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Thread: A3 Quattro TDI Re-Shell Into Audi TT225

  1. #1
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    A3 Quattro TDI Re-Shell Into Audi TT225

    Hey guys and girls fairly new to the site, but thought it was time to start my little build thread

    So for the last 3 years ish now i have been rocking around the shows in this



    but the time has come to build something new so i saved a few pennies and decided to buy this little toy :P






    found it down in s****horpe, so i have a run down from newcastle 1 night to collect her, turns out the previous owner to this lad lived about 5 miles from me haha so its come back home lol.

    before buying it i already new some of the plans i wanted to put into effect on this so i got to it, and then this happened






    and thats the engine and box all out ( god knows why im stripping a perfectly good working car :S lol)

    but anyways its all for a good cause .

    i forgot to take pics of some of the stages but i have bought an R32 steering rack, and fitted that when i stripped off the subframe for cleaning and painting. i also removed all hubs and trailing arms front and rear and spent a small fortune on these little beauties




    some nice rose jointed wishbone bushes to fit in my S3 cast wishbone and hub setup, so fitted those new ball joints, new genuine wheel bearings and inner + outer tracking arms the full front end is nearly brand new. A few weeks ago i also bought some of S3daves adjustable rear camber arms and fitted them along with the rest of the rear black series powerflex bushes, its going to be so stiff and handle like a beast!! lol

    also started to replace every brake line on the car with braided hose, will follow up with pics later.

    started to hunt for a new set of wheels for the ca as i didnt like the 18s that where on the car when i got it, so i found these S3 wheels local to me for a damn good price aswell but just needed a refurb,





    so i sent them of to get painted and they came back like this


    Last edited by Sandra; 12th November 2013 at 15:01. Reason: Title change
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  3. #2
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    then the next bit of purchasing began




    managed to pic these up at a nice cheap price so i could not resist and they also ended up like this :P


    now that those bits are all done, i let a few weeks go buy and it was time to start playing with the spare engine i purchased :P the fun begins.

    The engine came out of a crash damaged car which mounted a kurb and smashed the sump and gear box all over the road, so that ended up being no good to me, so the stripping began



    once the block was all stripped it went away to get deep cleaned at my mates workshop, came back all gleaming. Then the story continued as these arrived :P



    Brand new BHW 2.0l 81mm TDI pistons thanks to Ryan@darkside for helping me out on this so far with parts i need :P

    and that was the block away to get bored out to the correct size for the pistons, eagerly awaiting its return i was so i could carry on.

    next purchase was to be the connecting rods, so straight back on the phone to ryan for more bits. so i ordered Rods, new 2.0 headgasket, crank bearings, rods bearings cam end seal and injector hold down boats.

    [



    rosten H beam rods connected to my BHW pistons.

    that was me skint for a little while so i started working on the interior about more, stripped all the seats out steering wheel off and generally tidied it up.

    next purchase was to be a nice custom single mass paddle clutch :D that was to be created by dubforce who i had spoken to previously at VW festival
    Nigel was a great help and talked me through everything he was going to do, he clearly has his head screwed on and is going to be very well recommended by my so this is what arrived




    ooo all these parts are looking amaziing, seems a shame that none of them are going to be seen and all covered in oil or blocked by the gearbox lol

    and that was it, the final part i needed to send it all away to get balanced together :D sooo happy, i got everything i needed together and taken over too the engine shop in a rather large box along with my crank lol and this is how it all looked, minus the crank.



    and this is about as far as i have got up too now, alot more parts to buy.... but give me a little time and they will be ordered, hope you enjoyed the read so far and keep looking back for more updates, oh and petrol boys, be afraid, be VERY afraid :P mwahahaah
    Last edited by Sandra; 11th October 2013 at 17:27.

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    Fantastic. Please keep this thread updates regularly! Nice to see something different.
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    2008 8P S3- Black edition. 'all the options....'

