Nice one mate thatd be great. Ill do a bit of digging then let you know if i need one. Ill be able to drive it up yours now lol
MUSH Developments` S3
- Thread starter MUSH
- Start date
Nice one mate thatd be great. Ill do a bit of digging then let you know if i need one. Ill be able to drive it up yours now lol
Glad to hear it all turned out ok Mush! Finally you are close to the point where you get to enjoy the work you have done. Roll on the mapping.....
Might be worth replacing the brake pedal sensor, they dont cost much and Audi revised the design of the part.
Aye so far so good! cheers Andy, it certainly feels like im getting somewhere!
Hmm, think ill look into that bud cheers, would be easier to just replace than mess on if it is sticky.
Well, had a really busy christmas, my liver probably aint my best friend but ill blame the car for all the drinking...
After i had it MOT`d i still had a few little niggles to sort out, but i thought at least id get some miles on the car. How wrong was I...!!
So anyhoo, the few little problems were the brake pedal switch which was just a bit sticky. Thats freed off perfect now and works great so no worries there. I had a sidelight bulb out but that turned out to be a loose connection. The low signal fault from number 1 knock sensor turned out to be a totally disconnected sensor. I opened the bonnet to find the connector hanging under the inlet manifold. Result! Mustnt have connected it till it clicked, or i might even have not connected it....
lol cant remember now but its connected and fault free now so all good.
I decided i was going to drop the oil and then get the wheels aligned on the friday before christmas, and at least the oil drop went smooth. The magnetic sump plug even collected a little gloop of metal filings....
All to be expected of course so no worrying there. Whilst my head was under the bonnet i found a loose bolt here...
which again is to be expected with the newly heat cycled piping. Aslong as its just these and not the pain in the **** ones you cant easily reach then ill be happy. Most of the connections are nut and bolt with Nordlock washers however the wastegate connection as shown is tapped on the wastegate body so its only a bolt. This got retightened, and ill check them periodically to ensure it remains that way! lol
So after the little mini service i was supposed to take the car for its wheel alignment, however i only got 1/2 mile down the road when the clocks turned themselves off, and all the warning lights came on!!! Buzzers went and the engine died. I literally shat myself there and then and coasted to a stop to have a look at what had occurred. Luckily everything appeared to be fine, and the only code that showed up on the liquid gauge (did i mention how good the liquid gauge is...?!!) was a voltage limit exceeded code. So it appeared to be some sort of voltage spike which i confirmed when restarting the engine as the battery warning symbol showed up. I drove the 1/2 mile back home and whipped the test meter out to find that the alternator had just chucked its dummy out!!
No charge voltage present with all the wiring and alternator fuse in place and correct. So the alternator had most probably blown a diode in the rectifier box, and surged when it did so causing the voltage limit exceeded fault code.
Not the end of the world but i had hoped of enjoying the fruits of my labour before pulling it apart again. This was the nail in the coffin with regards to much of the festive driving that i had planned, so it got parked back up in the garage and left with me needing to find an alternator.
This turned out to be an easy task as me pal had one as a spare on his shelf, however after i got it home i span it round a bit, and it appeared to have a noisy bearing. I could have put up with this but to be honest there isnt a squeak/clunk/rattle (apart form the SMF of course) coming from the new engine, it purrs lovely so i didnt want to disturb the peace with a humming alternator. Lucky for me but not for me pal Chris (EddyS3), he managed to damage his motor so is breaking it, so i snaked in and whipped his off when i went up to his to pick up some shiny bits for me mates mk4 golf. So today i got it on and decided to do the swap!
Now this would have been much easier on a "normal" S3, as the engine bay metal boost pipe connects to a rubber item which then feeds down behind the offside headlamp. This being rubber allows you to remove the alternator and tensioner and have good access to the fan belt assembly. However i have replaced this pipe with a hard aliminium pipe when redoing my boost piping, so to take my alternator and tensioner off i had to remove the inlet manifold, and practice my exceptional dexterity...
It was relatively easy with the manifold off so worth it and still easily do-able.
So after that was all back together i finally got it for its wheels aligned...
Now,... the car felt good from the garage, as i had spent some time aligning by eye, but my my, after correct aligninment it feels ****** fantastic!!!
