Stacey's Belated Yo Yo Build Thread

The pistons definately look a lot worse and looks like one of the pistons and rods has been changed as casting marks on the rods are slightly different and piston is in good nick with no damage, but iirc that was cylinder 3?

Will chuck some pics of the pistons up shortly athough the markings/numbers have rubbed off so can't define which was no 1 :(
 
I think this is the order they were in but not entirely sure

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First one as lined up in the pic

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Forth as they're lined up

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Cheers Andrew was hoping for your advice ;)
 
Pistons will be new and probably 83mm bore this was just a spare engine I picked up on the basis I could build the bottom end up and just swap it with mine then same with the head at a later date ;)

Do you think the head will be ok to use?
 
They look like theyve seen better days mate.

83mm pistons, will that make the engine into 1900cc or just a bit over?
 
Definately seen better days mate was hoping to recoup some money by selling bits but don't think they'll be any good for resale? :(

Cc wise I'm not entirely sure what 83mm will achieve but I know that with a certain crank it's 2008cc iirc :whistle:
 
The head can be fixed easy

Depending how much its been skimmed already but if it was me i would do a bit of welding to the face of it were the get has marked it then skim it to the minimum amount

83mm bore with a 1.8 crank will give 1900, with a 2.0 crank 2008 and with the 1.9TDI crank 2067 like mine

There are other cranks out there that can be used rather than the FSI crank
 
Cheers Andrew appreciate the help :)

Do you know if there is an area or notch that I can measure to work out if it has been previously skimmed and if so how much?

I suspect I will be contacting you at some point for some prices for headwork, as much as I want to do it myself theirs only so much I could do and feel it'll probably be best left to the experts ;)
 
I've not previously mentioned but had noticed some issues with my dv, and after discussions with various people and forge they sent me a refurb kit and a revised piston :)

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I then thought that whilst the box was off it was the perfect opportunity to mod the shifter to make a short shifter

So far have done the forwards and back one and will do the side to side later on if nothing major breaks at work ;)

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Stace, you are on a mission mate! Are you removing all this in the rain too? I just wan to take my car out for a spin as its been garaged for a week and I can't even do that because of the rain!

Keep up the good work :thumbsup:
 
StaceyS3 said:
Cheers Andrew appreciate the help :)

Do you know if there is an area or notch that I can measure to work out if it has been previously skimmed and if so how much?

I suspect I will be contacting you at some point for some prices for headwork, as much as I want to do it myself theirs only so much I could do and feel it'll probably be best left to the experts ;)
Click to expand...

i think i have some info about and maybe able tell you how thick a standard unskimmed head is

not a problem on the the head work
 
Blimey that looks like some hardcore det. Was it knocking/pinking at at all?

Probably explains the high EGTs?
 
Westy said:
Stace, you are on a mission mate! Are you removing all this in the rain too? I just wan to take my car out for a spin as its been garaged for a week and I can't even do that because of the rain!

Keep up the good work :thumbsup:
Click to expand...

Cheers mate, not in the rain today as am at work all day but expect I will be tommorrow or another day this week as have got to fit the box and have got a week booked off holiday although I'm going to be in 1 day on ot already ;)
 
Andrew@A.L.D said:
If the head measures less than 139.2mm high then its scrap

I might have measurements for a brand new head somewhere?
Click to expand...

Cheers mate ;)

Have just measured it at 139.4 so not far off but not sure how much they usually take off when skimming it, suppose it all depends on the state of it?
 
Sam_ said:
Blimey that looks like some hardcore det. Was it knocking/pinking at at all?

Probably explains the high EGTs?
Click to expand...

Don't have a clue how it was running mate as was removed from the car when I bought it and the reason I've done so, is so that I can build it up at my leisure and still have a running car to drive around in ;)
 
Well had a bit more spare time this afternoon so have done the side to side shifter
All in all I should have reduced the throw 30% and the side to side 27% which the forge throw is up to 40% and they don't state what the side to side is so just went with a reasonable position ;)

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I had to make some tools to stop things getting damaged and to support it when I pressed the pin out as the steel plate one is a lot more flexible than the cast and when pressing it out it wanted to turn into some U shaped thing lol

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I've also found myself a reasonable sized cable to do the battery relocation at some point, ideally I'd love to put the WMi in it's place but really can't be ***** so not entirely sure what I'll do as had originally planned to get a monstrous filter like bills green cotton but have already bought a k&n like hollies TT??

Well at least I've got it for when I need it

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StaceyS3 said:
Don't have a clue how it was running mate as was removed from the car when I bought it and the reason I've done so, is so that I can build it up at my leisure and still have a running car to drive around in ;)
Click to expand...

Ah, this is the donor engine! Oh, that's cool then. And yeah, good idea to build it along side. I plan to do the same. I've just sourced an AGU lump for my build. Still about 1,000 miles away mind you heh
 
Hi stacey, didn't you weld the pins in the levers?I did weld mine in although the gear lever is made out of cast iron, i welded it with some weldall rods (high nikel content rod) for peace of mind, still going strong after 5 years.
 
Sam_ said:
Ah, this is the donor engine! Oh, that's cool then. And yeah, good idea to build it along side. I plan to do the same. I've just sourced an AGU lump for my build. Still about 1,000 miles away mind you heh
Click to expand...

