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Thread: BAM S3 full rebuild for Hybrid or BT

  1. #241
    hoffmanvp3's Avatar
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    Well look what turned up while I was in Saudi
    BBT Hybrid KO4




    Just waiting for a Relentless V3 exhaust manifold to come up for sale if any one knows one

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  3. #242
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    Probably dirtier than the one that came off!

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

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    I have a Relentless V2 (better than v3) for sale if you are interested - pm me
    MK1 Leon Cupra R: K04 Hybrid / AEM WMI / Wellycooler / Mocal Oil Cooler / Superpro Polybushed / Vibratech Mounts / KW V3's / Factory Recaros / 330bhp...

  5. #244
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    V3s don't crap tho also make great power with them too
    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

  6. #245
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    Don't want to be taking that head off again
    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

  7. #246
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    Surely the sensible choice for anyone fitting a ko4 of any type in the near future is to wait for Bills new manifold in the new year?

    It's only a few weeks away, and hopefully will be the answer we've all been looking for!
    chaz20vt likes this.
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  8. #247
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    Prawn that's my plan as I didn't know Bill had one being developed while I was on the hunt for a V3

  9. #248
    RIP S3dave

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    Quote Originally Posted by s3gazz View Post
    V3s don't crap tho
    eh?
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  10. #249
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    Quote Originally Posted by hoffmanvp3 View Post
    Prawn that's my plan as I didn't know Bill had one being developed while I was on the hunt for a V3
    Westy likes this.
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  11. #250
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    Bill you tease lol. That's the only thing I'm waiting on to fit my Hybrid

  12. #251
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    Well a little update.
    B5 V2.2 TIP install and replacing the old OCC system.







    And all finished


  13. #252
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    Well its been a while since i updated this Thread so here is the run down.
    (Moderators my web browser keeps crashing so getting bored of copying all this over and over again so am posting in multiple pages, I'm not trying to get my post count up lol cheers)

    Ive put the RS4 alloys onto the Skud missile (Mk1 octavia 4x4 1.8t on Shark stage1 map) for those who dont know it and got me some Rota Grid Drifts 9.5X18" all round with 225 yokohama Parada Spec2 rubber and it stretches bang on for the Stance point of view.






    Needed spacers tho running a 9.5 lol



  14. #253
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    Also fitted Bills High flow cast mani with large port mod and BBT stage4 hybrid KO4 also with large port mod.
    Here is the large ported stage4 Hybrid vs oem








    Bills ported section KO4 vs oem KO4



    And Bills large ported mani vs oem













  15. #254
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    Did have some problems with the EGT port not being machined correctly, basically the port was drilled too deep and didn't allow the crush washer on the egt probe to be held tight so a M5 copper washer takes up the slack and holds the probe secure.



    You can fit the turbo and mani with the head on but seeing as i run the ARP stud kit for the main and head it`ll only cost me a gasket to pull the head as you can reuse the stud kit and its a ****e load easier to complete.



    And a small tip...make sure the wells are dry for the head bolts as if there's fluid like oil or coolant in the well the bolts when torqued down will pressurize the fluid and crack the block, with a stud kit its not so much a problem as the stud is only screwed in hand tight.


    Alingment marks for the 3" down pipe to clear the prop damper and dp flexi joint, this was a feeker as the Pipe Werx didn't have elongated bolt holes for the KO4 hot side to the dp flange the first time i fitted every thing back together and was rubbing but all solved with a bit of a CNC and jiggery pokerie lol



    Nuns **** for clearance springs to mind, would appear the new mani has brought the dp over to the right a couple mm and was rubbing the first time i fitted every back together but this is as best as i can get without making a custom spacer gasket for the KO4 hotside to dp flange to push it back over to the left where it was before.



    So the Blocks back together.......for now lol (bigger plans to come)

    Last edited by hoffmanvp3; 20th April 2014 at 12:38.

  16. #255
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    Now to replace that tiny front mount intercooler as its way way to small for the flow i`ll be producing lol.



    Most people mount the fmic on the slam panel but looked shoody to me so I made a custome frame to carry the new Monster fmic




    And then to pressure test for leaks.



    My Custom boost system testers


    And the frame made fitting the bumper back a piece of cake but did take a while with finding the best position.


    Westy and snowy like this.

  17. #256
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    Still to wire up the Water Meth Injection and weld on the injector bung onto the fmic exit elbow tho, half way through it now but off shore in Saudi doesn't help



    Also vcds flagged up a DTC not supported or comms error with the Haldex coupling for the Quattro system and found this, a snapped Haldex earth strap due to corrosion.


    And surprise surprise the Skud missile had the same error message and snapped earth strap, once sorted the DTC clears
    Easy to fix with a batt earth cable wrapped in electrical tape, this is the Skuds below, the rusty exhaust kinda gives it away and different back box but who`s being picky anyway lol.


    Also heat wrapped the 3" down pipe and sports cat, even tho i soaked it in water over night it still itched the ****e outta me lol
    snowy likes this.

  18. #257
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    Looking really good mate!! Very interested in this keep the updates coming!!!
    Whens it being mapped?

  19. #258
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    Well that's the problem...Bills backed up till June and i work offshore a lot and don't get much in notice nor is it rotation by any means least so its basically who ever can fit me in next month, be it Shark, Niki, or just wait for Bill, but i`ll just get bored at looking at a S3 i cant really drive on actuator and probably pull the engine and re-bore / stroker it while i wait for bill lol.......who knows

  20. #259
    RIP S3dave

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    stroker ftw
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  21. #260
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    Do you not have a 1 way (check) valve on your brake booster/servo hose?
    Handling mods++. GTX30 soon-ish. Hiding parts from the mrs since 2011. Build thread

  22. #261
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    Nope, been meaning to get a new one but hasn't been a cause for concern

  23. #262
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    Interesting. I guess there must be one built into the servo...
    Handling mods++. GTX30 soon-ish. Hiding parts from the mrs since 2011. Build thread

  24. #263
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    Don't tempt me Bill lol
    I do have a wedding to save up for, been politely reminded lol

  25. #264
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    Quote Originally Posted by Sam_ View Post
    Interesting. I guess there must be one built into the servo...
    The Mk1 TT hasn't got one iirc

  26. #265
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    Quote Originally Posted by hoffmanvp3 View Post
    The Mk1 TT hasn't got one iirc
    You've got one up behind the bulkhead heatshielding

  27. #266
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    Really nice work, congratulations.
    Probably you will have the engine with more power with a hybrid.
    Last edited by Miguel_S#; 21st April 2014 at 02:34.

 

 
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