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Thread: A3 Quattro TDI Re-Shell Into Audi TT225

  1. #41
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    Quote Originally Posted by Jason.s View Post
    They`d match my car colour...

    Take it you got them from regal?
    yeah they came from regal, bit of a nightmare to get a hold of but once they eventually went and looked of the mounts and posted them they where here next day lol
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  3. #42
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    Awesome project you have going on here.

    I'm going to look like the thick one but how does the charge cooler work? are they air con pipes going into the core?

  4. #43
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    Quote Originally Posted by Paul_TDi View Post
    Awesome project you have going on here.

    I'm going to look like the thick one but how does the charge cooler work? are they air con pipes going into the core?
    dont be daft dude, its all about learning

    the charge cooler runs from a seperate water bottle with an inline pump, and just recirculates it it has a small radiator somewhere at the front to cool the water down

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    Ohhhh, same as a water cooled PC set up then. Cheers.

    Shame it's not going back into the A3, I have a A3 Quattro TDi myself.

  6. #45
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    Quote Originally Posted by Paul_TDi View Post
    Ohhhh, same as a water cooled PC set up then. Cheers.

    Shame it's not going back into the A3, I have a A3 Quattro TDi myself.
    yeah basically the same as tht mate, ahh really you done a thread or put pics o it up??

  7. #46
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    A3 Quattro TDI Build - NEW SHELL REVEAL

    im not doing to well at posting frequent updates but here is another 1 for you guys

    all that have read through my thread know that their is a change in shell coming, so i have been working on that the last couple of weeks and its taking great shape

    diesel fuel pump is all changed over and now in tank,
    filler neck is all modded to take diesel neck,
    glow plug wiring and relay all in and ready to be connected up,
    engine harness and ecu all in place and unlocked,
    fuel lines all fitted and diesel cooler ready to be mounted
    full car re-done in braided brake lines

    But now the time has come for the new shell reveal i bought a black y reg 225 TT back in july as a nice cheap doner car with all the usual 225 spec, xenon lights, full black leather, twin exhausts, all the normal stuff lol with the intent of making it something different :D

    ive managed to loose the pictures from when i first got her but here is some progress pics of her

    started stripping ready for the cage to get installed





    and here is some of the cage in mid fitting







    decided to cover windows at the start with application tape from work to save grinding and welding rash all over them lol



    decided to do some trial fittings to see how i wanted the door bars to fit and this is what i had initially decided on



    since i had decided on how my door bars where going to sit, i thought id start getting the seats into position



    and glovebox mounted ( with abit modification too lol)



    got back in the car this weekend and got the cage all painted up but changed my mind about the door bars whilst welding them in, as its going to be a daily i decided to just go with this setup instead







    still making it safe and easier to get in and out of as its a daily

    also got these couple of bits, adaptor to mount my gauge in the vent, and the startings of my tubular manifold, also hoping to have my fully built head back this week aswell with pics to follow



    hope you are all enjoying the read and look forward to reading your comments and PRAWNS " i told you so" speech :P
    Jason.s, StaceyS3, Sam_ and 2 others like this.

  8. #47
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    Diesel TT track car. Epic haha
    ScottD3, Sam_ and Airs like this.

    Cactus green 8L S3 - B5 TIP + Jetex, Revised 007p, R32 rear ARB, AP Coilovers, Compbrake rear arms, Full Powerflexed dogbone.

  9. #48
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    Are you going to gusset the cage to the A + B pillars?
    Handling mods++. GTX30 soon-ish. Hiding parts from the mrs since 2011. Build thread

  10. #49
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    That, is 100% amazing! Absolutely LOVE it!!!!!

    i told you it would be a TT
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    Prawns TFSI Turbo'd 1.8T Track Car

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  11. #50
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    Quote Originally Posted by Sam_ View Post
    Are you going to gusset the cage to the A + B pillars?
    na sam_ its just staying how it is, that is how custom cages spec'd it mate

  12. #51
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    Quote Originally Posted by Prawn View Post
    That, is 100% amazing! Absolutely LOVE it!!!!!

    i told you it would be a TT
    haha thanks alot mate :P i thought no one has really fone it, so why not be the knacker that does lol

    yeah you did, but i couldnt give it away that easy lol

  13. #52
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    Good that youl have 4wd to put down all the torque
    s3dave and Airs like this.