Think that's certinally the way to do it wish I had on my first build although that wasn't planned it was reactive ;)
 
Rosso TT said:
Hi stacey, didn't you weld the pins in the levers?I did weld mine in although the gear lever is made out of cast iron, i welded it with some weldall rods (high nikel content rod) for peace of mind, still going strong after 5 years.
Click to expand...

No didn't bother welding them, they had to be pushed in on a press but had counter sunk the hole on the other side and crowned it over with a ball pein hammer (riveted) like it was originally ;)

Idea is if I don't like it I can return it back to how it was easily enough and to be honest didnt even cross my mind about welding it lol
 
Well TSR have pulled through and the Mani has turned up and to be honest im impressed with the quality and the way it's made, the collector looks quite intricate

Pic next to my old MTM one

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Collector and have noticed the v band looks like it's had a dink at some point around the top of the v band and has been polished out

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The v band on the wastegate looks like it's had a file run over it to remove some spatter or something not sure if this will effect things

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I pressume if this isn't a nice smooth/ground finish it won't seal without a gasket?
 
Looks like they have fattened up the wastegate outlet but still in the same place as the one the LCR had... that means the Tial is gonna hit the gear cables...
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Do a test fit mate...

<tuffty/>
 
...although now looking at them side by side yours looks like it doesn't curve round towards the flange as much... maybe its what they did improve the clearance?

<tuffty/>
 
Yeah after speaking to bill and reading James thread the wastegate tube should be bigger and the v-band for a tial 44mm wastegate ;)

The new tial mvr wastegates are supposed to be considerably smaller than the old 44mm but how that compares to the 38mm I haven't a clue?
 
...although now looking at them side by side yours looks like it doesn't curve round towards the flange as much... maybe its what they did improve the clearance?

<tuffty/>
Click to expand...

I know that tsr did actually speak to bill directly at one point after I had spoke to them about my concerns and afaik he did advise of certain changes but not sure what changes and which ones they went ahead with.....time will tell ;)
 
Guys. I'm well out of my depth in this thread now :( I lost count of how many times I had to say to Stacey "I don't have a clue what you're talking about" when we were talking at Inters lol.

What's the benefits to an external wastegate?
 
Westy said:
Guys. I'm well out of my depth in this thread now :( I lost count of how many times I had to say to Stacey "I don't have a clue what you're talking about" when we were talking at Inters lol.

What's the benefits to an external wastegate?
Click to expand...

a non compromised hotside, and better management of boost on high flow...
 
Westy said:
Guys. I'm well out of my depth in this thread now :( I lost count of how many times I had to say to Stacey "I don't have a clue what you're talking about" when we were talking at Inters lol.

What's the benefits to an external wastegate?
Click to expand...
noob


stace, thats some nice engineering porn you have there.
really nice piece of kit!
 
Westy said:
Guys. I'm well out of my depth in this thread now :( I lost count of how many times I had to say to Stacey "I don't have a clue what you're talking about" when we were talking at Inters lol.

What's the benefits to an external wastegate?
Click to expand...

Lol iirc the main one was talking about a screamer pipe which is when using an external gate the pipe from the wastegate goes straight to atmosphere rather than back into the dp ;)

But all in all advantages are what bill said and to work on though I swear they're as a whole a complete pita
 
superkarl said:
noob


stace, thats some nice engineering porn you have there.
really nice piece of kit!
Click to expand...

Lol ;)

Cheers mate I nearly made a mess in my pants infront of the misses when opening it ;)

She did get the hump after a while asking how long I was gonna ****** look at a lump of metal lol
 
Well hopefully should have it up and running today as spent 5-6 hours on it yesterday and have got box + transfer in, subframe bolted back up, mounts on, dp on, one driveshaft and a few other bits and bobs ;)

Question just wanted to clarify is that can anyone confirm how much oil the box needs as my local audi dealer seemed a bit unsure but said 2.6 litres?

Cheers
 
StaceyS3 said:
Cheers for that bill I certinally couldn't into words like that ;)

What's your thoughts on the wastegate pos and the finish on the v-band?
Click to expand...
the seal face is the fire ring which will sit into the small counterbore, the other face should be ok. Not usually a linished finish tho I have to say.
position... hard to tell from the picture.. the manifold is subtley different to james's LCR one.
 
Rosso TT said:
That mani is a work of art.BTW what size are the runners, thickness of the tubes and diameter of the turbo vband?
Click to expand...

Cheers mate I do love it ;)

Will have a measure when I get in although won't be that accurate as not got any Calipers at home but will try my best with a tape


Car is all up and running and have been out for a few drives today and it is going like the clappers lol

The short shifter is taking a bit of getting used to but is an improvement

The boost problem I had previously I think could have also been related to the dv spring as boost is now going higher than I have ever seen it since it's been mapped I'm now seeing spikes around the 1.65 bar mark, which I had never seen prior but it does seem to be holding the boost better as well :)
 
Thank you very much mate, didn't have to go to the lengths of starting another thread for me :) :beerchug:

Suppose that'll bring my compression up reasonably with the thin gasket and that much removed off of the head?

I've just ordered over the weekend, some JE 9.0 CR pistons so expect that'll raise comp a lot? Read somewhere that the thiner gasket raises it 0.3 or 0.4 on the CR so expect with the head will be knocking on 10.1?
 
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