AH FabricationsBadger5
Results 1 to 39 of 39
  1. #1
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836

    My k04 conversion progress thread with pics !

    Hi there all I know I haven't had much time to be on here as much as I would like sorry about that all but thought I would keep everyone posted about my k04 conversion, ok as most people know I'm running stage 2 a3 agu with 222bhp and 250ftlb torque, and after meeting everyone at ace cafe with their ko4's I had to just do it thanks prawn mate !!! Lol no but before the stage 2 was warming up already started buying bits so well here I am and thought I give everyone a update with pics below as my iPad won't for so reason copy and paste my pics !!
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  2. # ADS
    ADS
    Join Date
    Always
    Location
    Global
    Posts
    Many
     
  3. #2
    Prawn's Avatar
    My other car is a MINI!!!!

    Status
    Online
    Join Date
    Dec 2006
    Location
    Basingstoke
    Posts
    9,358
    Bobby you lied.

    Thread title says with pics

    i see no pics

    I R SAD
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  4. #3
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    Ok firstly I went and bought a mint k04-023 and manifold both had only covered 44k and had all four sets of oil and water lines for a bargin £400




    then bought the vr6 maf and upgraded fuel pump bargin at both for only £60



    Then bought a set of Bosch red top 346cc injectors from dan( beachbuggy) for a bargin £80! Can't say thank you enought bro!

    Then bought a 80mm jetex cone filter for only £30 only covered few thousand miles! And came with extension hose,


    Then bought today a badger5 tip v1 for a fantastic £90 can't thank my mate Erdal enough!!


    Also have bought the vr6 flywheel clutch package for only £60! Set has only covered 2.5k, big thanks to Danny! Won't fit until my standard one goes boom!


    So this is my progress so far and now still on the hunt for a downpipe and decat as I can't use my ko3s one, still fighting wether to go and buy the relentless package set manifold and downpipe, as I'm not looking to go over 300bhp! But who knows,just wanted to say a massive thanks to all the great info and support from everyone (prawn, beachbuggy, arron, nik rtech, and anyone else i missed) so I'm nearly there and soon will get things sorted and back to rtech! And look forward to meeting everyone again at ace or other events and learning more! This thread is just the route I am taking and feel free to ask for any info I'm not here to tread on anyone's toes or say this is the best way to do it, just best for me costs and my budget and has made me fall in love with my car again lol

    Thanks for looking and reading

    Bobby aka customboy
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  5. #4
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    Prawn buddy sorry for delay iPad issues lol but thanks for the vr6 maf info glad I won't be lodging my new maf element, so the hunt for a decat goes on lol !
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  6. #5
    Prawn's Avatar
    My other car is a MINI!!!!

    Status
    Online
    Join Date
    Dec 2006
    Location
    Basingstoke
    Posts
    9,358
    get the relentless manifold / DP combo Bobby, you know it makes sense!
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  7. #6
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    Where they easy to fit? Or did they suffer from loads of fitting issues mate ?
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  8. #7
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    Well I'm fitting the jetex once the reducer arrives and plumbing it into the airbox can't wait !
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  9. #8
    flying oyster's Avatar
    flying oyster

    Status
    Offline
    Join Date
    Jul 2009
    Location
    wimbledon
    Posts
    547
    exciting times bobby the jigsaw is nearly complete good work fella
    S3 8L ming blue westys old car shed loads of mods

  10. #9
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    I getting there Neil mate few more bits to go then I'm coming after ya!!
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  11. #10
    BENJAMIN's Avatar
    2nd Gear

    Status
    Offline
    Join Date
    Mar 2011
    Posts
    471
    I've got a standard k04 downpipe you can have for free. A relentless one would obviously be better though!

