W3STY's Progress Thread

[Westy]

Oh yeah... and make sure you cover the crank journals so the crud doesn't get on them and watch the oil squirters!!!

<tuffty/>

What's the best way to protect the crank from any of the crap dropping down onto it?

 

[badger5]

Oh yeah... and make sure you cover the crank journals so the crud doesn't get on them and watch the oil squirters!!!

<tuffty/>

be very carefull doing honing remembering oil squirters are easily clobbered and bent.. AND also when you drop the rods in, make very sure they also dont clobber the squirters... very easy to clip them and bend them backwards with the rod.

 

[<tuffty/>]

What's the best way to protect the crank from any of the crap dropping down onto it?

Rags and shizzle

<tuffty/>

 

[Westy]

Rags and shizzle

<tuffty/>

Real technical yeah

 

[<tuffty/>]

Real technical yeah

Pretty much

<tuffty/>

 

[Westy]

I've been doing some reading on bore honing and surface prep and there seems to be mixed opinions. Some people say "leave it to the professionals" and some people say "DIY".

Apparently its easy to get it wrong if you hone at the wrong angle or at the wrong RPM. Bear in mind that I'll be doing it with the block in situ (decided to leave it in now) so would need to get the hone brush dead straight over the top of each bore to get it just right.

I assume that just banging in fresh rings without honing/prepping each bore is a big no no?

 

[<tuffty/>]

Its not that much of a black art... you do need to take the usual precuations but there are plenty of videos on youtube (including the ones in my build thread I linked too)

There needs to be a cross hatch pattern that helps 'machine' the rings to the bore.... don't fit rings if you are not honing

<tuffty/>

 

[Westy]

Its not that much of a black art... you do need to take the usual precuations but there are plenty of videos on youtube (including the ones in my build thread I linked too)

There needs to be a cross hatch pattern that helps 'machine' the rings to the bore.... don't fit rings if you are not honing

<tuffty/>

My main worry is that I could fit new rings and hone but still end up with problems due to me doing it wrong. Then again I could refit the worn rings and end up with problems at a later date too

 

[badger5]

I've been doing some reading on bore honing and surface prep and there seems to be mixed opinions. Some people say "leave it to the professionals" and some people say "DIY".

Apparently its easy to get it wrong if you hone at the wrong angle or at the wrong RPM. Bear in mind that I'll be doing it with the block in situ (decided to leave it in now) so would need to get the hone brush dead straight over the top of each bore to get it just right.

I assume that just banging in fresh rings without honing/prepping each bore is a big no no?

Given your cars performance is pretty good.... I doubt there's much wrong with your rings..
I would be temped to leave them and the bores alone. Clean the piston crowns and reinstall

unless you see nasty scoring when you take it apart it will be ok more than likely

you risk more than you are likely to "improve"

 

[Westy]

Given your cars performance is pretty good.... I doubt there's much wrong with your rings..
I would be temped to leave them and the bores alone. Clean the piston crowns and reinstall

unless you see nasty scoring when you take it apart it will be ok more than likely

you risk more than you are likely to "improve"

Thanks Bill. That's exactly what i'm worried about! I could do more harm by fitting new rings. I'll assess the rings and bores once it's apart.

 

[Reesy]

Thanks Bill. That's exactly what i'm worried about! I could do more harm by fitting new rings. I'll access the rings and bores once it's apart.

Access or assess?

 

[Westy]

Little bit of progress tonight. Firstly I wanted to line up the XS mani with the head to see what I'm working with getting the nuts onto the studs. It's tighter then a gnats a-hole! I'm going to do what Prawn did and get a 12mm ring spanner and cut enough out of it so I can get it over the nuts.

Here's some pics of how tight it is:

After knowing what i'd be dealing with when getting round to the mani I decided to start painting my spare BAM rocker cover in "Kermit Green"

It's coming along nicely. Going to leave it for a week now to dry before applying another 3 coats. I also need to bake it in the oven for an hour at 100C to cure it!

Last job of the night was to make my phenolic gasket into a transition gasket so that there's a smooth transition between the small port inlet manifold and the larg port head:

Small Port side:

Large port side:

And with the large port gasket over the top you can see I still need to tidy up the edges a bit:

 

[Jimgrim77]

I hear you in the tight fit experience. Mine was a ***** to fit.

I just to give you a heads up for your clutch install too. Was speaking to my Mechanic today and he mentioned how little space there is to work on the car with all of the uprated parts like arbs, Downpipe, mani, turbo etc...to physically access get to the clutch and flywheel. He said it delayed him a couple of hours over standard set up. You may experience the same.

 

[s3dave]

Nice progress, hair dryer works a treat for hi gloss....

 

[Dane]

Try putting the mani in the oven for fifteen mins it might make it a lil bit more willing to play ball and make it a wee bit easier

 

[Westy]

Try putting the mani in the oven for fifteen mins it might make it a lil bit more willing to play ball and make it a wee bit easier

What do you mean mate? Surely all that will happen is I'll end up with a hot manifold that's now even more difficult to get a nut onto an already tight stud?!