  14. #53
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    Quote Originally Posted by superkarl View Post
    Good that youl have 4wd to put down all the torque
    Yeah karl that was my main thing for the new building, my bora is running 1 of these turbos already at around 230 bhp and it just spins the wheels up for fun lol

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    what sort of figures are we looking at? On darksides website it seems they run anywhere between 230 and 300 with like 360 torques?

    Cactus green 8L S3 - B5 TIP + Jetex, Revised 007p, R32 rear ARB, AP Coilovers, Compbrake rear arms, Full Powerflexed dogbone.

  16. #55
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    Quote Originally Posted by Jason.s View Post
    what sort of figures are we looking at? On darksides website it seems they run anywhere between 230 and 300 with like 360 torques?
    im hoping for around 320+ jason, those figures you mentioned are based on:

    1.9 bottom end - mine is now a 2.0 with bigger pistons
    fard +80%injectors - i have +120% injectors
    standard cam - i have an uprated cam
    standard head - mine is all ported and gas flowed along with inlet manifold too ( plus not using a standard 130 tdi inlet, i have something alot different lol)
    standard/uprated intercooler - im running a charge cooler so will get lower inlet temps
    plus i will be running water meth so that will help a little too

    have an update coming later today hopefully as my head arrived back yesterday all built and was at darkside picking up some more goodies too lol
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  17. #56
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    Should be a proper animal then!

    Look forward to more updates and pictures.

    Possibly one of the most exciting builds to come from here in a while. Shame most people will probably see diesel build and ignore it.
    Airs likes this.

    Cactus green 8L S3 - B5 TIP + Jetex, Revised 007p, R32 rear ARB, AP Coilovers, Compbrake rear arms, Full Powerflexed dogbone.

  18. #57
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    Quote Originally Posted by Jason.s View Post
    Should be a proper animal then!

    Look forward to more updates and pictures.

    Possibly one of the most exciting builds to come from here in a while. Shame most people will probably see diesel build and ignore it.
    yeah im hoping for it to be abit of an animal and really surprise some people :P lol

    i will see if i can get more updates today mate

    cheers for the comment, i really appreciate it, i wasnt even going to do a build thread at the tart tbh, but im glad i have now as their has some genuine interest in it
    Jason.s likes this.

  19. #58
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    definitely one of the more exciting and different builds on here, really looking forward to it!

    Certainly has the potential to re-write the rule book on soot chuckers!

    Hurry up and do something else that we can look at
    Airs likes this.
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  20. #59
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    Got a nice phone call from my dad yesterday saying there was a couple of big boxes arrived for me at home midday yesterday whilst i was already on my way to darkside for more toys lol (boost gauge isnt connected atm)



    this is what i came away with, not the best photo but all bundled up nicely on me passenger seat lol



    brand new GTB2260vk, Braided oil feed, Custom oil return pipe and 6 speed clutch slave cylinder

    so upon arriving home i seen this laying in the middle of the floor in my unfinished living room (house is undergoing and extension so its totally upside down atm lol)



    i was like a small child at Christmas unwrapping presents
    first box contained my inlet manifold, which is possibly going to spark a few questions :P lol



    it came back absolutely gleaming and freshly painted silver

    next was a slightly bigger box, i wonder whats inside this 1



    any guesses yet?? and yes that is my tumble dryer in the living room lol



    and here it is











    i was totally astonished when i opened the boxes to see them, their was never any mention of them being painted and being made to look so new, the service i have received from HIGH FLOW HEADS is 2nd to none, this is 1 guy that i will definitely be recommending to people for work to be done, so any1 after and head flowing, or any head or engine work at all hit up Andy at high flow heads, he is a sound guy and will help you every step of the way

    more updates to come, keep your eyes peeled guys

  21. #60
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    Quote Originally Posted by Prawn View Post
    definitely one of the more exciting and different builds on here, really looking forward to it!

    Certainly has the potential to re-write the rule book on soot chuckers!