Nice and smooth, no knocks or rattles, goes where i point it and it all feels really good. The engine has freed off some more and appears to be a bit more revvy, and the pickup from low RPMs is much better than from when i first started it. Theres obvious lag of course but it still feels a little pokey and builds the speed well. As soon as 3-3.5krpm comes the boost builds and by 4-4.5krpm it has hit the set pressure of 0.5/6 and holds it lovely. It appears to be taking off at them levels which lets face it is only a smidge of its planned capabilities, but im happy it feels good at least.
So ive had it around the doors this afternoon but that got interrupted by my daddy duties so ill endeavour to do some more tomorrow and in the next coming weeks.
EDIT... it appears ive went on a touch...lol
After i had it MOT`d i still had a few little niggles to sort out, but i thought at least id get some miles on the car. How wrong was I...!!
So anyhoo, the few little problems were the brake pedal switch which was just a bit sticky. Thats freed off perfect now and works great so no worries there. I had a sidelight bulb out but that turned out to be a loose connection. The low signal fault from number 1 knock sensor turned out to be a totally disconnected sensor. I opened the bonnet to find the connector hanging under the inlet manifold. Result! Mustnt have connected it till it clicked, or i might even have not connected it....
lol cant remember now but its connected and fault free now so all good.I decided i was going to drop the oil and then get the wheels aligned on the friday before christmas, and at least the oil drop went smooth. The magnetic sump plug even collected a little gloop of metal filings....
All to be expected of course so no worrying there. Whilst my head was under the bonnet i found a loose bolt here...
which again is to be expected with the newly heat cycled piping. Aslong as its just these and not the pain in the **** ones you cant easily reach then ill be happy. Most of the connections are nut and bolt with Nordlock washers however the wastegate connection as shown is tapped on the wastegate body so its only a bolt. This got retightened, and ill check them periodically to ensure it remains that way! lol
So after the little mini service i was supposed to take the car for its wheel alignment, however i only got 1/2 mile down the road when the clocks turned themselves off, and all the warning lights came on!!! Buzzers went and the engine died. I literally shat myself there and then and coasted to a stop to have a look at what had occurred. Luckily everything appeared to be fine, and the only code that showed up on the liquid gauge (did i mention how good the liquid gauge is...?!!) was a voltage limit exceeded code. So it appeared to be some sort of voltage spike which i confirmed when restarting the engine as the battery warning symbol showed up. I drove the 1/2 mile back home and whipped the test meter out to find that the alternator had just chucked its dummy out!!
No charge voltage present with all the wiring and alternator fuse in place and correct. So the alternator had most probably blown a diode in the rectifier box, and surged when it did so causing the voltage limit exceeded fault code.
Not the end of the world but i had hoped of enjoying the fruits of my labour before pulling it apart again. This was the nail in the coffin with regards to much of the festive driving that i had planned, so it got parked back up in the garage and left with me needing to find an alternator.
This turned out to be an easy task as me pal had one as a spare on his shelf, however after i got it home i span it round a bit, and it appeared to have a noisy bearing. I could have put up with this but to be honest there isnt a squeak/clunk/rattle (apart form the SMF of course) coming from the new engine, it purrs lovely so i didnt want to disturb the peace with a humming alternator. Lucky for me but not for me pal Chris (EddyS3), he managed to damage his motor so is breaking it, so i snaked in and whipped his off when i went up to his to pick up some shiny bits for me mates mk4 golf. So today i got it on and decided to do the swap!
Now this would have been much easier on a "normal" S3, as the engine bay metal boost pipe connects to a rubber item which then feeds down behind the offside headlamp. This being rubber allows you to remove the alternator and tensioner and have good access to the fan belt assembly. However i have replaced this pipe with a hard aliminium pipe when redoing my boost piping, so to take my alternator and tensioner off i had to remove the inlet manifold, and practice my exceptional dexterity...
It was relatively easy with the manifold off so worth it and still easily do-able.
So after that was all back together i finally got it for its wheels aligned...
Now,... the car felt good from the garage, as i had spent some time aligning by eye, but my my, after correct aligninment it feels ****** fantastic!!!
