My minor modding thread

Tuffty, do yo think that your mission to keep the engine bay looking as OEM as possible may have hindered your end goal of 400+bhp? The new mods you're planning will obviously change the look of the bay but hopefully get you the power you want.
 
<tuffty/> said:
Then of course comes WMI, inlet manifold, revised charge pipes, TFSI coil packs yadda yadda... never ending but always tweaking ;P

<tuffty/>
Click to expand...

Youd only get bored if there wasnt a list though... :p
 
Westy said:
Tuffty, do yo think that your mission to keep the engine bay looking as OEM as possible may have hindered your end goal of 400+bhp? The new mods you're planning will obviously change the look of the bay but hopefully get you the power you want.
Click to expand...

Possibly.... getting inherently clear that to get power some sacrifices have to be made... however I am confident that I can break 400hp without changing the inlet Mani and charge pipe but I would like to evolve the build further to the fabricated inlet etc... I think while not obviously OEM it will retain the feel which I can live with...

<tuffty/>
 
<tuffty/> said:
Humm... when I fitted the SEM it was tight and fitted a SEM to a TT last week where bill made up a special adaptor to go from the OEM MAP tube... I'll see if he tool a pic... fairly sure he would have done..

But yes, I do intend to look into making this manifold... :D




You and me both mate... been a few years now but the is (mostly) in sight... lol

Then of course comes WMI, inlet manifold, revised charge pipes, TFSI coil packs yadda yadda... never ending but always tweaking ;P

<tuffty/>
Click to expand...

SEM-R32-adaptor.jpg
 
Well... made a start today...

First thing I noticed while draining the fluids was that the rear earth strap was broken... typically as its been a bit of a topic at Bills recently with a couple of cars coming in like it...
CameraZOOM-20111217102930917.jpg


Normally this leads to the haldex not working but mine is as far as I am aware but will be sorting this out anyway... more info here about this problem.. http://www.audi-sport.net/vb/a3-s3-...working-no-communication-etc-look-inside.html

So here we are again, head off for the <insert random number here>th time... sumps off for reasons I will explain later..
CameraZOOM-20111217161631935.jpg


Found why the exhaust was blowing...
CameraZOOM-20111217132823750.jpg


Found another little gem while removing the hotside for the swap... its cracked... again!!!
CameraZOOM-20111217153117260.jpg


Really obvious this hotside does not like running much boost at all (not that I was tbh)... test fitted the new hotside...
CameraZOOM-20111217161148460.jpg


Sadly it is a little taller so will ****** up my already tight clearance on the bevel box and has also sat the turbo closer to the engine as its now close in places it wasn't before :(
CameraZOOM-20111217161256704.jpg


Bit of work to do then... will be getting the 6 speed quattro box Bill has in his garage over to mock up the fitment and see what can be done... bit of machining here and there should sort it out

Be worth it... quite a difference in size between the T25 and the new (essentially a T3) housing
CameraZOOM-20111217161526019.jpg


Popped the pistons out to see if I could rule out the small ends as the rattle I have been getting... first issue... broken piston ring... brilliant!!!
CameraZOOM-20111217164106254.jpg


Second issue... worn gudgeon pins
CameraZOOM-20111217170945685.jpg


That'll be my rattle then... meanwhile back in the Badger Cave...
CameraZOOM-20111217173213693.jpg


Bill is a star... has all sorts of goodies lying about including some Ibiza pistons (20mm) with as new condition pins... so, four new set of rings, a good honing and new pins... hopefully that should sort that lot out...

All in all a bit of a crap day... nothing but problems presenting themselves... however there are no problems only solutions so will take that into tomorrow and sort the turbo fitment out and clean up the pistons ready for the new rings...

Hopefully have a better day tomorrow

<tuffty/>
 
Last edited:
Along day by the looks of things & a lot done.
Are those rings the original's or were they new when you changed the rods?

Pat
 
Unlucky mate

Best of luck with it though, that hotside is bound to flow a load more!

And theres nowt like a bit of parts hoardage! Lol, gets you out the poop every now and then!!
 
pats3poa said:
Along day by the looks of things & a lot done.
Are those rings the original's or were they new when you changed the rods?

Pat
Click to expand...