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    Great write up so far, what power/torque are you hoping for I love tuned dervs I've had loads of pug 306td in the past
    2001 s3, stage 1 amk, nogaro blue, bilstein shocks, eibach springs, forge adjustable tie bars, Red power flex dog bone bush, Awesome heavy duty clutch, 18" nouvalari alloys, ambient lighting, tt pedals, led side lights, led number plate lights, abt number plate surrounds, badger 5 tip, jetex filter, resonated milltek cat back exhaust, bailey dv,

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    Very nice, Pinks a brave color but them wheels pull it off

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    Wow, very different indeed, and seems to be well thought out!

    really looking forward to seeing where this goes

    what are the plans engine wise?
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    You're brave, going for a single mass flywheel with rose joints in the front arms and powerflex black bushes / mounts!
    Vibrations ahoy!

    Nice build though, brings back memories of my PD rebuild. Can't beat their performance for the economy when tuned.

    What turbo are you going for? Keeping standard injectors?

  9. #8
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    Do love an oil burner. Also interested to hear what the plans for the engine are.
    '02 A3 TDI quattro sport

    8L IS DE BEST

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    Nice to see something different.
    2000 AMK S3, Revo'd, forge 007p, B8's, H&R's, tarox g88's, ferrodo ds2500's, and in the fastest colour



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    My other car is a MINI!!!!

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    I hate oil burners, there the plague of the earth, but I do admire anyone mad enough to carry on regardless and tune one to such extremes

    hats off to you !
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  12. #11
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    I don't think Ive ever seen pics of the inside of a diesel engine. Great thread so far keep it up, this will be a beast by the looks of it.
    8P A3 TDI - 220bhp - 335lbft
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    You are a god dam hero.

    What is that pink? Or is it custom mixed? I like
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    I know of a tuned golf 1.9 tdi which had about 240bhp and still returned over 25 mpg even though it had the tits thrashed out of it every second of its life, got to admire a tuned tdi.

    I like this thread!

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    I love this!!

    Good luck with the project. I'll keep an eye on this one!
    Word!!!

    My A3/Martys Golf would smash that, and this guys £7000 GT9743 supercharged love machine.

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    Quote Originally Posted by Westy View Post
    I don't think Ive ever seen pics of the inside of a diesel engine. Great thread so far keep it up, this will be a beast by the looks of it.
    Looks the same as every other naked 4 pot block - boring compared to bigger bretheren

    Quote Originally Posted by smurfworth View Post
    I know of a tuned golf 1.9 tdi which had about 240bhp and still returned over 25 mpg even though it had the tits thrashed out of it every second of its life, got to admire a tuned tdi.

    I like this thread!
    Even more impressive is when it is cruising on the motorway at 60/70 will return stock MPG of 50+!

    This looks like a fantastic project. I must ask though, what power are you trying to acheive, as 240bhp can be had without the block and rods flinching, the PD guts are mostly forged from the factory. So although rods are always a good idea, and the 2.0 pistons and rebore will gain you some tidy additional torque, its all a bit of a waste (dont mean to criticise).

    These engines will do 220-230bhp with a hybrid turbo and a remap (see turbo dynamics MD376), and return 45MPG when cruising all day long.

    If you want 260 - 300 you are looking at a GTB1756 - GTB2026 with big valve head before any additional strengthening is needed.

    Anyways, hats off to you you, keep up the good work.

    And excellent choice of motor
    A3 PD130 TDI Quattro - the discerning mans choice
    (or as I like to think of it the rarer more exclusive S3 derv edition)

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    Quote Originally Posted by Kave View Post
    Looks the same as every other naked 4 pot block - boring compared to bigger bretheren



    Even more impressive is when it is cruising on the motorway at 60/70 will return stock MPG of 50+!

    This looks like a fantastic project. I must ask though, what power are you trying to acheive, as 240bhp can be had without the block and rods flinching, the PD guts are mostly forged from the factory. So although rods are always a good idea, and the 2.0 pistons and rebore will gain you some tidy additional torque, its all a bit of a waste (dont mean to criticise).

    These engines will do 220-230bhp with a hybrid turbo and a remap (see turbo dynamics MD376), and return 45MPG when cruising all day long.

    If you want 260 - 300 you are looking at a GTB1756 - GTB2026 with big valve head before any additional strengthening is needed.

    Anyways, hats off to you you, keep up the good work.