Nice and smooth, no knocks or rattles, goes where i point it and it all feels really good. The engine has freed off some more and appears to be a bit more revvy, and the pickup from low RPMs is much better than from when i first started it. Theres obvious lag of course but it still feels a little pokey and builds the speed well. As soon as 3-3.5krpm comes the boost builds and by 4-4.5krpm it has hit the set pressure of 0.5/6 and holds it lovely. It appears to be taking off at them levels which lets face it is only a smidge of its planned capabilities, but im happy it feels good at least.So ive had it around the doors this afternoon but that got interrupted by my daddy duties so ill endeavour to do some more tomorrow and in the next coming weeks.
EDIT... it appears ive went on a touch...lol
Dan the sump plug is an ebay jobby. Ive heard they leak so i didnt use the copper washer that came with it, i used a nice chunkier one from a motor factor. I havnt had any leaks from mine though.
Magnetic Sump Plug for VW Golf GTi 1.8T 20v Turbo Audi | eBay
The heat wrap on the downpipe and wastegate piping was done by AAS who built the exhaust. Not sure on the make but i doubt they use shyte mind considering what they do. Ive used some leftover stuff in my bay to wrap the breather pipes, but thats just ebay £20 a roll stuff that i had kicking around from past projects.
Magnetic Sump Plug for VW Golf GTi 1.8T 20v Turbo Audi | eBay
The heat wrap on the downpipe and wastegate piping was done by AAS who built the exhaust. Not sure on the make but i doubt they use shyte mind considering what they do. Ive used some leftover stuff in my bay to wrap the breather pipes, but thats just ebay £20 a roll stuff that i had kicking around from past projects.
- Joined
- Dec 8, 2006
- Messages
- 12,100
- Reaction score
- 4,340
- Points
- 113
- Location
- Eastleigh
- Website
- twitter.com
Awesome news mate, it wouldn't be a christmas holiday without a minor breakdown! haha. mine threw a driveshaft bolt and developed a killer wobbly whilst out for a hoon!
Car looks good on those wheels too, I like, very purposeful.
I think I'm slowly coming round to the idea of an S3 should I ever bin the track car
Car looks good on those wheels too, I like, very purposeful.
I think I'm slowly coming round to the idea of an S3 should I ever bin the track car
- Joined
- May 28, 2004
- Messages
- 10,217
- Reaction score
- 2,385
- Points
- 113
- Location
- nr Glos
- Website
- www.badger5.co.uk
what turbo is on the cts kit you have?
how did you find fitment and clearances on their external wg setup?
I have one here for going onto a TT and the fit is shyte... rejecting it.
how did you find fitment and clearances on their external wg setup?
I have one here for going onto a TT and the fit is shyte... rejecting it.
Awesome news mate, it wouldn't be a christmas holiday without a minor breakdown! haha. mine threw a driveshaft bolt and developed a killer wobbly whilst out for a hoon!
Car looks good on those wheels too, I like, very purposeful.
I think I'm slowly coming round to the idea of an S3 should I ever bin the track car
Cheers Nick, yeah im certainly happy with the wheels, considering i didnt choose them, and probably wouldnt in a million years. But they do look good. They fill the arches nicely and look ace in any on the move reflective surfaces... lol
The S3 is certainly a good looker so you wouldnt be thought bad of for liking it.
Bill my turbo is a GT3071 built by Turbo Dynamics to a customers request. It has the 0.63 hotside and the coldside is a polished compressor cover from an unknown source. For fitment the only problem i had was slight clearance issues on the bulkhead, on the engine bay side of the scuttle, which i bashed a little to aid in clearance.
The only thing CTS supplied was the manifold. The rest i have built up myself, hence the pipework is custom and fits perfect. It is a bit tight down there though, and given the choice again, i would go for a tubular setup with turbo positioning much like yours and JBS`s manifolds.
Last edited:
Cars looking really good there mate. Must be great to have got to the light at the end of the tunnel!!! I have just got one of the Liquid Gauges for Christmas (present from the other half) they are a really neat piece of kit.
Cheers! Not quite at the end of the tunnel yet matey, but theres definate rays of light....lol
The liquid is worth every penny for me. It has enabled me to diagnose faults very quickly without getting the laptop out and has proved to be invaluable with regards to keeping my eye on the brand new engine, so that everything is within tolerance and working fine. For example if the liquid showed some dodgy results like bad afr`s/missfiring etc then i would have acted accordingly as situations like that could have bad affects on the whole of the engines life. With no liquid it is possible i could miss these or worse still have to gett he laptop out constantly, which i would to be fair as im a touch pedantic...
