S3 PE1820 big turbo build

Dani_B19 said:
Very nice, you just use normal flap wheels? Looking into starting mine next, should be fun :) lol.
Click to expand...

No, not flap wheels, I'll photo the implement used - it's like a flap wheel, but a rotary bit with just a harsh grade sand paper outer.

I've got a spare TB here so I don't mind messing about with this one. I'll see what it's like and then maybe do a bit more.
 
Looks awesome Welly!

Best of luck dude, REALLY looking forward to seeing the results you get from this!
 
Another milestone on the road to completion yesterday - the head.

I'm a bit nervous of the 20V heads due to their tightness on the inlet side, so enlisted the help of a friend who has got some reasonable experience with them....

Tuffty!

All his work on the head, stem seals and cam seals have all been replaced. The stem seals were a bit weepy and the cam seals were completely shot and leaking. So hopefully no more leakyness now.

Photos:

tuffty1.jpg


tuffty2.jpg


tuffty3.jpg


Head is now back with me at home after collecting yesterday.

Big thanks to Tuffty for doing this - a lot of skill, work and time went into it to complete it. Thanks dude :thumbsup:.

Awaiting oil and coolant line's completion tomorrow and we should be good to go on building back up...
 
Oh, also trial fitted the TIP to see how it fits - well is the answer....

35.jpg
 
Last edited:
superkarl said:
Is that a worthwhile bit of maintenance to do when I remove my head, stem and cam seals? Expensive parts?
Thanks
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The head set to buy is around £70 - includes a HG, stem seals, cam seals, chain tensioner seals, inlet manifold gasket, exhaust manifold gasket and a rocker cover gasket. Not bad all in all.

I would say they are worth changing once the engine gets over 100K - the seals tend to become dry.
 
OK, so had a night on it tonight.

Initially concerned that the turbo oil return hose was a little short - however it turned out to be fine.

Many thanks to Bill for grabbing them for me today :).

So... here they are:

36.jpg


Score. Total cost of £136.96 wasn't the cheapest, however they are made out of PTFA internal braided hose - so should be pretty heat proof.

I have also heat wrapped (two layer, firstly with exhaust wrap, and then with silver foil tape followed by SS wrap straps) the two pipes that will run underneath the manifold.

37.jpg


Thats done, it was time to start rebuilding..... Started by fitting the exhaust mani to the head, and then the head to the car. Only mocking at this point.

Fitted the oil lines to the turbo and then the coolant lines. Basically I followed my normal rebuild procedure... lol. Torqued the head, fitted turbo, fitted remaining coolant lines, etc etc etc.

Have finished up the night in this state by close of play tonight...

38.jpg


Engine bay as is.

39.jpg


Coolant return pipe coming out of the turbo and winding it's way around the bay to the original coolant K04 return feed.

40.jpg


Here, Bill has welded the 007P directly the the TIP 76mm joiner. This is purely a space saving measure as it means less hosing in the engine bay.

41.jpg


Oil return, coolant feed and oil feed pipes visible along the bottom of the head/turbo area.

So, all in all a good night. Spent a little while standing back admiring it.... lol. (sad...)

On a side note, the funny story from the evening is as follows.

Get home, start fitting the oil return line and the gasket falls down somewhere in the engine bay. ****. It's grey so finding it in a black engine bay is next to impossible.

Spend an hour or so poking around looking for it. Nowhere to be seen. Stopped briefly as Dane came to pick up the hybrid from my yard, then eventually found it luring down on one of the heat shields.

Now, we have a new (and bonkers) labradoodle puppy, who has taken to sitting under my car (as she's up in the air). I suspect she has actually eaten some missing bolts that were under there - and aren't now.

I manage to poke the gasket out from where it was, and it dropped to the deck.

At which point the puppy promptly saw, and ate it (it was only a paper gasket). Amused I was not. In fact I went absolutely bonkers having spent an hour looking for the damn thing.

Then had to go to Bill's to get another suitable gasket.

****** dog! :mad:
 
Welly said:
On a side note, the funny story from the evening is as follows.

Get home, start fitting the oil return line and the gasket falls down somewhere in the engine bay. ****. It's grey so finding it in a black engine bay is next to impossible.

Spend an hour or so poking around looking for it. Nowhere to be seen. Stopped briefly as Dane came to pick up the hybrid from my yard, then eventually found it luring down on one of the heat shields.

Now, we have a new (and bonkers) labradoodle puppy, who has taken to sitting under my car (as she's up in the air). I suspect she has actually eaten some missing bolts that were under there - and aren't now.

I manage to poke the gasket out from where it was, and it dropped to the deck.

At which point the puppy promptly saw, and ate it (it was only a paper gasket). Amused I was not. In fact I went absolutely bonkers having spent an hour looking for the damn thing.

Then had to go to Bill's to get another suitable gasket.

****** dog! :mad:
Click to expand...

Lol! Reminds me of the dog in Gone in 60 Seconds eating the Merc keys!
 
Another long night spent in the garage last night, however it did bear some fruit....

It's done - a few odds and sods aside at least. Awaiting delivery of a few pipes and fittings, however, the bulk of the work is now completed.

Usual stuff done last night, timed the engine, fitted the timing belt covers, inlet manifold etc etc etc.

So, will finish up tonight, and then it's ready to roll up to Bill's at the weekend - which is nice.

Photos:

42.jpg


43.jpg


44.jpg


45.jpg
 
This weekend? Im so there, let me know when and I'll pop over.

Good work man!
 
audi upgrades
Westle said:
I only see my gf at the weekends so I have loads of time during the week for late night mechanics ;)

It's just a shame my mechanical skills aren't as good as yours!
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It doesn't work yet..... lol. Rumours of my skills are greatly exaggerated.
 
Nice work buddy and liking your sticker.

Welly 2 questions, whats the name of the turbine housing outlet flange, and I thought you was running a catch can, cant see it in your pics tho. What one have you got if you have that is.
 
S3 Nattie said:
Welly 2 questions, whats the name of the turbine housing outlet flange, and I thought you was running a catch can, cant see it in your pics tho. What one have you got if you have that is.
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The name of it? Ummmmm, pass. It's just a boggo IHI outlet to be honest dude - I don't know if it has a specific name.

Secondly, I was running a catch can, however ended up binning ti as it was a pain during the cold weather. It was metal, and thus got cold at night, combined with a warm engine just caused condensation and I ended up emptying water out of it most of the time.
 
audi upgrades
I wasnt to sure if there was a name for the outlet either, thats why I asked. I was just thinking if you was having a custom downpipe made up what would they called the flange thats all as its a pretty strange flange.

Did you upgrade your breather hoses to Forge ones then, any links for the can you did have mate.
 
S3 Nattie said:
I wasnt to sure if there was a name for the outlet either, thats why I asked. I was just thinking if you was having a custom downpipe made up what would they called the flange thats all as its a pretty strange flange.

Did you upgrade your breather hoses to Forge ones then, any links for the can you did have mate.
Click to expand...

It Flangetastic..... Turbo Flange SUBARU Liberty Legacy IHI VF38 VF44 VF45 | eBay UK

Just made my own out of silicone hosing mate TBH.
 
I suppose you would just called it a subaru/IHI flange then lol.

Cheers for that welly
 
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