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Thread: My minor modding thread

  1. #2321
    RIP S3dave

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    two of you in the room... Damn.... Scarey Mary

    lmao

    out OCD'd on cambelt.. made me smile
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  3. #2322
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    to be technically correct and factory, which way should the writing be on the cambelt?

    Not that I'm going to change mine if it's wrong of course
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  4. #2323
    RIP S3dave

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    I presume viewed from #1 end it should read correct?

    good question..
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  5. #2324
    "Stick a V8 in it!"

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    The Audi service manual makes no mention of belt installation orientation.

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  6. #2325
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    That made me laugh! I have no idea which way mine is facing, but I do care about it staying tensioned and on!
    Silver 2002 Audi S3 225 (BAM) since March 2011.

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  7. #2326
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    the cambelt is an easy fix, just paint it black
    no writing = no problem

  8. #2327
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    It should be covered up anyway....
    Handling mods++. HTA3582 stroker soon-ish. Hiding parts from the mrs since 2011. Build thread

  9. #2328
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    Quote Originally Posted by Sam_ View Post
    It should be covered up anyway....
    It will be once I have decided if I am just painting the old cover or getting a new one

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

  10. #2329
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    I like how much detail you go into with this
    Spot on...

  11. #2330
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    Little something turned up at the Badger Cave today :D







    ...project manifold is a go then

    <tuffty/>
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  12. #2331
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    Thought you were making a Pegani Zonda exhaust
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  13. #2332
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    Where and how much please.
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  14. #2333
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    Quote Originally Posted by Andrew@A.L.D View Post
    Where and how much please.
    Here ->collector info

    <tuffty/>
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  15. #2334
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    Where are you sourcing the tubing Tuffty? and what schedule?

  16. #2335
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  17. #2336
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    Oooh- looks very interesting! Very nice car mate- been working my way steadily through your thread- it's a real credit to you 8)
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  18. #2337
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    Been a little while since my last update as I have been helping Bill catch up on stuff and had to send the collector back as they had made it in 1.25" ID tube rather than 1.5" ID tube... in the mean time I got the 70mm TB blasted ready for having beads welded on and of course painting :D




    I also painted the cam belt cover and modded it for the manual tensioner




    The new collector turned up Friday so game on...


    ...Nortech (the stars that they are) even did the final capping run on this one...


    ...and of course the obvious difference between 1.25" and 1.5"...


    ...it begins...


    So tomorrow I am gonna make a start and see where I end up... what is evident from my initial faffing is that its not as easy as you would imagine to work out where all this goes and to keep it all away from stuff that could melt...

    I have not discounted going underslung either...

    Hopefully some progress pics tomorrow...

    <tuffty/>
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  19. #2338
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    I have not discounted going underslung either...
    actual YAY !!!

  20. #2339
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    Long but productive day...

    rigged up a bracket to hold the collector in place as its next to impossible to hold that and tubing etc at the same time...


    Started with cyl 1 runner as this would have to tuck close to the block..




    Unfortunately some idiot had put a transfer box in the way and both the runner and the collector was too low to get anything else in so pulled it apart and started again... moved the collector a little higher and re-did runner 1


    runner 2 in weld tape (tm) stage...


    Runner 2 coming together...




    Now clears stuff and fits nice...


    Runners 3 and 4 were pretty straight forward comparatively...



    Had to make some adjustments to the bends to allow clearance (not loads of course but hopefully enough)




    Need to trim the transfer box bracket though...


    ...but it seems to fit ok and looks pretty good all things considered...




    ...so of course I had to try it on the new engine...












    ...and of course I made sure that all the studs were accessible... the most "awkward" ones being..


    ...and



    The manifold should be easy to fit in situe which of course is the next thing I have to do and once fitted to the mock up engine in the car I can work out where the wastegate will go

    All in all not too bad considering its my first attempt and I have never used a welder before... started just after 10am and finished up around 7pm... rather tired now to say the least lol..

    Plan to grab a couple of days off work to finish it off and then it can be welded up... :D

    <tuffty/>
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  21. #2340
    RIP S3dave

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    Superb
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  22. #2341
    Neutral

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    like it paul. Personally id want it a little higher purely to stop it cooking the TB. bt mines more track than road so you'll have lower temps. Great job....i got competition ;]
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  23. #2342
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    Quote Originally Posted by badger5 View Post
    Superb
    x2
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  24. #2343
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    Looks absolutely brilliant! Was following this all day on FB!
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    Quote Originally Posted by <tuffty/> View Post
    its either mapped or broken...

  25. #2344
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    That looks the nuts Paul. Easily on par with some of the professional manifolds available.
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  26. #2345
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    Nice... you will be making TFSI Quatrro Downpipes soon...
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  27. #2346
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    How did you figure out where to mount the turbo? I mean whats the thought process behind the collector being in between 3 and 4? Youl obv have loads of room for the downpipe

  28. #2347
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    Awesome work. Placement looks close to TSR but lower and more central between 3 and 4 whereas TSR is closer to 3.
    Handling mods++. HTA3582 stroker soon-ish. Hiding parts from the mrs since 2011. Build thread

  29. #2348
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    Fantastic work PT!

    Drilling into that with a big holesaw to add the waste gate will be a scary moment!

    I assume the WG take off HAS to come from the very top of the collector so as to divert gasses from all 4 runners?
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  30. #2349
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    Thanks guys... I was quite surprised how well its gone so far... didn't expect to be this far along... of course the tricky bit now is getting the weld sequence right so as not to 'paint yourself into a corner' so to speak...