On that size project I think you have to be pedantic or you are going to miss something really important or more likely expensive!!
I hope the end of that tunnel is not to far away and you get PLAY :thumbsup:
I hope the end of that tunnel is not to far away and you get PLAY :thumbsup:
tony696
Registered User
After a good 2 cups of tea, a nando's, trip to tesco and an apple ive read the whole thing! Such a good thread MUSH! You've done some excellent work here! One thing i need to do is re-align my headlights as one seems to be abit wonky so i had a peek at your pics! lol
Cheers bud, you have good taste, love nandos....
Bit of an update on this one now. Car is, or was running mint! Feels really smooth and its nice and poky now. Had a few minor issues what with the paggered alternator, but apart from that its been quite good.
One slight issue i had was that the boost gauge stopped going to -0.6 bar when idling, and would then not shoot up to 0.5 bar when on boost as it had been doing. The boost gauge was also acting a little lazy. Coupled to the fact that i have terrible mpg at around 20, i at first thought i had a boost leak. So took the car up to me pals house and got the boost leak tester on the go. Found a few minor leaks but nothing major. Fixed them up but the gauge still read low. With every worst thought imaginable going through my head including either a nackered boost gauge as i had tampered with it to change the colours, or even worse a duff engine that wasnt sealing hence lack of vacuum.
Luckily i started by pulling the A pillar off to check the operation of the boost gauge and found the pipe kinked behind!! woop woop. Easy fix so i cut that bit of pipe off and reconnected and its now reading as it should at -0.8/-0.9 on idle and it also shoots to 0.7 bar on boost. which is exactly what the wastegate spring is set to so all good!!! It only ever went to 0.5/0.6 bar on boost so now its reading correctly i feel a bit better. This was also confirmed with the liquid gauge boost readout. So now with 850 miles on the engine and the turbo boosting to 0.7 bar, afrs looking good albeit a tad rich (more on this), im registering this on the liquid...
However it didnt solve my overfuelling issue. MPG as mentioned is around 20, and on boost im hitting 0.82 lambda which is just a tad rich so next point to look at was the temperature which has always been on my mind as although the cockpit gauge goes to 90, we all know they err.... LIE. The liquid gauge shows the temp to be more like 75-80ish degrees so i at first swapped the CTS with a good one i have, but that read the same. So the obvious next point was the thermostat. So a bit of draining...
and err, minor engine disassembly...
I could then get at the thermostat. I did try to remove it with everything in place but the bottom bolt was a cow whore, so i just whipped the inlet off aswell to save time and aggro. Ive got big mitts and my 1/4 socket set wobble bar is knackered so getting into this gap was challenging...
When removed, all was clear as to why the engine was running a bit cooler. Id wrongly been sent a 71 degree VR6 low temp stat, instead of the 82 degree 1.8t stat. Now im partly to blame here for not checking (how naiive of myself to think i would get the product i have ordered), but its all in hand now and im getting sent the correct one now so all is good. Thatll not be here til monday so the car will have to wait for now.
Another job to look at was the slight blow coming from the exhaust manifold area. This only showed itself after reading Andrews thread on this subject (Doh) so i needed to have a look at that. The soot had blackened the exhaust heatshielding around the turbo...
Not that the pic is that clear, but luckily for me when i started to strip things i found this...
[video]http://s82.photobucket.com/albums/j259/mush_bucket/?action=view&current=e400d05b.mp4[/video]
which is the wastegate dump pipe. It had worked its way loose. Luckily its an easy fix as all i had to remove then was the turbo intake pipe, so i could reach down and around with a 13mm spanner and tighten the nuts up again. Got them nice and tight so hopefully thats it fixed. If it comes loose again ill chuck some nordlocks on there aswell. Already got them on the manifold to turbo flange and thats solid.
Last but not least was the fact that i couldnt recline my drivers seat back support. Now im sure i had doen this when i first got the car but i must have dreamt it up as when i removed the seat to investigate, i found the connector...
simply wasnt connected! So another easy fix and now the seat works fine!
So at the minute, the car is off the road, waiting for the new stat to arrive and then itll be in with hopefully a better temperature and MPG to boot!!