    And excellent choice of motor
    I'm currently running 250 flywheel bhp on the bora atm, 211 t the wheels, it goes like their is no tomorrow its awesome, just done a round trip to wales and managed to plug 66mpg!!! done 690 miles on a tank of regular diesel :D super happy with that.

    power wise guys I'm trying to get into the 300's which should be easily achieve able with the mods I'm doing and more to come :P

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    Quite a few people breaking the 300 mark now so would be awesome to see that with quattro. Darkside`s Arosa doing a 10.8 at pod was epic.

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

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    Hey guys sorry for the slight delay in updates, been busy busy. Been collecting more parts and doing more mods, but the biggest update is that i have had a change of heart in the shell its going into, its going to be even more unique :P but all will be revealed in due course

    so heres an update: decided it was about time to splash out bait more cash towards the build,

    started to look into new engine mounts for the build and their are a lot of good stuff out their, but what i finally decided on due to quality and they look freaking awesome is the black forest industry mounts as pictured below, I'm sure these will help with the stiffness :P



    next on my list was something that would keep the car stuck to the floor on the corners and have a slightly comfier ride then the normal crap coil overs you can buy,
    decided on a set BC racing BR coil overs, they have fully adjust compression and rebound dampening so they should set up a treat








    next i started to think about g=how to keep this thing cool, picked these up for a steal of a price from the bay my new direnza alloy radiator and universal charge cooler
    the alloy rad has a nice think core on it so its going to help keep engine temps ok, and the charge cooler is going help keep intake temps down too.



    inlets on this bad boy are 3.5" its going to be fun getting the size down with such a short boost circuit lol








    i'd been having thought about all this power I'm going to be running through the car and thinking about starting track days, now in the back of my mind I've thought what if it bin it and have a bad crash, or someone crashes into me, its going to cause a lot of damage, so i invested more money into chassis mods, with a full weld in 6 point roll cage from custom cages, :D this thing is a work of art with all its bends, don't have any tease pics of it just this 1 for now, but more can be revealed once the new shell has been announced


    the next piece of the puzzle to arrive in the post at work where these babies, a set of +120% farad injectors and my fully rebuilt GTB2260vk turbo with vacuum actuator conversion, all received with help again from Ryan and Scott @ darkside developments


    Then finally the bit you lot have possibly been waiting for is my engine back from the engine builders :D this baby is a work of art (does need another lick of paint before I'm happy yet though)



    haha just teasing guys heres the nice pics :P lol





    off up to high flow heads tomorrow to drop in my cylinder head for gas flowing so more updates coming soon

    hope your enjoying the read guys
    Last edited by Sandra; 11th October 2013 at 20:57.
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    Its going to be an S3 shell isnt it lol.

    Aslong as its quattro im not fussed what it`ll be. I just know its going to smash 95% of the cars in this section when its finished.

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

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    Quote Originally Posted by Jason.s View Post
    Its going to be an S3 shell isnt it lol.

    Aslong as its quattro im not fussed what it`ll be. I just know its going to smash 95% of the cars in this section when its finished.
    im sorry to say jason your not right on the shell, but yes it is still a quattro shell

    haha thanks mate, yeah im really hoping so

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    Shame would have been funny seeing an S3 Diesel lol.
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    Cactus green 8L S3 - B5 TIP + Jetex, Revised 007p, R32 rear ARB, AP Coilovers, Compbrake rear arms, Full Powerflexed dogbone.

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    Quote Originally Posted by Jason.s View Post
    Shame would have been funny seeing an S3 Diesel lol.
    Haha dont worry this will possibly annoy people more :P

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    Still Audi? Is it a TT? lol

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    Quote Originally Posted by Jason.s View Post
    Still Audi? Is it a TT? lol

    all details and more will be revealled in a later episode :P

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    grr lol

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  27. #26
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    My other car is a MINI!!!!

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    TT Coupe I'm guessing.
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  28. #27
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    My other car is a MINI!!!!