  12. #11
    Westy's Avatar
    Double Dark Side! Diesel & 8P

    Status
    Offline
    Join Date
    Dec 2008
    Location
    Cambridgeshire sometimes Hertfordshire
    Posts
    17,273
    Blimey, you're like some automobile bargain hunter

    Good luck with the build.
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  13. #12
    knoxie's Avatar
    K4OXE

    Status
    Offline
    Join Date
    Aug 2011
    Location
    harlow, essex
    Posts
    619
    he is a bargain hunter!!! good for keeping costs low, wish i had the time to look around for bits, badly want the car lower atm but cost so much on an s3 :-/
    Silver S3 02 AMK
    !!!!STANDARD S3 EXHAUST FOR SALE!!!!
    PM FOR DETAILS
    click here for
    IN AND AROUND THE M25 RING MEETS

  14. #13
    Paradox1's Avatar
    6th Gear

    Status
    Offline
    Join Date
    Aug 2011
    Location
    SoUf EaSt,Uk
    Posts
    1,829
    Quote Originally Posted by Customboy View Post
    Well I'm fitting the jetex once the reducer arrives and plumbing it into the airbox can't wait !
    Any chance you got that off E-bay.

    I missed the bit. damn it

    Good luck with the conversion though mate. Looking forward to seeing it completed

  15. #14
    Reverse Gear

    Status
    Offline
    Join Date
    Dec 2011
    Posts
    16
    Much love for this thread as Id like to go ko4 on my AUM but wouldnt know where to start so this will help greatly =D

    What sort of figures will you be looking at ???

    Also does anyone know what sorta figures you can look at before needing to uprate the internals???

  16. #15
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    Hi dark night well having listened to the great people here I'm looking for about 260-280bhp I would be more then happy with that, I do know that once u hit 300bhp and beyond engine will need stronger rods etc , I'm just looking for great useable everyday power with great reliability

    Benjamin where about are u mate your a star!!
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  17. #16
    Reverse Gear

    Status
    Offline
    Join Date
    Dec 2011
    Posts
    16
    Cheers mate much appreciated for that reply......once ive got a few more bits sorted out ill start with my list of components....im gonna go straight to ko4 rather than down the stage 2 route first.

    do you know would 260/270 be achievable with a ko3/ko4 hybrid?? as surely that would save swapping over alot of the components like the manifold and downpipe etc or is just as easy to get a new manifold / turbo and downpipe?

  18. #17
    Prawn's Avatar
    My other car is a MINI!!!!

    Status
    Online
    Join Date
    Dec 2006
    Location
    Basingstoke
    Posts
    9,358
    To be honest guys, there is no set figure at which you need uprated rods.

    Wellys rods failled at stage 1, around 250-260bhp on a tired old ko4 turbo

    There are all sorts of figures banded around, but to be honest, when your time's up.... BOOM!

    Age and mileage are playing a much greater part these days, when the S3 and LCR first came out and people were mapping them, they were new and fresh. They're now all 10years old or more, and getting on a tad.

    If bobby sticks with the standard manifold and downpipe I'd expect him to see 250-270bhp depending on engine health, if he fitted the XS manifold and downpipe, It'd be more like 270-290bhp
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  19. #18
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    Well at the moment car has only covered 88k got full Audi service history and replaced anything that makes a funny noise or problem but I'm liking the sound of 270-290 bhp lol maybe time to buy the relentless package !!!
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  20. #19
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    Anyone know if the relentless manifold and downpipe have any issues regarding fitting?
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  21. #20
    Jay A3's Avatar
    come fly with me

    Status
    Offline
    Join Date
    Mar 2011
    Location
    Greenhithe, Kent
    Posts
    1,786
    Prawn, Audi's are like Stilton cheese! They mature better with age!
    <Jay A3 build thread>



    241bhp K03s - R Tech

  22. #21
    Westy's Avatar
    Double Dark Side! Diesel & 8P

    Status
    Offline
    Join Date
    Dec 2008
    Location
    Cambridgeshire sometimes Hertfordshire
    Posts
    17,273
    Quote Originally Posted by Customboy View Post
    Anyone know if the relentless manifold and downpipe have any issues regarding fitting?
    I had fitting issues with the mani blocking access to the top DP bolt on the turbo:





    But I'm not 100% convinced that my mani is the same as the current batch as mine was the 1st one that welly got back after relentless/xs power made their revisions.
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  23. #22
    Reesy's Avatar
    6th Gear

    Status
    Offline
    Join Date
    Jan 2010
    Location
    East Sussex
    Posts
    3,604
    Talk is cheap, we want to see progress


  24. #23
    4th Gear

    Status
    Offline
    Join Date
    Feb 2012
    Location
    bedfordshire
    Posts
    748
    Good to see things rolling nicely mate ATB with the build and see yer at ace cafe

  25. #24
    BENJAMIN's Avatar
    2nd Gear

    Status
    Offline
    Join Date
    Mar 2011
    Posts
    471
    Quote Originally Posted by Customboy View Post
    Hi dark night well having listened to the great people here I'm looking for about 260-280bhp I would be more then happy with that, I do know that once u hit 300bhp and beyond engine will need stronger rods etc , I'm just looking for great useable everyday power with great reliability

    Benjamin where about are u mate your a star!!
    West Sussex mate. On the a23. I also have the exhaust hanger that bolts to the subframe for the ko4 setup.

