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  1. #1
    S3 all the way Baby

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    PaulyPaul's Build Thread.....Its HYBRID Time

    Hi all,
    Ive been a member for quite a while now i joined when i bought my 01 S3 in 2008,The turbo blew a couple of months after i bought the car,i took the turbo out but like everything else it got put on the long finger and my S3 has been parked up since.I bought the car in England and i live in Ireland so there was no come back really,I didnt mind too much as i always had a car to drive,garage car or a customers but up until recently i was working in a VW,Audi garage as a technician and had been there for 9 years but things have gone quite so redundancy was offered and i took it and i thought what better way to spend a few quid and get my S3 right again.
    So after Hours and Hours,Days and Days of reading up on this Forum(what great info) i decided to go for the CR Hybrid Turbo and all the bits i need to go with it.
    So here Goes
    First job was to get her up on stands and start stripping.

    I had a Oem clutch kit bought for the car a while ago so that was the first job.
    I had been on to Bill about a hybrid turbo (Thanks)and then got on to CR Turbos about gettin my old K04 hybridized,I was happy with the price so off it went 2 weeks later it came back and it looks lovely.
    Same turbo Bill has put in to Speedy Steve's.
    OLD

    NEW





    Cr have done a great job on the turbo as you can see.
    Bill advised me to change the rods so i ordered a set of IE rods and a AH FMIC and all the pipe work from Tuffybloke's build thread (i have too say Thanks and what a build thread)
    next it was off with the head and out with the pistons



    Word of advice if you have never removed your sump and checked the oil pump strainer then do so,sooner rather than later.I have seen so many 1.8t engines ruined over the years from the stainer getting blocked and never checked mine and yes,it was blocked full of carbon deposits and the oil feed to the turbo was blocked too obviously the cause of the turbo failure.But if that didn't happen then all this work might not of happened.
    This is the lad,Almost fully blocked turbo side.

    Still no sign of me Rods so i went about cleaning all the parts and fitting the turbo

    What an easy job it makes it with the head off i remember removing the turbo with the head on and that was a pain in the arse.

    I got the FMIC and all the pipe work so i started to fit that its more or less button up just have to wait till the head goes back on before i fit the clamps,I must say fair play to Tuffy(Thanks)his step buy step made it very easy and looks the business.



    So this is where I'am at waiting on Parts rods and head gasket are the main ones,I have also ordered OCC and piping,boost hoses,phenolic insulator for inlet mani,THS Dog bone mount,boost gauge and i bought a second hand 42 draft designs downpipe from Ebay but the lambda probe bung has to be moved to fit in place.


    I shall keep ye posted.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



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  3. #2
    <tuffty/>'s Avatar
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    Nice work mate... looking forward to it

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

  4. #3
    s3dave's Avatar
    TFSI Hybrid

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    great job so far....looks like you have plenty of room thing going on there

  5. #4
    S3 all the way Baby

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    Thanks Man you were my inspiration to do it.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  6. #5
    finesse's Avatar
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    Excellent work both Paul's!!
    Ibiza Cupra TDI

    Gone:

    Audi C5 RS 6 - Stage 2
    Audi 8L S3 - Revo'd

  7. #6
    S3 all the way Baby

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    Yeup loads of room,out of the way i can tip away at it when i want,Its great.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  8. #7
    S3 all the way Baby

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    Thanks alot
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  9. #8
    Dani_B19's Avatar
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    That's it, im stopping coming on here, there's too much bloody temptation, im going to end up cracking
    Driving the most secretive S3 on ASN

  10. #9
    ALPINE's Avatar
    Yes its diesel, now cry u lost

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    Quote Originally Posted by Dani_B19 View Post
    That's it, im stopping coming on here, there's too much bloody temptation, im going to end up cracking

    i know the feeling... my redudndancy doe was gonna be a Big turbo... .. .. shame it aint gonna happen now




    Good work paulypaul.. cant wait to see this thread grow

    Now to many mods to list! Lots of power, torque and Leather!