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    You can't go sneaking around asking questions about haldex things then not tell us what you're planning, it's not fair
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    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

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  29. #28
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    Quote Originally Posted by Prawn View Post
    You can't go sneaking around asking questions about haldex things then not tell us what you're planning, it's not fair
    dum dum dummmmmm :P cage is 3/4 in so wont be long before an update lol
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  30. #29
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    talk about a cliff hanger lol... this will be epic good job...
    1999 apy s3, n249 delete, sai and n112 delete. bbs lm reps, s2000 filter, relentless v3 manifold, relentless downpipe and sports cat, scorpion cat back system, badger 5 v3 tip, bam rocker cover, push in coilpacks, toyosports fmic, amd remapped to 280.3 bhp and 263.9 lb/ft.

  31. #30
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    just a little update guys been working on the car the last few night doing bit and bobs here's a couple of pics for you

    fitted the new bc racing coil overs, went in nice and easy and look awesome, fitted with brand new genuine strut top bearings and black series poly top mounts to match everything else black series, just a slight difference in shock length :P



    oh and fitted some little porsche 911 4 pots with 334mm R32 discs swell :P lol



    was up at high flow heads the other week dropping my head and the rest of the stuff off to get port and polished and built, heres a sneak pic of a previously done 1.9tdi head already done for a big diesel tuning company we have all heard off lol this is what mine will look like when i received it back next week





    then was a spot of welding to be done, every1 loves a good welding pic lol



    the start of the roll cage floor plates going in have more of these but not sure about reviling atm lol



    this is how my charge cooler setup will be fitted, but won't be using that small little manifold, i have a nice BIG 1 to go on :P but this is just for example



    oh almost forgot, i have completed the full braided brake lines setup throughout the whole car, wasn't cheap but they look awesome in the bay hope every1 is enjoying this so far
    Last edited by Sandra; 11th October 2013 at 20:59.
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  32. #31
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    Looking good mate!

    One thing about the brakes: are you sure they're R32 discs?

    Looking at the re-drilling, I'd say they're most likely 996 fronts with Alfa brera 330x28 discs redrilled. Bloody good kit either way.

    This is going to look lovely on the TT Not that you've told us it's a TT yet.
    -------------------------------------------------------------------------------------------------

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  34. #33
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    dieSel3 ftw <------ see what i did there, thats my guess

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    Full black series bushes across the car? This thing is going to be a weapon. Bone shattering on the road but epic all the same lol.

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

  36. #35
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    Quote Originally Posted by Prawn View Post
    Looking good mate!

    One thing about the brakes: are you sure they're R32 discs?

    Looking at the re-drilling, I'd say they're most likely 996 fronts with Alfa brera 330x28 discs redrilled. Bloody good kit either way.

    This is going to look lovely on the TT Not that you've told us it's a TT yet.
    As far as i was aware prawn they where R32 discs but you may be correct i will do some digging on this

    no1 has mentions TT PRAWN :P


    QUOTE=superkarl;1966995]dieSel3 ftw <------ see what i did there, thats my guess[/QUOTE]

    love keeping you guys guessing :P

    Quote Originally Posted by Jason.s View Post
    Full black series bushes across the car? This thing is going to be a weapon. Bone shattering on the road but epic all the same lol.
    yeah its going to be rigid, black cries bushes, upper and lower front braces, black forest poly engine mounts think I'm going to loose some teeth :P lol

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    Was just talking to a tech here that used to work for the TTShop and he said he fitted some black forest engine mounts to a TTRS and he said they were really nice. Not too much cabin vibration but were nice and firm.

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

  38. #37
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    Quote Originally Posted by Jason.s View Post
    Was just talking to a tech here that used to work for the TTShop and he said he fitted some black forest engine mounts to a TTRS and he said they were really nice. Not too much cabin vibration but were nice and firm.
    well thats a good think to hear Jason.s hopefully its isn't un-driveable as its going to be my daily :P lol

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    Scrolling futher up they look like the stage2 mounts? 85shore so yeah might be quite hard then lol.

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

  40. #39
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    Quote Originally Posted by Jason.s View Post
    Scrolling futher up they look like the stage2 mounts? 85shore so yeah might be quite hard then lol.
    yeah they are stage 2, was only around £20 difference so i thought why not when I'm spending so much just pay the little extra for what it was, plus a nicer colour then yellow lol

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    They`d match my car colour...

    Take it you got them from regal?

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