  26. #25
    6th Gear

    Status
    Online
    Join Date
    Feb 2008
    Posts
    2,817
    You don't hang about bobby. Good luck with the thread bud.
    2000 AMK S3, Revo'd, forge 007p, B8's, H&R's, tarox g88's, ferrodo ds2500's, and in the fastest colour



  27. #26
    Prawn's Avatar
    My other car is a MINI!!!!

    Status
    Online
    Join Date
    Dec 2006
    Location
    Basingstoke
    Posts
    9,358
    Wierd that you have that issues Westy! mine wasn't even close there at all! bloody loads of room! Most odd. perhaps it's the perspective, but I don't recall having any issues.

    Bobby: on the whole, the products fit absolutely fine, BUT, they are difficult and fiddly to fit. they bolt on and work, but take a bit more time and patience than the average mechanic would be willing to put in. I think this is why some people have issues, because they pay a garage to do it, and they don't have the patience (or ability to charge) for the time it should take, and bodge them on as quick as possible.

    if it's your pride and joy, and you're willing to put the effort in, they fit, and they work unquestionably well
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  28. #27
    Reesy's Avatar
    6th Gear

    Status
    Offline
    Join Date
    Jan 2010
    Location
    East Sussex
    Posts
    3,604
    Remember that rods will be needed, just make sure to keep everyone informed in most threads or you'll always get people asking when you are going to do them!


  29. #28
    Westy's Avatar
    Double Dark Side! Diesel & 8P

    Status
    Offline
    Join Date
    Dec 2008
    Location
    Cambridgeshire sometimes Hertfordshire
    Posts
    17,273
    Quote Originally Posted by Prawn View Post
    Wierd that you have that issues Westy! mine wasn't even close there at all! bloody loads of room! Most odd. perhaps it's the perspective, but I don't recall having any issues.
    As you can see from the top pic, the bolt head doesn't even clear the mani runner. And pic 2 shows the hacked ground down heat to make it fit. When I change to studs I wont be able to get a nut on there so might need a custom nut with a collar to make that work. In hindsight I wish I'd put a slight dent in the runner when it was off.
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  30. #29
    <tuffty/>'s Avatar
    Badger 5 Edition

    Status
    Offline
    Join Date
    Sep 2008
    Location
    Gloucestershire
    Posts
    15,556
    Quote Originally Posted by Westy View Post
    As you can see from the top pic, the bolt head doesn't even clear the mani runner. And pic 2 shows the hacked ground down heat to make it fit. When I change to studs I wont be able to get a nut on there so might need a custom nut with a collar to make that work. In hindsight I wish I'd put a slight dent in the runner when it was off.
    I think this fitting of XS products can be largely dependant on manufacturing tolerances as it would seem they still vary (even if a better fit than any of the earlier ones).. I had to remove and shape the flange on an XS DP the other week for an S3 we had in...

    Simple advice is to test fit while the kit is off the car and make sure it all lines up as it should adjusting as required...

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

  31. #30
    Prawn's Avatar
    My other car is a MINI!!!!

    Status
    Online
    Join Date
    Dec 2006
    Location
    Basingstoke
    Posts
    9,358
    ^^^ Couldn't agree more PT, I have a spare head on the bench and I test fitted everything to it before installing on the car, it made my life so much easier!
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  32. #31
    Westy's Avatar
    Double Dark Side! Diesel & 8P

    Status
    Offline
    Join Date
    Dec 2008
    Location
    Cambridgeshire sometimes Hertfordshire
    Posts
    17,273
    Well I did do a test fit lol:



    I knew it would be tight so we modded the bolt to fit instead of denting anything. Seemed like a good idea at the time.
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  33. #32
    superkarl's Avatar
    MAN OF STEEL

    Status
    Offline
    Join Date
    Mar 2010
    Location
    Liverpool/Southport. N west
    Posts
    7,533
    i think when i fit my xs downpipe i might compare the 2 flanges and mate them together to see how they match, and if need be get the grinder out and trim the xs to exactly the same profile as oem. If its all that different.