Aye its a fooker, i could get to it with an allen key with a wibble end but it snapped the wobble end clean off it was that tight. So i just took the manifold off, and it became easy.
Funny thingis ive just changed a stat on my pals non aircon mk4 1.8t and it was a doddle, 20 mins max!!
- Joined
- May 28, 2004
- Messages
- 10,217
- Reaction score
- 2,385
- Points
- 113
- Location
- nr Glos
- Website
- www.badger5.co.uk
0.82 is'nt too rich under boost.. maybe a little for 0.7bar but not catastrophic... got logs of what its requesting vs boost? (031,115)
Ive now got the new thermostat fitted. This one maintains the correct temperatures though!
Previously i found that i had a 71 deg stat instead of the required 82 deg. Now its swapped the coolant temperatures are up, and now hover around the 85-90 degree level as read from the liquid gauge. Oil temps are stay around 85-90 so its all sitting nice. Ambient at the time of reading was todays 13 deg. Another improvement is that the mpg has gone up, with the screen now up to 25mpg from the quick 10 mile drive i had earlier.
I also had to dismantle the top of the engine again though, to get to the blow in the exhaust that hadnt been fixed by tightening up the wastegate pipe bolts. I removed the turbo intake pipe and then started the car up. With my hand down the back of the manifold i could feel the hot air escaping from the same spot. So off with the strut brace, wastegate into downpipe dump pipe, wastegate, and then finally the wastegate dump pipe from the flange on the mainfold. With everything removed, the exhaust blow was evident....
The gasket on the left was the gasket that had failed (obviously). My analysis is that the initial heat cycle put through the system has expanded the relevant fixing bolts and allowed them to loosen slightly (VBand flanges FTW). This also happened on the top wastegate piping bolts, however i managed to resecure them as they were in sight from up above. The resultant movement in the pipe and manifold flange has allowed exhaust gas to blow through the gasket as can be seen. The disturbing find is that the failed gasket has also been modified to allow for a bigger bolt spacing. This also may have contributed to the gasket failing. The other two gaskets are those that were supplied with the wastgate itself and they down look up to much either.
So i headed back over to AAS and Stu kindly replaced all the gaskets with decent metal items and i put it all back together. The failed gasket flange went back together without the requirement for modification, and the rest bolted up fine. Its a bit of a pig getting to the wastegate flange on the manifold, but doable if you sprawl yourself over the engine bay and reach around with a 13mm ring spanner.
Needless to say now its all back together and running perfect again with now leaks, so im a happy bunny.
My ******* (formerly) trusty garage laptopamabob has just decided to spit its dummy out though so im going to have to get a new battery before i can get back out on the road for some testing.
Im seriously considering booking the car in to get mapped soon aswell as its pretty much ready bar the inlet manifold. Id like to get that made up but theres a lot more work involved including new fuel lines/mounting the fuel pressure regulator/new boost piping including DV piping and most probably, relocating the battery. So the mainfold might have to wait for a bit. Id rather drive the car mapped and then maybe add all that a bit later on...
Previously i found that i had a 71 deg stat instead of the required 82 deg. Now its swapped the coolant temperatures are up, and now hover around the 85-90 degree level as read from the liquid gauge. Oil temps are stay around 85-90 so its all sitting nice. Ambient at the time of reading was todays 13 deg. Another improvement is that the mpg has gone up, with the screen now up to 25mpg from the quick 10 mile drive i had earlier.
I also had to dismantle the top of the engine again though, to get to the blow in the exhaust that hadnt been fixed by tightening up the wastegate pipe bolts. I removed the turbo intake pipe and then started the car up. With my hand down the back of the manifold i could feel the hot air escaping from the same spot. So off with the strut brace, wastegate into downpipe dump pipe, wastegate, and then finally the wastegate dump pipe from the flange on the mainfold. With everything removed, the exhaust blow was evident....
The gasket on the left was the gasket that had failed (obviously). My analysis is that the initial heat cycle put through the system has expanded the relevant fixing bolts and allowed them to loosen slightly (VBand flanges FTW). This also happened on the top wastegate piping bolts, however i managed to resecure them as they were in sight from up above. The resultant movement in the pipe and manifold flange has allowed exhaust gas to blow through the gasket as can be seen. The disturbing find is that the failed gasket has also been modified to allow for a bigger bolt spacing. This also may have contributed to the gasket failing. The other two gaskets are those that were supplied with the wastgate itself and they down look up to much either.
