Reesy's Big Turbo A3

[Jay A3]

Didn't even know you took half those pics!

Hopefully when you get the 90 degree pipe it should slot in nicely, if not a little bit of adjusting may be in order, so the DV and N75 fits

Love those brackets! they were very solid! Might have to get some too.

 

[Reesy]

And now for Jay's pics:

The set up for the day:

Bent rad :

Dave's monster brackets mounted to the core:

and then to the car:

Just a bit of a difference!

MAP sensor location:

Cold Side:

Ready for testing, all be it slightly irregal

I also swapped the bottom from my old bumper as the current one was pikey'd on one side before I got it:

After getting the 90 back on Jay's car, it was running rough. We hadn't put the N75 pipe back on, stopped sorted it, he gave it beans, it was rough again. Stopped, tightened everything up whilst scanning the car, and problem was sorted. Result.

 

[Jay A3]

Here is proof...
Reesy does do work! (Or at least very good at making himself look busy)

 

[superkarl]

he looks like a yound child poking things for fun lol.

nice work though lads, looks like alot of fun.
and now with at least 3 times the surface area of the old smic you wont have MENTAL iats of 80degrees!

i need some lnm/sunday mechanic sessions, il have to mither damo to death to buy some *** mods.

 

[damo.h]

Good bit of progress again reesy. Nice job jay ( looks like you did most of the work lol )

Almost time for the avus

 

[Reesy]

The bumper is on

Will try and get the fogs back in, but if they wont I'll try and get a bit better fit on Saturday morning when I go to Ben's to get the other bits done.

Their was no need to cut the alloy 90 as we trimmed the silicone reducer last night.

The source of my coolant leak is pictured here:

and the solution:

Will get that fitted tomorrow evening. Only need to do about 25 miles before it gets sorted so I'll just take some water with me.

Also got a dipstick holder as mine is ******.

 

[BENJAMIN]

Who tig'd those outlets on? They look awesome. Jus' sayin'.

 

[superkarl]

its a ****** that coolant pipe.
does it have a crack in it? mine had a hairline crack. thats what i was fitting in that picture i posted above. not a hard job though so you'l be reet.

 

[Reesy]

Who tig'd those outlets on? They look awesome. Jus' sayin'.

A seriously impressive job mate, proper neat and tidy. Not as good as the forged banking plate.

its a ****** that coolant pipe.
does it have a crack in it? mine had a hairline crack. thats what i was fitting in that picture i posted above. not a hard job though so you'l be reet.

It's not thi pipe, it's the plastic bit that houses the O-ring that joins to the head. Got dark so cba tonight, getting it done in the morning.


I HAVE LOGS

Ignore the coolant temp issue, that's being sorted. Ambient was about 15 degrees.

 

[superkarl]

yesss, my guess was good. 32 being the highest. so a reduction of a massive 48 degrees! thats just crazy!
how does the car feel?


p.s. you are horrendous at logging.

 

[Reesy]

yesss, my guess was good. 32 being the highest. so a reduction of a massive 48 degrees! thats just crazy!how does the car feel?p.s. you are horrendous at logging.

84 was the highest karlos, so 52 degree lOSS in temps! I was in a rush with the logging

 

[Prawn]

Really? If you were in a rush there would be more WOT and less buggering around on part throttle surely?

Looking good mate very nice install. How does it look with the bumper back on?

 

[Reesy]

Sorry *****y *****es! I will re do the logs today, with full WOT. Any one got any other blocks they recommend logging, to spice things up a bit?

Just about to sort the coolant leak.

Prawn, IC looks good, and very subtle, but need to relocate the horn so i can get the fog light in on that side. I'll get a pic once that's done

 

[Reesy]

Great success. Coolant issue is sorted, light cleared through vcds.

Going to try and sort the issue with the cruise control tonight, get the fog light in and whack a self tapper in the bottom of the bumper.

Then that's the car ready for Thursday evening's mapping.

 

[Westy]

Good work Reesbag, you've almost got a respectable car now

 

[Jay A3]

The 2 extra doors are weighing you down

 

[Reesy]

5 months after install, the cruise now works :cheers:

The cider swiller had put the pins in 76 and 77, not 75 and 76, so got that sorted this evening.