Originals... hindsight of course is a wonderful thing but they looked fine and had no compression issues or heavy breathing...

I have accepted it now lol but still a pain in the **** when you are not expecting it...

<tuffty/>
 
Yes, but in all fairness they have done really well!
Is there any damage to the bore?

Pat
 
pats3poa said:
Yes, but in all fairness they have done really well!
Is there any damage to the bore?

Pat
Click to expand...

A couple of marks yes... will have to see how well they hone out... not that I have much choice in the matter tbh as I can't stretch to new pistons and a rebore at the moment...

Plan was to rebuild the bottom end with an 82.5mm rebore and JE pistons but thats a little way off..

<tuffty/>
 
What a f****r!! I'll keep my fingers crossed that they do hone out.
Just out of interest what is the wear like on the big end shells etc?

Pat
 
pats3poa said:
What a f****r!! I'll keep my fingers crossed that they do hone out.
Just out of interest what is the wear like on the big end shells etc?

Pat
Click to expand...

Shells look ok tbh but there are a new set on the shelf so all things considered I am just gonna change um any way...

<tuffty/>
 
Start as you mean to carrie on I say & If in doubt replace it!
Look forward to more updates & I hope they are good ones

Pat
 
Unlucky tuffty, what hotside has cracked again, a t25 like mine? What boost are you running?

(I know these answers are in this thread but searching through 28 pages will take me forever on a phone! )
 
Last edited:
Sorry to hear about the issues mate. Hotside isn't much of a downer as you were replacing that anyway but the ring and pins are annoying. What egt's were you seeing at peak boost, the probe was in the downpipe wasn't it? Looks like these internal t25's can't take the heat particularly well but your new housing will improve the flow and heat much more especially as the external gated exhaust flow won't be interfering with the flow of the exhaust out of the turbine. Good luck with it anyway and hopefully there aren't any other major headaches.
 
I would say thats good news to find the small damage when you did as if you kept on driving like that then it would of done a bit more damage.

Seams like the hot side is no good for your need and external gate is the way to go
 
Lee172 said:
Unlucky tuffty, what hotside has cracked again, a t25 like mine? What boost are you running?

(I know these answers are in this thread but searching through 28 pages will take me forever on a phone! )
Click to expand...

Technically the same as yours but I have had mine modded for the full size GT30 turbine... seeing as these hotsides don't flow fantasically well (was informed that the T3 .63 I now have flows like a T25 .82 or .86 can't remember which now, we have the T25 .64) so put a bigger turbine in and I guess its going to be less happy than befpre...

Boost wise I was running 1.4/1.5 bar but... I did have boost control issues that I never got to the bottom of and occasionally would see excursions to 2bar... never good...

These hotsides just don't like too much boost...

Andy123 said:
Sorry to hear about the issues mate. Hotside isn't much of a downer as you were replacing that anyway but the ring and pins are annoying. What egt's were you seeing at peak boost, the probe was in the downpipe wasn't it? Looks like these internal t25's can't take the heat particularly well but your new housing will improve the flow and heat much more especially as the external gated exhaust flow won't be interfering with the flow of the exhaust out of the turbine. Good luck with it anyway and hopefully there aren't any other major headaches.
Click to expand...

As above mate, the .63 I have now should flow loads better... I normally see 750 deg tops on the dyno where the probe is currently placed which is 850 ish across the turbine... when I have had the boost issues though I have seen 900's... probably what killed it eventually... boo

Andrew@A.L.D said:
I would say thats good news to find the small damage when you did as if you kept on driving like that then it would of done a bit more damage.

Seams like the hot side is no good for your need and external gate is the way to go
Click to expand...

Indeed... cold light of day and I am feeling better about it... expense of it is the issue tbh.. if it needs doing then I do it.. but really could have done without that little gem...

The housing on Welly's FP is internally gated but is larger all round so internally gated hotsides can work but I am starting to question Garretts logic on fitting such a small hotside to such a big turbo...

Ah well... live and learn... deal with and move on... :)

<tuffty/>
 
an as supplied garrett hotside on gt30 creeps... and they supply it like that???
Hmmmm

Not a fan of T25 fitment things at all.... T3 is what use.. they seem to work well without the issues the internal gate ones have.
 