So i headed back over to AAS and Stu kindly replaced all the gaskets with decent metal items and i put it all back together. The failed gasket flange went back together without the requirement for modification, and the rest bolted up fine. Its a bit of a pig getting to the wastegate flange on the manifold, but doable if you sprawl yourself over the engine bay and reach around with a 13mm ring spanner.
Needless to say now its all back together and running perfect again with now leaks, so im a happy bunny.
My ******* (formerly) trusty garage laptopamabob has just decided to spit its dummy out though so im going to have to get a new battery before i can get back out on the road for some testing.
Im seriously considering booking the car in to get mapped soon aswell as its pretty much ready bar the inlet manifold. Id like to get that made up but theres a lot more work involved including new fuel lines/mounting the fuel pressure regulator/new boost piping including DV piping and most probably, relocating the battery. So the mainfold might have to wait for a bit. Id rather drive the car mapped and then maybe add all that a bit later on...
- Joined
- Nov 11, 2009
- Messages
- 10,099
- Reaction score
- 739
- Points
- 38
- Location
- west yorks
- Website
- www.stainless-engineering.co.uk
What happened!? An untimely death of a great build thread???
Oops!!
Suppose it has been a while... Cars still goin great, unmapped as yet as ive just been far too busy with other things. Everythings working fine but one thing that needs addressed is i think i need a firmer dogbone mount as the current THS isnt coping well and you can feel some movement. Ive already got the firmer bush so that will go on soon.
Got my fuel pump ready to go on aswell... DA31
So ill update soon with them bits. I have been driving it plenty though...
- Joined
- Dec 8, 2006
- Messages
- 12,100
- Reaction score
- 4,340
- Points
- 113
- Location
- Eastleigh
- Website
- twitter.com
Lame update but things are progressing. As ever got a million things on at the minute and the car hasnt even been on the road for the past month. The tax ran out and ive been on my hols etc so i just sorn`d it. Its now back on the road and going great.
Got the DA-31 pump fitted. Was a doddle really. Fitted the pump with 034 motorsport fittings so they clip into the existing fuel lines. Then cabled the mini loom from the existing fuel pump wiring. Added an extra earthing point under the rear seat as ive known the earth not being very good to the pump so its all good. I wrapped the pump in a bit of rubber and then taped round it just to make it a bit neater.
Naff picture but i was sick of being on my back stinking of petrol...
Ive also relocated the filter to the bay using a cupra filter and some more vag fuel pipe fittings. ill get some pics of that up soon. Its located under the boost pipe on the lhs of the engine, however i might change the location again when i fit the RMR manifold. Good news on that is that ive mocked it up, marked it and its now with Mick at MB motorsport getting welded up so itll be back to me soon. Then itlll just be a slight change to the charge piping to the throttle body to get that fitted. Cant wait as thats the last job needed before i get it mapped.
Ive spoke to Paul Murray, and im looking at getting it in for mapping end of july/Early August depending on his holidays. So im well excited about that.
The other job ive got on with is the dogbone movement i was getting. The mounts are 6 month old THS mounts and the pendulum mounts are still pretty soild but the dogbone was letting the engine rock on gear change etc. You could feel the hesitation in the car. So i whipped the mount off. The rear bushes were still pretty damn solid but the front bush that connects to the gearbox was embarrassingly floppy. I could literally move it fully with my hand...
So i got a superflex front bush kit, and already had the red diesel rear bushes so i thought id just strip and refit the lot for peace of mind...
And now its perfect!! No movement, and no additional vibration. It feels solid, and planted so im happy with that!
And as weve not had storms today, i got caught in the tyne tunnel last thursday...
Ive spent a few hours cleaning/polishing/waxing the car today. Not that you can tell because its silver and looks no better than when i started!
Got the DA-31 pump fitted. Was a doddle really. Fitted the pump with 034 motorsport fittings so they clip into the existing fuel lines. Then cabled the mini loom from the existing fuel pump wiring. Added an extra earthing point under the rear seat as ive known the earth not being very good to the pump so its all good. I wrapped the pump in a bit of rubber and then taped round it just to make it a bit neater.