  11. #10
    Dani_B19's Avatar
    Audi-sports own special child.

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    Quote Originally Posted by ALPINE View Post
    i know the feeling... my redudndancy doe was gonna be a Big turbo... .. .. shame it aint gonna happen now




    Good work paulypaul.. cant wait to see this thread grow
    My problem is a missus who wants a house, asked her why we just cant live in the car, its got heating, what more does she want lol.
    Driving the most secretive S3 on ASN

  12. #11
    ALPINE's Avatar
    Yes its diesel, now cry u lost

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    Quote Originally Posted by Dani_B19 View Post
    My problem is a missus who wants a house, asked her why we just cant live in the car, its got heating, what more does she want lol.
    hahahahaha!! i have also tryed that 1.. dont think the 2 kids would approve!! ill stick with a generic till my turbo blows up and i mite go hybrid. I know ill get slated for saying this, but i think if i want big power ill just buy another Jap car, 3K plus on my Audi just does not seem sensible. Works out alot cheaper to get another jap deffo.!

    Now to many mods to list! Lots of power, torque and Leather!

  13. #12
    s3dave's Avatar
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    Quote Originally Posted by ALPINE View Post
    hahahahaha!! i have also tryed that 1.. dont think the 2 kids would approve!! ill stick with a generic till my turbo blows up and i mite go hybrid. I know ill get slated for saying this, but i think if i want big power ill just buy another Jap car, 3K plus on my Audi just does not seem sensible. Works out alot cheaper to get another jap deffo.!
    unless you get your hands dirty

  14. #13
    ALPINE's Avatar
    Yes its diesel, now cry u lost

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    i always get me hands dirty!! lol

    Now to many mods to list! Lots of power, torque and Leather!

  15. #14
    voorhees's Avatar
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    Quote Originally Posted by ALPINE View Post
    if i want big power ill just buy another Jap car, 3K plus on my Audi just does not seem sensible. Works out alot cheaper to get another jap deffo.!

  16. #15
    S3 all the way Baby

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    That's it, im stopping coming on here, there's too much bloody temptation, im going to end up cracking

    Thats what happened to me too much temptation,I cracked
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  17. #16
    1animal1's Avatar
    The Clar!! it mouves!!!

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    Dani at least you can resort to ya stage 1 for cheap thrills dood
    Xbox 360 gamer ID : Timffy

    Black FZ6 - Turbo car 'slapper'
    Silver BMW 535D Tourer - Fully loaded 340BHP 700NM torque
    2009 8P3 S3 Brilliant Red - Sold
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  18. #17
    S3 all the way Baby

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    Quote Originally Posted by ALPINE View Post
    i know the feeling... my redudndancy doe was gonna be a Big turbo... .. .. shame it aint gonna happen now




    Good work paulypaul.. cant wait to see this thread grow
    Thanks alot Alpine
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  19. #18
    SteveBAM's Avatar
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    that turbo looks pretty spunky ..!!!

  20. #19
    S3 all the way Baby

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    Quote Originally Posted by ALPINE View Post
    hahahahaha!! i have also tryed that 1.. dont think the 2 kids would approve!! ill stick with a generic till my turbo blows up and i mite go hybrid. I know ill get slated for saying this, but i think if i want big power ill just buy another Jap car, 3K plus on my Audi just does not seem sensible. Works out alot cheaper to get another jap deffo.!
    Iam looking around 2000 all done except for the remap and i dont know yet about the injectors have to see what Bill reckons.
    But doing the work yourself does help you know its done right and its fun doing it too.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  21. #20
    S3 all the way Baby

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    Quote Originally Posted by SteveBAM View Post
    that turbo looks pretty spunky ..!!!
    Spunky lol...Yeup it is a completely different turbo cant wait to hear it spool up.Cr do a Awesome job.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  22. #21
    SteveBAM's Avatar
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    its good to see you also went for rods aswell.. will be waiting to see how it goes..
    good luck