    Hurry up and do something else that we can look at
    haha thanks a lot prawn i appreciate it

    their is a little update for you lol

  22. #61
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    Quote Originally Posted by Airs View Post


    i was like a small child at Christmas unwrapping presents
    first box contained my inlet manifold, which is possibly going to spark a few questions :P lol


    I'm sure there's a genuinely exciting reason why this should spark off a few questions, but I think the honest truth is, that so few of us know anything at all about these engines that most of us won't have a clue what it is myself included!

    perhaps that's why it's so interesting, it's all unknown and new to everyone.

    either way, I think it's awesome.
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  23. #62
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    I remember High Flow Heads from my Peugeot days, although his results in those days weren't anything to write home about. Hopefully he's better these days! That was like 6 years ago now.
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    Handling mods++. GTX30 soon-ish. Hiding parts from the mrs since 2011. Build thread

  24. #63
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    Quote Originally Posted by Prawn View Post
    I'm sure there's a genuinely exciting reason why this should spark off a few questions, but I think the honest truth is, that so few of us know anything at all about these engines that most of us won't have a clue what it is myself included!

    perhaps that's why it's so interesting, it's all unknown and new to everyone.

    either way, I think it's awesome.
    you may well be right the PRAWN, i keep forgetting ive been doing this for a few years now lol

    on all the 130/150 bhp diesel golfs/boras etc etc this is 1 of the standard inlet manifolds



    the are a good manifold for upgrading the small bhp diesels, but for the power im wanting i thought if i can get a bigger inlet manifold is should flow alot better,



    this manifold is actually from a 6 cylinder volvo none turbo that they use more over in europe, they are as rare as hens teeth over here, so with a little guidance from 1 of my friends i got may hands on this 1 and decided to lop 2 of the ports off and re modify the internal ports from being oval as standard to the D shape that the standard 1 is

    but the realy strange thing about this manifold is that its all stamped with VW part no's lol priced 1 up from TPS and they wanted £750!! i nearly collapsed lol

    sorry for the little rant, just thought id explain lol

  25. #64
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    It`s all interesting stuff dont worry. Ramble on lol
    Airs likes this.

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  26. #65
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    Quote Originally Posted by Sam_ View Post
    I remember High Flow Heads from my Peugeot days, although his results in those days weren't anything to write home about. Hopefully he's better these days! That was like 6 years ago now.
    yeah sam he does alot of pug/cit stuff for the rally cross boys, his work seems to be very very good i had a flowed head on my old clio 172 a few years back, and holy hell it revved like their was no tomorrow!!

  27. #66
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    Quote Originally Posted by Airs View Post
    you may well be right the PRAWN, i keep forgetting ive been doing this for a few years now lol
    Why is my name Shouted :'(

    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  28. #67
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    Quote Originally Posted by Prawn View Post
    Why is my name Shouted :'(

    Sorry dude, i glanced at it on your avatar and thought it was caps lol apologies Prawn

  29. #68
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    Its a D24 manifold, they're not that uncommon!

    They're used on older VW LT vans, as well as the Volvo 240 and 740 diesels.

    I guess its just that the vehicles they were fitted to have mostly rotted away at this point, they're a bit harder to get hold of!

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  30. #69
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    Quote Originally Posted by aragorn View Post
    Its a D24 manifold, they're not that uncommon!

    They're used on older VW LT vans, as well as the Volvo 240 and 740 diesels.

    I guess its just that the vehicles they were fitted to have mostly rotted away at this point, they're a bit harder to get hold of!
    yeah thats what i thought mate but this is different to the LT model, my mate ARD has 1 similar to this aswell

  31. #70
    "Stick a V8 in it!"

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    Its not different, its the same part number thats listed in ETKA against the LT 2.4 Diesel

    There were a few other manifolds used as well though, on the turbo models.