Naff picture but i was sick of being on my back stinking of petrol...
Ive also relocated the filter to the bay using a cupra filter and some more vag fuel pipe fittings. ill get some pics of that up soon. Its located under the boost pipe on the lhs of the engine, however i might change the location again when i fit the RMR manifold. Good news on that is that ive mocked it up, marked it and its now with Mick at MB motorsport getting welded up so itll be back to me soon. Then itlll just be a slight change to the charge piping to the throttle body to get that fitted. Cant wait as thats the last job needed before i get it mapped.
Ive spoke to Paul Murray, and im looking at getting it in for mapping end of july/Early August depending on his holidays. So im well excited about that.
The other job ive got on with is the dogbone movement i was getting. The mounts are 6 month old THS mounts and the pendulum mounts are still pretty soild but the dogbone was letting the engine rock on gear change etc. You could feel the hesitation in the car. So i whipped the mount off. The rear bushes were still pretty damn solid but the front bush that connects to the gearbox was embarrassingly floppy. I could literally move it fully with my hand...
So i got a superflex front bush kit, and already had the red diesel rear bushes so i thought id just strip and refit the lot for peace of mind...
And now its perfect!! No movement, and no additional vibration. It feels solid, and planted so im happy with that!
And as weve not had storms today, i got caught in the tyne tunnel last thursday...
Ive spent a few hours cleaning/polishing/waxing the car today. Not that you can tell because its silver and looks no better than when i started!
- Joined
- Sep 14, 2008
- Messages
- 24,836
- Reaction score
- 6,078
- Points
- 113
- Location
- Wibbleton
- Website
- www.tuffty.co.uk
Good work mate... seems to be a resurgence of activity on our build threads recently as we find time (and a little cash) to do stuff...
<tuffty/>
<tuffty/>
- Joined
- Sep 14, 2008
- Messages
- 24,836
- Reaction score
- 6,078
- Points
- 113
- Location
- Wibbleton
- Website
- www.tuffty.co.uk
....Probably be done by now if we had some decent weather to enjoy it in...
Amen to that brother... all I wanted to do today was fit the new engine earth cable I made up but no... didn't rain all day... 10mins after getting home from Bill's and down it comes!!! ***!!
<tuffty/>
- Joined
- Nov 11, 2009
- Messages
- 10,099
- Reaction score
- 739
- Points
- 38
- Location
- west yorks
- Website
- www.stainless-engineering.co.uk
Have you a pic of the LCR filter, just bought a replacement filter but it is bigger than the one that's on!
- Joined
- Sep 14, 2008
- Messages
- 24,836
- Reaction score
- 6,078
- Points
- 113
- Location
- Wibbleton
- Website
- www.tuffty.co.uk
Cupra could be an Ibiza too.. Ibiza filter is the smaller one and what I have used...
<tuffty/>
<tuffty/>
- Joined
- Nov 11, 2009
- Messages
- 10,099
- Reaction score
- 739
- Points
- 38
- Location
- west yorks
- Website
- www.stainless-engineering.co.uk
Decided id had enough of the coilies, they were literally stopping me from getting the car out because i didnt like the ride. The whole point of this car and my previous projects have been the ability to storm down this particular bit of B road close to my house, and on the FK coilovers this wasnt possible. The car would crash heavily from the front, appear skittish over the bumps and not handle well around the harsh bends. Not that theres anything wrong with the suspension, but they were just the wrong choice for hte task in hand.
So, ive just received these bad boys from me good pal Damian @ DPM...
Which are nice and shiny...
Its the KW 20/15mm lowered sports kit. Looks the dogs danglys and with good reports coming from Westy and a few others i thought this was the way to go.
My only sceptical thought was with how the car would sit as theres many that sit with positive rake, which i cant stand the look of, nowt like a bit of negative rake nose down aggressiveness... lol
But it appears they sort this with this spacer pad that goes between the chassis and the rubber upper spring seat. Spacer on the left...
So got cracking with the rears first and had them swapped over in no time. Had to compress the new springs a bit to get them in, but apart from that it was all basic shizzle. Was gutted as i forgot to unhook the level sensor and ended up snapping the plastic hook, but that was sorted with a few oversize washers either side that clamped the plastic shut and enable correct operation.