Better day today...

Started a little badly of course... my plan to use the pins from the other pistons failed at the first hurdle..
CameraZOOM-20111218104040942.jpg


So sod it... I cleaned up the Ibiza pistons... (9.5:1 comp ratio :thumbsup:)
CameraZOOM-20111218115332333.jpg


...fitted them on the rods....
CameraZOOM-20111218124417451.jpg


...and honed the bores...
CameraZOOM-20111218160022117.jpg


...there are still a couple of deeper scratches on the top of cyl 1 but short of a rebore (which I can't afford right now) it will have to do..
CameraZOOM-20111218155947601.jpg


Rings will be ordered in the morning and will be gapping them up and fitting the pistons back in...

Also fitted my manifold and turbo to the build engine... the new hotside has moved the turbo closer to the block, hangs a little lower than before and has moved the compressor over to flywheel side a bit... doesn't sound or look much but with the tight clearances I already have being underslung it may as well be a mile...

Anyway, did some measurements and looks like the turbo needs to lift by 4/5mm so the plan is to machine the manifold as there is quite a bit of meat there and some other stuff needs a bit of clearancing too... not taken pics yet as it was getting late and we knocked it on the head early...

While under the car I undid the nut for the rear diff earth strap which thankfully didn't shear off and the bolt came off the diff too so looking up... will be making a new strap out of some 25mm2 battery cable... nice and thick so should last a bit better and provide a decent earth..

Will get some pics tomorrow of the turbo setup as I need to fit it all to a bare head and sit it on the engine to see what hits what as the bevel box Bill had to use on the build engine is a different/earlier version to mine and the case is different so won't help gauging clearances :(

Got a couple more days off to work on the car... not going to be finished before Christmas as there will be some fabrication work to do... water pipes don't fit and will need tweaking plus the manifold needs machining and welding for the external gate fittings...

<tuffty/>
 
I'm glad it was a better day for you, although not being able to get further due to not having rings is a bummer!

Do you think maybe the next step would be a 2ltr Stroker kit instead of just a rebore to 82.5?

Pat
 
pats3poa said:
I'm glad it was a better day for you, although not being able to get further due to not having rings is a bummer!

Do you think maybe the next step would be a 2ltr Stroker kit instead of just a rebore to 82.5?

Pat
Click to expand...

Funny you should say that... thats exactly what Bill said LOL... we will see... I am not ruling it out ;P

I only need pistons and a crank anyways... if I can source a TFSI crank cheaply enough and get the machining done in the UK them I only need the pistons...

<tuffty/>
 
Lol you know what they say..... Great minds think alike!!.......

Also... Do it do it do it!!!

Pat
 
Small update... spent most of the day lifting a head (with turbo and manifold fitted) in and out of the engine bay while I played about with working out clearance issues... rings are on order and will be arriving tomorrow..

The problem I have is the new hotside has moved everything about... its a pain but can't do anything about that...

With the taller hotside I have no clearance on the bevel box now so have fixed that by first clocking the comp housing around away from the manifold as before one of the housing bolts dropped neatly in between the webbing of the modded bevel box... now the turbo sits closer to the block it now hits that... so clocking has moved it to the other side of the webbing but now as the turbo is lower and move over slightly towards cyl 4 it now sits on top of the webbing at the back!!!

This is an old picture of when I had the old hotside on to give you an idea... I haven't taken any pics of it today as I didn't think about it... lifting a head and GT30 setup in and out of an engine bay all day long kinda focusses you a bit :)
20090916_CRW_3695.jpg


...mounted on the build engine...
CameraZOOM-20111219131534609.jpg


Lifting the turbo will fix this so the plan is to loose 5mm off the turbo mounting face of the manifold to lift it enough to clear... Just below the hole where I originally fitted the EGT probe...
CameraZOOM-20111219131555509.jpg


There is quite a bit of meat to play with so will see whats what... will go M10 too for the bolt size as there will be less thread to bite into so should give them a chance at least...

Clocking the comp housing has giving me another issue to sort out (fix one, find one... seems to be the way!!!0
CameraZOOM-20111219131622071.jpg


Will worry about sorting that issue out once I have the clearance sorted and the head sits flat ...