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
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  32. #71
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    Another small update, with more to follow at the weekend

    managed to get alot of my interior trim back into the car over the last weekend, along with so much needed bmxing and a charity do lol

    some of the trim needed to be modify to go around the cage but looks ok now its in







    i need to make some ducts to fill in the gaps where the dash was cut for the cage and to point the vents up on the windows too
    but A pillars went back in with modification lol



    and centre console



    plus the roof linking which im chuffed about yo can see where i had to trim the A pillars as the go right accross the top of the doors, but the cage touches the roof sides so needed modding



    and couple of bits i had laying around that i forgot about, my 2.0 8v head gasket, custom tdi head studs



    spent an hour or so last night in next doors garage painting my engine with another couple of coats, was looking glossy but hoping it finishes up matt, will follow up with pics tonight hopefully.

    Roll on the weekend, hoping to get the top and bottom mounted together and some ancillaries put back on her keep your eyes peeled
    s3dave, Jason.s, StaceyS3 and 1 others like this.

  33. #72
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    just another small update,

    decided it was time to start fitting more engine parts, so got the head studs out the box and fitted those, plus ancillary bracket, thermostat, modified oil filter housing and couple other small parts







    started to fit the head all on and started torquing it down, and had a small mishap with 1 of the studs, so this has knocked me back a little with the engine, but its getting dropped off tomorrow to hopefully get sorted out,

    my tubular exhaust manifold is vey near completion (eventually!!) so hoping to receive that back in next couple of days and will upload some shots of that too.

    a few more goods have landed from TPS too so will get some pics tonight of those too
    Jason.s, StaceyS3 and Sam_ like this.

  34. #73
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    Very jealous of this, that cage inside the TT just looks amazing!
    Airs likes this.
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  35. #74
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    Quote Originally Posted by Prawn View Post
    Very jealous of this, that cage inside the TT just looks amazing!
    Cheers Prawn it was a nightmare to fit, first time doing 1 and can honestly say i don't think i would again lol welds arnt the neatest but its structural :P lol

  36. #75
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    Well ladies and gents here goes another update

    whilst I've been waiting for my engineers to get this snapped head stud out i decided to get my new wheels out of the shed and give them a coupe of coats of wax and heres how the first 1 looks



    and with the flash on they look like this :P (just ignore the trainers, i may of been polishing them in the house where it was warm lol )



    also got a call of the dude fabricating my tubular manifold to say it was ready





    once i stripped it all off the old engine we noticed their was still some metal filings inside of the manifold so we cleaned it all out with spray degreaser and cleaner, then go bait stupid, but got some cool pics lol



    cam was all re-bolted down, injectors fitted into the head, injector loom fitted, and surface all cleaned for rocker cover



    Flywheel, clutch plate and pressure plate all fitted, for it being a custom billet flywheel, their is still some bloody weight in it!!



    engine all timed up, belt covers re-fitted, new water pump,



    Gearbox all fitted and re-painted (quickly)



    and then the exciting bits started t happen :D





    big inlet fitted





    still some finishing to do on the inlet to make it look more asthetically pleasing,

    one question for some of the more knowledgeable people, when i have mounted the turbo up to the manifold on the engine, when you stand at the rear where the turbo is, the turbo sits slightly on the wonk and the core is not perfectly vertical :S does this make any difference to it?? its not massively out but it is out, any help would be awesome thanks
    s3 Hoggy, Jason.s and StaceyS3 like this.

  37. #76
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    Nice work dude... great to see an actual TDi tuning project... bit thin on the ground in this section and something I personally have no experience of...

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

  38. #77
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    Quote Originally Posted by <tuffty/> View Post
    Nice work dude... great to see an actual TDi tuning project... bit thin on the ground in this section and something I personally have no experience of...

    <tuffty/>
    Thanks <tuffty/> yeah not a lot of people really going this deep into it tbh, i have cam across a few stumbling blocks along the way finding some bits and using things from different engines accros the board, wether it be petrol or diesel lol

    can't wait to get it all up and running, especially with this bad weather we are meant to be getting :P 4x4 for the win
    <tuffty/> and Westy like this.

  39. #78
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    Just looked through this all, pretty fricking cool! Cant be many diesel 8n's around .

  40. #79
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    Quote Originally Posted by Rice View Post
    Just looked through this all, pretty fricking cool! Cant be many diesel 8n's around .
    hey matey thanks for looking, as far as im currently aware, their is 1 2wd 8n in the uk and 1 quattro in the states

    so pretty rare lol

  41. #80
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    proper love this

 

 
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