  34. #33
    Customboy's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    SE London
    Posts
    836
    More great info thanks everyone maybe time to lighten my wallet!!
    p

    THE BLUE BEAST, TAKEN FROM ME, GONE BUT NOT FORGOTTEN
    RTECH STAGE 2 REMAP NOW RUNNING 223 BHP AND 253 FTLB OF TORQUE,
    SUBARU IMPREZA WRX ESTATE SOON TO BE RUNNING 340 BHP
    ANTI LAG/LAUNCH CONTROL/MAF LESS/ LOVE IT !!

  35. #34
    BENJAMIN's Avatar
    2nd Gear

    Status
    Offline
    Join Date
    Mar 2011
    Posts
    471
    They're certainly a tight fit!!


  36. #35
    Westy's Avatar
    Double Dark Side! Diesel & 8P

    Status
    Offline
    Join Date
    Dec 2008
    Location
    Cambridgeshire sometimes Hertfordshire
    Posts
    17,273
    Ben, did you get a nut on that top stud ok? Look how much closer mine is in comparison.
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  37. #36
    Prawn's Avatar
    My other car is a MINI!!!!

    Status
    Online
    Join Date
    Dec 2006
    Location
    Basingstoke
    Posts
    9,358
    and mine was so far away I honestly don't even remember there being the potential for a clash, and that's on two manifolds now!
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  38. #37
    BENJAMIN's Avatar
    2nd Gear

    Status
    Offline
    Join Date
    Mar 2011
    Posts
    471
    Out of 4 of these I've fitted now. Only one was really tight to get a nut on! I use downpipe securing nuts with a 15mm hex, makes it easier to get a socket on to tighten them.

  39. #38
    5th Gear

    Status
    Offline
    Join Date
    Aug 2010
    Location
    bradford
    Posts
    1,252
    hi customboy ill have my v1 xs power downpipe and decat for sale soon depending when u want it pal and good look with the progress
    350bhp & 316ftlb BBT new k16 7+7 blade hybrid turbo, Welly cooler, jetex filter, relentless ported v3 manifold 3" downpipe & de-cat, liquid gauge, r32 rear arb, AGU ported and polished Head, 550cc injectors, kw v2 Coilovers, s3dave tie bars & heat sheild, milltek cat back, I.E forged rods, brembos, inline fuel pump, v3 badger 5 tip, devils own WMI kit, AGU pistons, rear grooved discs & brembo pads, ds2500 pads & EBC ultimax disc, stack boost gauge

  40. #39
    ChaddyA3's Avatar
    1st Gear

    Status
    Offline
    Join Date
    Jan 2012
    Location
    South Africa
    Posts
    254
    Wow nice progress buddy and really taking tips here :-) thanks for the heads up aswell :-) will be asking alot of questions soon i hope ;-) Happy building and good luck buddy Cheers
    As Long as you in an Audi.......You doing it best!



    Specs:


    -Audi A3 8l 1.8T Silver 2003

 

 

Similar Threads

  1. Jay A3 KO4 build
    By Jay A3 in forum A3/S3 Forum (8L Chassis)
    Replies: 653
    Last Post: 5 Days Ago, 21:02
  2. my new s3 8l progress thread
    By s3schofield in forum A3/S3 Forum (8L Chassis)
    Replies: 26
    Last Post: 2nd June 2014, 18:59
  3. W3STY's Progress Thread
    By Westy in forum A3/S3 Forum (8L Chassis)
    Replies: 3583
    Last Post: 4th March 2014, 12:55
  4. RS4 b5 progress thread
    By colicabcadam in forum RS4 Forum (B5 and B7 Chassis)
    Replies: 28
    Last Post: 10th December 2012, 11:25
  5. Progress Thread
    By MickM in forum A3/S3 Forum (8L Chassis)
    Replies: 9
    Last Post: 30th May 2010, 21:29

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Single Sign On provided by vBSSO

Garage Plus, Vendor Tools vBulletin Plugins by Drive Thru Online, Inc.

Content Relevant URLs by vBSEO