    Karl... most of the mani's I have worked with or seen tend to place the turbo centrally between cyl 2 and 3 or just over cyl 3... they also stick the turbo high up which on smaller turbos works ok but they all still make the DP a challenge... most manis are made for the US market and they don't have servo's and other stuff in the way so I wanted the turbo in a more OE position so it gave me more room there...

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

  31. #2350
    <tuffty/>'s Avatar
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    Quote Originally Posted by Prawn View Post
    Fantastic work PT!

    Drilling into that with a big holesaw to add the waste gate will be a scary moment!

    I assume the WG take off HAS to come from the very top of the collector so as to divert gasses from all 4 runners?
    Yeah pretty much... this is why it will be measure twice and cut once

    Will have a faff at the weekend

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

  32. #2351
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    can't wait until it's all done mate, getting the mani out of the way seems like a massive step
    -------------------------------------------------------------------------------------------------

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    But I know nothing so ignore me.

  33. #2352
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    Quote Originally Posted by <tuffty/> View Post
    Thanks guys... I was quite surprised how well its gone so far... didn't expect to be this far along... of course the tricky bit now is getting the weld sequence right so as not to 'paint yourself into a corner' so to speak...

    Karl... most of the mani's I have worked with or seen tend to place the turbo centrally between cyl 2 and 3 or just over cyl 3... they also stick the turbo high up which on smaller turbos works ok but they all still make the DP a challenge... most manis are made for the US market and they don't have servo's and other stuff in the way so I wanted the turbo in a more OE position so it gave me more room there...

    <tuffty/>
    Awesome work meneer

    When the guys welded my mani together, they started with the runners, once they were all done, its was a calculation game to see which runner to weld at what time to the collector. But im sure you know all this by now after welding for a day


    LHD and RHD manis both have their issues. RHD has more space on the TIP side, where LHD has limited space on the TIP side. On mine, a 4" to 3.5" silicone reducer just fits past the valve cover and brake servo and my turbo sits higher up. Would never fit if I mounted mine at your level. I would have to go TIPless
    Then on the exhaust side, RHD is limited by brake servo and LHD could fit a 5" DP


    Also with the turbo being lower you have tighter angles to work with for the downpipe VS the turbo being a bit higher up you have a bit more room, not much but every ball hair counts

    S3 with longitudinal setup FTW

    Interested to see where you route the wastegate pipe? Similar to what Bill did on Stacey's?

  34. #2353
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    Quote Originally Posted by Scullies View Post
    Awesome work meneer

    When the guys welded my mani together, they started with the runners, once they were all done, its was a calculation game to see which runner to weld at what time to the collector. But im sure you know all this by now after welding for a day


    LHD and RHD manis both have their issues. RHD has more space on the TIP side, where LHD has limited space on the TIP side. On mine, a 4" to 3.5" silicone reducer just fits past the valve cover and brake servo and my turbo sits higher up. Would never fit if I mounted mine at your level. I would have to go TIPless
    Then on the exhaust side, RHD is limited by brake servo and LHD could fit a 5" DP


    Also with the turbo being lower you have tighter angles to work with for the downpipe VS the turbo being a bit higher up you have a bit more room, not much but every ball hair counts

    S3 with longitudinal setup FTW

    Interested to see where you route the wastegate pipe? Similar to what Bill did on Stacey's?
    I am no stranger to the awkwardness of making a DP for a low turbo... my last setup was underslung remember ;P

    I might look at using 3.5" out the turbo but tbh 3" serves Bill's Ibiza ok so rather than try to fit large stuff in a small place I may just stick to 3" all the way... not chasing numbers with this so its down to whatever is practical...

    <tuffty/>
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  35. #2354
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    Very impressive mate!

    you must have the patience of a saint.........I'd be dying to drive it , clucking to get it finished lol

    Sean
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  36. #2355
    RIP S3dave

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    Quote Originally Posted by <tuffty/> View Post
    I am no stranger to the awkwardness of making a DP for a low turbo... my last setup was underslung remember ;P

    I might look at using 3.5" out the turbo but tbh 3" serves Bill's Ibiza ok so rather than try to fit large stuff in a small place I may just stick to 3" all the way... not chasing numbers with this so its down to whatever is practical...

    <tuffty/>
    feck that lol... biggest we can fit in there dude

    'because we can'
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  37. #2356
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    Quote Originally Posted by badger5 View Post
    feck that lol... biggest we can fit in there dude

    'because we can'
    Well... thats the down pipe plans sorted LOL... :D

    <tuffty/>
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  38. #2357
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    Quote Originally Posted by s33nyboy12 View Post
    Very impressive mate!

    you must have the patience of a saint.........I'd be dying to drive it , clucking to get it finished lol

    Sean
    My patience is a side effect of my OCD... I do want to get it done and it kills me not being able to drive her but it needs to be done right and it would kill me more if I rushed anything for the sake of it and it wasn't right

    <tuffty/>
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  39. #2358
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    Awesome work mate, this is some car!
    REVO Stage 2, Eibach anti roll bar kit, forge 007p diverter valve (yellow spring), Badger5 turbo intake pipe with Jetex filter and Neuspeed heat shield, Forge upper bost hoses, N75, DV and Cam breather hoses, XS Power 3" downpipe 200cell cat and 3" cat back system, Apex 30mm springs, N249 bypass, Oil catch can and PVC delete, Front Mount Intercooler............

  40. #2359
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    Quote Originally Posted by badger5 View Post
    feck that lol... biggest we can fit in there dude

    'because we can'
    Forward planning for the 40 psi
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  41. #2360
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    Quote Originally Posted by Sam_ View Post
    Forward planning for the 40 psi
    Thats pretty low

 

 

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