  23. #22
    ALPINE's Avatar
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    Quote Originally Posted by paulypaul View Post
    Iam looking around €2000 all done except for the remap and i dont know yet about the injectors have to see what Bill reckons.
    But doing the work yourself does help you know its done right and its fun doing it too.
    yep it is indeed. i rebuilt my Scooby engine my self and loved every minute of it. i learnt so much too. (like dripping the Vpower out the fuel rails over the nice new laminate floor pi$$s the wife off big time!!) I broke my back a few months ago and have nerve damage all over the place. Im limited to what i can do now days, unfortunatly, changing my head lights to face lift ones has mullerd me enough, still suffering today. such is life so they say!!!! Im just glad i have some really good mates with garages!! lol

    I look forwards to seeing you build a beast, Its studdy time for me now, ill leave the pratical for others!

    Now to many mods to list! Lots of power, torque and Leather!

  24. #23
    1animal1's Avatar
    The Clar!! it mouves!!!

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    yeah the G's are gonna reec havoc on ya back when the map comes
    Xbox 360 gamer ID : Timffy

    Black FZ6 - Turbo car 'slapper'
    Silver BMW 535D Tourer - Fully loaded 340BHP 700NM torque
    2009 8P3 S3 Brilliant Red - Sold
    2001 F/L S3 Dolphin Grey - Sold
    1999 Pre F/L Silver A3 1.8T - Sold

  25. #24
    ALPINE's Avatar
    Yes its diesel, now cry u lost

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    Quote Originally Posted by 1animal1 View Post
    yeah the G's are gonna reec havoc on ya back when the map comes

    im sure my little Audi will be ok.. my mate Els 500+ bhp scoob is ok on me back!! lol I say its a good advert for those JOM coiovers i have too! lol

    Now to many mods to list! Lots of power, torque and Leather!

  26. #25
    Speedy Steve's Avatar
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    Looking good there! Your at a further state than me so maybe you will get it running before me the race is on!
    Ive been Badger 5'd

    Can we break the magic 300?????? In a word Yes 314 BHP 249 lbft at Badger 5

    Quote Originally Posted by badger5 View Post
    steves is way quicker than any stock turbo'd s3 i have driven
    I only date skinny Women! They keep my power to weight higher...

  27. #26
    S3KO4's Avatar
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    what price did you pay to have it hybrid?
    S3-8L REVO stage 2, Milltek, 3" DP & custom 3" decat, RS2 spark plugs, 4 bar FPR, Green-Cotton uprated upper/lower boost hose & TIP, Front Zimmerman & Ferrodo. LCR spliter. boost gauge, smoothed AB. Aero blades, H&R 5mm spacers. Best time 14.03sec, 0-62 in 5.7sec. 207gs @ 25psi , polished inlet mani. VAGCOM 805.1

  28. #27
    Andrew@A.L.D's Avatar
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    Quote Originally Posted by S3KO4 View Post
    what price did you pay to have it hybrid?


    +2

    It maybe some tome before i go BT
    Was 531bhp 8L S3 thats going to break the 600+ bhp Club then break something else. Lets see what this OD HTAGT3582r can do
    My S3 Twists Drive shafts for fun.

    FOR SALE
    Sparco Torino 2 sport seats
    Adjustable FPR from 1-5 bar, 2 sets of Unused ARP 3/8 2000 rod bolts
    , relentless 200 cell cat pipe, Std AGU Crankshaft. Ported & Reconditioned Cylinder head service.