 

[StaceyS3]

Will expand very marginally, usually heat external bearings sleeves if they're an interference fit as can make it expand enough to slide on a shaft then shrinks back tight as it cools, may be enough if you've got one stud that doesn't quite line up with a hole but would usually only expand couple of hundreths of a mm

It's looking good mate all prep for it's Easter treat

 

[Westy]

Will expand very marginally, usually heat external bearings sleeves if they're an interference fit as can make it expand enough to slide on a shaft then shrinks back tight as it cools, may be enough if you've got one stud that doesn't quite line up with a hole but would usually only expand couple of hundreths of a mm

It's looking good mate all prep for it's Easter treat

There's no problem with fitment at all, it goes over all studs like a glove. Just not looking forward to getting cramp trying to tighten the nuts for those difficult studs

Prep wise I'm now there. Just need to wet and dry the phenolic gasket so it's spot on and give the rocker cover another few coats of paint.

I've now got all the parts I need except the 2 most important, the rods and the clutch!

 

[Sandra]

You re making fantastic progress now westy. Im loving the Kermit green mani. When are you getting the clutch and the rods? Will you have them on time for the easter build? Keep up the good work westy.

 

[Westy]

You re making fantastic progress now westy. Im loving the Kermit green mani. When are you getting the clutch and the rods? Will you have them on time for the easter build? Keep up the good work westy.

Rods should be within the next week or two. Backdraft are chasing IE up. The clutch kit is coming from Awesome and even though they said that the parts are out of stock, they told me that they can get them in within 2 days. So far it's been a week!

Still got 4 weeks till the build so I should have everything in time. I bought everything nice and early just incase I encountered any delays like this.

 

[Westy]

My parcel from awesome turned up today.

1 slave cylinder/release bearing:

1 black coolant bottle cap:

1 clutch plate:

And 1 pressure plate:

Just waiting in the rods from IE now which are due to be dispatched from the states in the next few days so should have them by next week.

 

[<tuffty/>]

Have you/are you fitting a single mass flywheel mate? like you and my thread I can't keep up with yours either lol ;P

<tuffty/>

 

[Westy]

Whoops, I missed the flywheel.

SMF weighted to give the same pedal feel as a double apparently:

 

[<tuffty/>]

Phew!

<tuffty/>

 

[Westy]

Phew!

<tuffty/>

I started making dinner and I was thinking to myself that box was rather heavy considering there wasn't much in it. Then the penny dropped

 

[Andrew@A.L.D]

What clutch is that? It better not be one of them red crap techniclutches!!

 

[Westy]

What clutch is that? It better not be one of them red crap techniclutches!!

Haha no mate I wa warned to steer clear of those, maybe by yourself. This is Awesome GTIs clutch kit which they have apparently been testing for a while and run on one of their cars puttin out over 400lbft torque.

Nobody had tried it on their S3 so I thought I'd be the ginnea pig

 

[Andrew@A.L.D]

Thank god

Was the testing done in a FWD of 4WD car?

 

[Westy]

Thank god

Was the testing done in a FWD of 4WD car?

It doesn't say. Take a look here:

http://www.awesome-gti.co.uk/product.php?xProd=47051&xSec=9418

 

[s3dave]

Haha no mate I wa warned to steer clear of those, maybe by yourself. This is Awesome GTIs clutch kit which they have apparently been testing for a while and run on one of their cars puttin out over 400lbft torque.

Nobody had tried it on their S3 so I thought I'd be the ginnea pig

The birth of the Freddo clutch.....:icon_thumright:

 

[Dani_B19]

Any idea what the weight of the smf is compared to the dmf westy?

 

[Westy]

Any idea what the weight of the smf is compared to the dmf westy?

I'm guessing this one will be similar to the duel mass as it's weighted so it feels the same but I'll weight them both for you if you like?

 

[Jason.s]

Same as the diesel flys we use on the a4s. Wish I had it lightened though

 

[Westy]

Same as the diesel flys we use on the a4s. Wish I had it lightened though

Thing is, I've had harsh clutches on other cars in the past and it doesn't bother me for the short trips I normally do. I'm not fussed about messing withthis flywheel I'll just fit it all as it is.

 

[Dani_B19]

Yeah if you can please mate.

 

[<tuffty/>]

Same as the diesel flys we use on the a4s. Wish I had it lightened though

So Westy's SMF is an actual VAG part?

<tuffty/>

 

[Jason.s]

Nah i just mean the diesel SMF we use on the A4`s are the same weight as the DMF sadly. No idea what fly the Awesome kit uses.

 

[Westy]

Nah i just mean the diesel SMF we use on the A4`s are the same weight as the DMF sadly. No idea what fly the Awesome kit uses.

I wouldn't be surprised if it was a sodding VAG part from another model.

 

[Westy]

I thought I'd grab a few rocker cover shots with the R8 cap on it (just for Sportstractor) before I put the last coats of paint on it. Just needs to be cured in the oven now then a coat of lacquer to finish it off.

 

[sportstractor]

Nice, won't look so great when covered in oily finger prints though.

Also just seen on Facebook. Rtech have managed to get a ko4 to 304bhp... On their rollers anyway... But you will easily smash that with your r8 cap