I have the S2000 filter to test. At the moment my logging test track is about an inch deep in water, but the rain has died down now so I'll try and log this evening.

Removed a horn for now, so I can get the fog light back in and sorted out the underside of the bumper so the car doesn't look like it's had a stroke.

 

[Reesy]

Put the S2000 filter on. It is merhoosive. Had to take the heat shield off as it wouldn't have fitted otherwise!

I have some logs, and I hope they are to your satisfaction Karlos..

Pre filter:

Post S2000 filter:

I got the highest I have got with the k&n, 175 g/s, but the last two times I have logged it has been 174.. S2000 filter reads 174 anyway, and will have better filtration then the k&n, so I can't see a downside personally, other then a tweak to the heatshield.

 

[superkarl]

i see 178 g/s at time stamp 71.22!
and only just 174 with the s2000 filter.

but like you say, for better filtration, and the price, id stick with it. do you know the size of it?

car looks good though!
next job, try and plot your afr in a graph :icon_thumright:

 

[s3dave]

i see 178 g/s at time stamp 71.22!
and only just 174 with the s2000 filter.

but like you say, for better filtration, and the price, id stick with it. do you know the size of it?

car looks good though!
next job, try and plot your afr in a graph :icon_thumright:

Is that faster than yours Karlos??,,,

 

[beachbuggy]

Just looking at your Logs, the CF's are good, well in so much there is no timing pull so more timing can definately be added and also the boost in 115, is not quite meeting specified but the N75 DC is at 90% so that could be part of the issue or the spring is a bit weak.. There's definately more in there though for you..

 

[superkarl]

Is that faster than yours Karlos??,,,

*** dave.
even if it is faster, our cars work!

 

[Reesy]

All the logs were done on 95 octane fuel, as I had 10 miles left and the shell garage only had the nasty regular unleaded, and I wasn't going to make it to the next garage. Good job I got rid of it quickly, less then 30 miles and the fuel light is on. I reckon I will get 45 miles to £15 Will have V power back in tonight for the mapping tomorrow.

 

[Reesy]

Well, bit of a mixed bag last night.

Left work about 6ish, met Ben locally as he was dropping off his drift wagon for some exhaust changing.

Set off for Dan's (beachbuggy) about 6.45, stopped for a burger king. They had these giant vending machine type things and instead of the 4/5 choices, their was over a 100! Plus free refills which is ideal because I regularly finish a large fizzy drink and want more .. Anyway, got to Dan's about 8ish, he got to work, but the ECU wouldn't respond to his laptop.. So, in the ******* down rain, we whipped the ECU out and Dan went in to his house to sort it out whilst we watched driving fails on youtube (this is one of the best 'did the tyre pop?')
The map eventually went on and I went out to do some logging.

1st Run: 1 psi lower then Stage 1 map but a steady 15-16psi until very high up the rev range.

Came back, explained it felt slower, which Dan couldn't really understand as the necessary things were cranked up higher then my Stage 1. Tweaked a bit more and loaded on another map. Went out again.

2nd Run: Similar pattern to my Stage 1, where it goes to about 17-18, then drops to 13-14, then 16 steady before tailing off. No real feel of any more power, and it was actually requesting less when we looked at the logs..

After this we decided it could be the actuator, or the maps. We quickly checked that map 5 was the super duper map, and they hadn't gone out of sequence, but they were fine. As Ben knows what they request, we flashed on a Revo Stage 1 trial and hit the road. It felt more punchy giving it a bit of boost and then letting off, but when we did WOT in 3rd, it was pretty much doing the same thing as the others. Just to be sure, we cranked a couple of bits up to 9 and it still didn't change it.

Whilst out, got the oil light '3 beeps', but as quick as it was on the DIS, it had disappeared. Must've been a bit of water in the old Mk2 Golf one I'm using, so will just get the proper one again I think!.

After looking at some of the software Dan is using, and chatting turbo's with him, we left him about 11.45, having put the car back to standard with the Revo, then putting his custom map on the car but no more power at the moment

On the way, stopped and swapped the Maf as the car was idling just a little bit funny, but I think it's a tweak that needs doing to the map. Also put the K&N back on as my S2000 tests were concluded. I'll be getting one for sure.

