Chrome Audi Number plate surrounds

    PM for info.

  41. #240
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    Quote Originally Posted by S3 Nattie View Post
    I suppose you would just called it a subaru/IHI flange then lol.
    Yeah, they're pretty common to be fair, all of the VF series have that flange.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




 

 

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