After that was all sorted i moved onto the fronts, which went quite well. Id chucked the old suspension a long time ago, which meant i had no bump stops, dust covers or top spring plates. So a trip to TPS got me the bump stops and spring plates, and a trip down to Veedubs to see Gilly had me some dust covers and the newer rubber spring seats for the rear as i had to mod mine to fit the FKs. Along with new standard top mounts and bearings, got them built up on the bench...
and then transferred to the car. These needed no compression which was nice, and then it was a case of just bolting them all up. Also had to change to standard ARB drop links as i had the shorter ones needed for the FKS. The shorter drop links were surprisingly rotten and were a right pain to get off the ARB.
Got them all on and the car together and took it for a good blast to see how the new setup holds up. The answer is absolutely class!! Without stating the obvious, the kit has totally transformed the car, and it handles great. On the same road where the FKs made the car a pain, the KWs make it a dream to drive. It glides over the bumps with great feedback and now the car sticks in the corners which means i can push it much harder. It certainly does`nt crash out and now ive got confidence again in the chassis.
And after a good drive it has settled and sits pretty darn good too...
So celebrations...
Just leaves mapping to sort which im ashamed to say hasnt happened yet. I took the inlet off to get sorted but Mick whos welding it has been rushed off his feet so hasnt got round to it. If he cant do it in the next week ill probably get it back and give it to someone else to sort. Ive got an RS4 maf, bigger filter, 630cc injectors, BKR8s all ready to go in when required.
In unmapped state of tune i still whipped an astra GTE yesterday though, which made me smile...
So, ive just received these bad boys from me good pal Damian @ DPM...
Which are nice and shiny...
Its the KW 20/15mm lowered sports kit. Looks the dogs danglys and with good reports coming from Westy and a few others i thought this was the way to go.
My only sceptical thought was with how the car would sit as theres many that sit with positive rake, which i cant stand the look of, nowt like a bit of negative rake nose down aggressiveness... lol
But it appears they sort this with this spacer pad that goes between the chassis and the rubber upper spring seat. Spacer on the left...
So got cracking with the rears first and had them swapped over in no time. Had to compress the new springs a bit to get them in, but apart from that it was all basic shizzle. Was gutted as i forgot to unhook the level sensor and ended up snapping the plastic hook, but that was sorted with a few oversize washers either side that clamped the plastic shut and enable correct operation.
After that was all sorted i moved onto the fronts, which went quite well. Id chucked the old suspension a long time ago, which meant i had no bump stops, dust covers or top spring plates. So a trip to TPS got me the bump stops and spring plates, and a trip down to Veedubs to see Gilly had me some dust covers and the newer rubber spring seats for the rear as i had to mod mine to fit the FKs. Along with new standard top mounts and bearings, got them built up on the bench...
and then transferred to the car. These needed no compression which was nice, and then it was a case of just bolting them all up. Also had to change to standard ARB drop links as i had the shorter ones needed for the FKS. The shorter drop links were surprisingly rotten and were a right pain to get off the ARB.
Got them all on and the car together and took it for a good blast to see how the new setup holds up. The answer is absolutely class!! Without stating the obvious, the kit has totally transformed the car, and it handles great. On the same road where the FKs made the car a pain, the KWs make it a dream to drive. It glides over the bumps with great feedback and now the car sticks in the corners which means i can push it much harder. It certainly does`nt crash out and now ive got confidence again in the chassis.
And after a good drive it has settled and sits pretty darn good too...
So celebrations...
Just leaves mapping to sort which im ashamed to say hasnt happened yet. I took the inlet off to get sorted but Mick whos welding it has been rushed off his feet so hasnt got round to it. If he cant do it in the next week ill probably get it back and give it to someone else to sort. Ive got an RS4 maf, bigger filter, 630cc injectors, BKR8s all ready to go in when required.
In unmapped state of tune i still whipped an astra GTE yesterday though, which made me smile...
- Joined
- Dec 2, 2008
- Messages
- 17,400
- Reaction score
- 1,104
- Points
- 113
I'm glad you like the suspension mate. I've been raving about set height kits over coils for roads cars. I love my KW kit.
Yeah must say the kit is pretty good, one of the best mods ive done to the car! Love how it drives now!
Similar threads