So the plans now are to wind a load of preload into the actuator, then if it's definitely an actuator problem, whipping the turbo off as and when I next get a large amount of engine work done..

Their's always something when you want more BHP.

Oh and the injectors look to be getting very high loads, so possibly a 4 bar reg on the cards soon.

 

[superkarl]

so to conclude, cars are gay.

 

[Reesy]

Another Saturday,another day spent trying to sort the car. After establishing it was probably the actuator, we had a look at sorting that.

Due to it absolutely lashing down, we sacked off the planned evap delete and the trip to the scrap yard and decided to get my car to a local dyno to tweak the actuator between runs to try and get an idea of what was going on..

After a drive to the dyno, Ben wound the actuator out a fair way and we took it for a test drive. It was boosting about 3 psi higher, but still dropping below 15psi, before hitting 16 and tailing off. Unplugged N75 and even with the actuator being wound out, the car was boosting 4psi.

Unplugged the MAF and the car didn't really do anything different which is odd.

Decided to sack off the dyno work as the actuator was soft. On the way back the car was basically picking a random number between 15 + 21 and surging to that, before dropping off and then going back up a bit.. Put in a 4 bar reg, found the O ring on the 3 bar was knackered, so swapped that on to the 3 bar, put it back in and the numbers in vcds looked a lot better.

As well as all this, their is a definite hissing from engine bay area that needs to be found. Removed these on Sat:

Went and picked up Ben's s2000 and had a bit of a blast against it. Suprisingly evenly matched, despite him having more bhp and the car weighing less. It being damp helped my case, as he can't get the power down properly.

 

[Reesy]

I used lots of fuel, it was later then I thought and we were heading to Freds. Thrashed the life out the car to Jays, got their at 10 past 9, Decided to go to Westy's in mine, so we got a groove on, car was running right and we got their at 10.30ish. He was battered, we had a good time and had a chat with Stacey who was also up their.. Did hit a massive bump though, and that has possibly caused a problem that I will mention later..

Left Fred's at 3.45, after clearing a fault code. Got home at 5.30 and then was up at 9.30. Also had a bit of razecar driving against Jay, and finally the TQS has the legs on him.

The code, which reappeared today when I was on 1 stage of the map. Changed map after I cleared it and it seems fine now, so one of the maps needs tweaking..

Basically I think the car has a snapped front d/s spring. Getting a rattling sort of noise in that area, and I don't think it's the bumper.

This car is ****.

 

[superkarl]

eventful weekend then.
you sure you've bust a spring, must have been a big *** bump.

are you going to get hold of an oem actuator? or new spring?
you said it was at 4psi on actuator pressure tho, isnt that right?

 

[Reesy]

eventful weekend then.
you sure you've bust a spring, must have been a big *** bump.

are you going to get hold of an oem actuator? or new spring?
you said it was at 4psi on actuator pressure tho, isnt that right?

It was a monster of a bump. The whole section of road was just bump after bump.
I didn't notice it on the journey back, the thrashing with Jay or the drive to Bristol today, but after going over some speedbumps and granny driving pace, I noticed the dull rattle. Need to whip the wheel off and have a look really.

Not sure mate, think a Forged actuator will be going on.
I was told actuator pressure is 5-6, but the way it was wound out it should have been higher. Also, after the failed dynoing, we found a stretch of road and did 3/4 logs with the actuator in different places and it basically did naff all.

Was random that it didn't really make a difference when we unplugged the MAF as well.

 

[superkarl]

so your car runs identical with the maf unplugged? that is weird and suggests its ********. but then you still get good airflow
try swapping your sensor for jays, that will help eliminate it.

 

[Reesy]

so your car runs identical with the maf unplugged? that is weird and suggests its ********. but then you still get good airflow
try swapping your sensor for jays, that will help eliminate it.

There's that and the fact that it sound awful if the maf is ******, and I have swapped the MAF for another one, although that was old as well and perhaps they are both knackered. Just seems a bit odd. Think Ben is ordering in a new MAF to help eliminate that problem, or at least diagnose it..