  29. #28
    S3 all the way Baby

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    Quote Originally Posted by Speedy Steve View Post
    Looking good there! Your at a further state than me so maybe you will get it running before me the race is on!
    Bill beat me too it with a Build thread but i'am alot further away from Bill than you are so you might get it all done first,time will tell.
    How is yours going are you driving it?
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  30. #29
    S3 all the way Baby

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    Quote Originally Posted by S3KO4 View Post
    what price did you pay to have it hybrid?
    CR do a few different options they quoted me between 425 to 575 plus carriage plus vat to have my own turbo reconditioned depending on its condition,The exhaust housing was cracked so i knew it was gonna be closer to the 575.For a finish the only original part left on the turbo was the inlet housing it cost 565 +vat +P&P.
    Cracking looking turbo though as you can see,Lets hope it will perform as good as it looks.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  31. #30
    S3 all the way Baby

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    Quote Originally Posted by SteveBAM View Post
    its good to see you also went for rods aswell.. will be waiting to see how it goes..
    good luck
    I didn't intend to get rods as everything i had read said there good for 400 odd ponies but after speaking with bill he advised me to do so,and this man obviously knows his stuff so i placed the order.Peace of mind is a great thing if the boost needs to be turned up.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  32. #31
    optio's Avatar
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    PaulyPauls Build Thread Its HYBRID Time

    Any chance of SW build a droid parts here too?

  33. #32
    S3 Johnny's Avatar
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    Hi mate, Where did you get your FMIC from? I'm looking at getting one myself.
    Thanks.

  34. #33
    <tuffty/>'s Avatar
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    Quote Originally Posted by S3 Johnny View Post
    Hi mate, Where did you get your FMIC from? I'm looking at getting one myself.
    Thanks.
    http://www.audi-sport.net/vb/showthr...image-heavy%29

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

  35. #34
    Speedy Steve's Avatar
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    Quote Originally Posted by paulypaul View Post
    Bill beat me too it with a Build thread but i'am alot further away from Bill than you are so you might get it all done first,time will tell.
    How is yours going are you driving it?
    You may be further away but with the chance of buying a house soon it may take me a little longer. Mine is running but not mapped so N75 is disconnected( no Boost ) I drove it back from Bills some 90+ miles with no problems just slower than normal> Im currently waiting on my hoses and FMIC to come in after ordering it all
    Ive been Badger 5'd

    Can we break the magic 300?????? In a word Yes 314 BHP 249 lbft at Badger 5

    Quote Originally Posted by badger5 View Post
    steves is way quicker than any stock turbo'd s3 i have driven
    I only date skinny Women! They keep my power to weight higher...

  36. #35
    S3 all the way Baby

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    Quote Originally Posted by optio View Post
    Any chance of SW build a droid parts here too?
    Ha?
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  37. #36
    <tuffty/>'s Avatar
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    Quote Originally Posted by optio View Post
    Any chance of SW build a droid parts here too?
    Quote Originally Posted by paulypaul View Post
    Ha?
    Yep... lost me too

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

  38. #37
    S3 all the way Baby

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    Question..I have a K&N panel filter is it worth changing for a green cotton or another air filter.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  39. #38
    <tuffty/>'s Avatar
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    Quote Originally Posted by paulypaul View Post
    Question..I have a K&N panel filter is it worth changing for a green cotton or another air filter.
    K&N tend to be oilier than Green Cotton ones and can cover the MAF element in oil making it fail prematurely (not that it takes much to make them fail any other time)... I used to have a Pipercross foam filter but changed to a Green Cotton...

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

  40. #39
    S3 all the way Baby

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    well i have been on to jbs about there manifold for k04 and it doesn't look like i get one any time soon they wont say when but they will contact me,
    I wont hold my breath.
    so i think i might have a go at porting the oem one,i wonder has anyone tried this?would it weaken it?



    The manifold is already cracked the gasket was split in 3 pieces,but ill have to make do with it welded up.
    Last edited by paulypaul; 10th May 2010 at 22:40.
    PaulyPaul

    01 AMK,Soon to be Hybrid
    My BuildThread
    http://www.audi-sport.net/vb/showthr...ts-HYBRID-Time



  41. #40
    www.badger5.co.uk

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    I have ported the k03 manifold and achieved same flow performance as the "hi-flow" ones I have also fitted/mapped..

    K04 one however is already thin and weak..
    **http://www.facebook.com/Badger5Ltd**

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