So... will be looking to fabricate a new downpipe as no amount of modding will get the one I have to fit... its moved things too far fitting the new hotside... the other biggy is likely to be the oil drain which was tight before and plain silly now and the water pipe to the block which we have always had issues with... seriously thinking of taking the bevel box off my gearbox to attach to the build engine so we can see off the car what we have to deal with...

Rings tomorrow so should have the bottom end back together by close of play...

<tuffty/>
 
wow, it never rains, it only pours!

Still, there is literally no better place, and no better hands it could be in to get the best possible result at the end of all this!

Can't WAIT to have a ride when I finally make my own way to Bills!
 
Prawn said:
wow, it never rains, it only pours!

Still, there is literally no better place, and no better hands it could be in to get the best possible result at the end of all this!

Can't WAIT to have a ride when I finally make my own way to Bills!
Click to expand...

It has been a bit of a roller coaster ride getting here but its been a fantastic ride non the less... considering I knew nothing about forced induction cars before getting my S3 I think I have done ok...

Was taking to Mark earlier today and he suggested maybe bore wash could have contributed to the rings early demise... this rings (no pun intended lol) true tbh as while having the EGT issues and the ECU having a spaz for no good reason I was getting a lot of fuel poured into the cylinders... never a good thing...

Anyhoo, as you say I have the expert eye of Bill watching over me as I sort stuff out and I am extremely grateful for all the help and advice (and fabricating...) that he and of course Tony have provided over the years... I feel extremely privileged to be involved in the work he is doing...

Anyhoo... yes... should be a bit differnt to the last time you had a ride Nick ;P

<tuffty/>
 
Where are you placing the wastegate port on the manifold mate? The throat on the new hotside looks even bigger when it is mounted in place so looking forward to seeing the results of that. That transfer box is a ****** when you go fitting big old underslung units- good luck with clearing it though, lucky there is a fair bit of meat on the manifold exit. Good luck for the rest of the week.
 
Andy123 said:
Where are you placing the wastegate port on the manifold mate? The throat on the new hotside looks even bigger when it is mounted in place so looking forward to seeing the results of that. That transfer box is a ****** when you go fitting big old underslung units- good luck with clearing it though, lucky there is a fair bit of meat on the manifold exit. Good luck for the rest of the week.
Click to expand...

There is a cast platform on the manifold for a 2 bolt style wastgate...
IMG_3509.jpg


Plan is to bore this with a recess to weld a stub on for the Tial v band to sit on... will have pics later when all done of course...

Underslung is a challenge especially as the mani I have is designed for an inline 20v... Bill is always mumbling about top mounts lol... secretly though I think he likes the challenge as much as me :D

<tuffty/>
 
Couldn't see that from the other picture, shouldn't take much to sort that out then. There's nothing better than a challenge and overcoming it! I'm back over to Bill's on the 7th so chop chop, get some sleep and get it sorted! :thumbsup:
 
Andy123 said:
Couldn't see that from the other picture, shouldn't take much to sort that out then. There's nothing better than a challenge and overcoming it! I'm back over to Bill's on the 7th so chop chop, get some sleep and get it sorted! :thumbsup:
Click to expand...

Good work... I hope it will be done by then... once the head is back on then its DP fabrication etc... that will be Tony and Bill as I can't weld and Tony is a whizz with downpipes and Bill TIG skillage is fantastic...

The Badgerwagon will be worked on over Christmas too so I will be doing bits on that inbetween mine

<tuffty/>
 
<tuffty/> said:
Good work... I hope it will be done by then... once the head is back on then its DP fabrication etc... that will be Tony and Bill as I can't weld and Tony is a whizz with downpipes and Bill TIG skillage is fantastic...

The Badgerwagon will be worked on over Christmas too so I will be doing bits on that inbetween mine

<tuffty/>
Click to expand...
Once they have done yours, I'm next for fab skillage, LOL
 
Sorry to hear that you have had more problems to day.
Hopefully tomorrow WILL be a better day!
But at least come the end of this you'll have bigger biceps & deltoids from all this lifting, a popeye! Lol

Pat
 
Nice, nothing beats a little project to get you out of the laziness of the Xmas period. Get those dyno runs when it's stone cold too ;)
 
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