Should have swapped it for Jay's over the weekend, his isn't that old either.

 

[superkarl]

you get amazingly good airflow figures though which is odd. or maybe a fluke. and it is infact limiting your boost, if thats possible.

 

[beachbuggy]

Try another n75.

 

[Reesy]

So changed the N75. Made the car boost worst, and I got 3 surge boost, so swapped the N75 back.

Creation TIP is here and it looks well made and of good quality.

The rattling noise that I mentioned is a 'destroyed top mount'. The only thing I didn't change when the suspension overhaul was done. I know you can get lcr ones, but I'm not convinced they will make that much of a difference so might just get stock ones.

Other then that the turbo works will take place on August 4th.

 

[Prawn]

What about the Polybush poly top mounts? Only about £40 per set

 

[superkarl]

he moans about the ride enough dont you reesy. put a pair of pillows in there for your soft southern ****

 

[Reesy]

What about the Polybush poly top mounts? Only about £40 per set

Not really thought about it. Are they not slightly overkill on a road going sport back?

he moans about the ride enough dont you reesy. put a pair of pillows in there for your soft southern ****

Not anymore, I only moaned when it was too low to go round roundabouts

 

[CHEZ]

Not anymore, I only moaned when it was too low to go round reacharounds [/QUOTE]

 

[Reesy]

Not updated this for a while.

Top mounts are ordered and will be fitted this weekend as will the job of gaining me more bhp. Can't wait to get this issue sorted as the car needs more power.

Picked these up for a bargain price :

Prefer them to these:

Although, having unplugged my clocks, thinking about fitting the replacements, deciding I couldn't be ***** and refitting the a3 ones, my DIS appears to be fully functional

Prawn came up last night to collect my old A3 bumper, ended up chatting for a couple of hours and then guiding him on his way. He was impressed by the noise of the sportback, so I need to get someone to do a drive by as I still haven't heard the car from outside..

All ready for the weekend, got a new cambelt which will mean a sad end to the disco belt I have at the moment. Also got an array of gaskets and new oil and filters going in.

 

[Reesy]

Right here we go. Write up won't be the best as I can't really be bothered!

After much abuse and the realisation that the actuator on my turbo was knackered, something had to be done.

Started on Friday night, and decided as the cambelt was being done and we were checking the clutch, we'd just whip the engine out. Well that and the fact that:




























About 3 weeks ago, I was having a casual look out for K04 bits and pieces when I came across a TT engine, with k04, all bits needed including the loom, as well as alternator, stock mani and downpipe but decided against the ecu as I was going to stay wideband.

After a bit of negotiating, the engine was bought and 2 weeks ago we went up to Doncaster to collect it. We decided to collect it as it was so cheap and I thought their had to be something wrong with it! After a mammoth effort and a McDonalds, by the van which has done 218k, we got to Doncaster collected the engine and set off back. It decided to be super hot on the day of the epic journey, and the van is lacking in the A/C.

A couple of days later, we cleaned the pick-up pipe and sump and had a look around the engine and it looked mint. We were both amazed. The advert said 60k, assumed that they had probably taken about 30k off the actual mileage but when we investigated it had the original belt and water pump and they both looked in decent condition, and definitely hadn't come off a really high miled car.

Over the next 8-9 days gathered and / or fitted the cambelt and water pumppppppp, array of gaskets, relentless downpipe, relentless manifold, got some bits powder-coated, exchanged the k03 creation motorsport tip for the k04 3” tip, got a map sorted on a spare ecu, sai delete, n249 etc etc delete, welly cooler, ic pipes and clutch kit.

Stripped Engine:

Bits off for Powdercoating:

SAI Delete:

Engine Well Underway:

Mani On:

And complete and ready:

Started Friday night about 6.15. By 8.20 the engine was out which I thought was impressive.. Checked the clutch over to see that it was almost gone. With the added power it wouldn't have been long before it was slipping, and that would have been more work. The original had done 110k so it's about due a change really.
Got the other engine ready to put in on Saturday morning and by the time we had sorted some other bits, we left about 11.

Engine Readt to come out:

Out:

And from this to this:



Some clutch pics:

More to come.