Prawn and BigAls A3 Track Car

[coatesy]

mmmm sounds nice... runs off to look at 3" exhausts

 

[Neru]

man, your just making me so excited for my car to be done

 

[beachbuggy]

Apparently you could smell the panic on the m25.

 

[badger5]

so what happened... the suspense is killing..

 

[coatesy]

so what happened... the suspense is killing..

I'm going to guess something came loose/fell off. Them prawns ar$e fell out. Panic set in and it turned out to be nothing ?

 

[nightroamer]

I'm going to guess something came loose/fell off. Them prawns ar$e fell out. Panic set in and it turned out to be nothing ?

I'm with coatesy on this one :thumbup:

 

[superkarl]

my guess is that he was overtaken by a suprisingly quick S3 and prawn had an emotional break down at the side of the road.
the smell of panic was in fact prawns heart dissolving in his tears, pouring out onto the road.
he promptly phoned dan and tuffty for reassurance that this couldnt happen, and speaking from experience they broke the news to him ever so gently....

S3's are faster.

the end

 

[coatesy]

S3's are faster.

the end

Haha your a silly face.


This isn't true folks.

Don't believe what sk says he's full of cack.

 

[bigal 1]

The TRUTH is we were going down to the pub. I was on my Kona and I gave him a head start. The inevitable happened. I overtook him.

 

[Prawn]

Apparently you could smell the panic on the m25.

Was I that worried on the voicemail I left you? haha.

So, a little update for you folks. I've been slack taking pictures, because frankly, I got bored of it.

After a chat with PT, I decided to fit a shim in my DV with the forge yellow spring.

DV all cleaned out:

And shim installed (my god this is interesting stuff )

later that evening Andy came round in his cupra to go for a spin:

And then to my garage for him to try out his new seat I've got for him:

Sadly, the light in the above picture is provided by my headlights, and then my car wouldn't start, so the lads had to push me in the rain to bump it:

I had the morning off on Monday, so decided to fit my 3'' exhaust.

For those of you that don't know about these yet, it's a full 3'' turbo back system for a ko3/s mk4 golf, downpipe, decat, and full turbo back exhaust all in 3'' TIG welded stainless steel. it's got two straight through resonator boxes, no baffles, no restrictions, just lots of flow.

It's also rediculously expensive, at just £220 shipped from the states!

http://www.ebay.co.uk/itm/99-04-VW-...42205982747496630&pid=100 011&prg=1005&rk=2&

Got the car up on the ramps:

And laid out the new exhaust to make sure it's all there:

After MUCH struggling with the miltek system, it simply refused to seperate at the axle pipe - back box joint, so sadly, I had to cut it off. I sliced the axle pipe as it's the cheapest part to replace!

I removed the decat section of my relentless downpipe too, as this would need adjusting to suit the ko3S fitment exhaust.

The relentless has always had a bent in the decat section, which I think is to aid clearing the prop on the S3, but it made the system hang VERY low, and it was forever catching as can be seen:

Luckily, the new exhaust came with two tailpipes, one of which was the perfect length to replace the bent section of the relentless decat!"

Perfect, and it now maintains 3'' from the turbo to the tailpipe

I just had to cut this lip off

At this point I got bored, because time was moving on, and I had to get the car finished so I could drive it down to cornwall as part of my running in mission, so I just finished it off without taking any more pictures.

The tailpipe still needs trimming down, but it was originally about 9'' longer than this to suit a bora! Work in progress

I then drove 200 fault free miles down to cornwall to Mum and Dads, where Big Bad Dad and I got to work on changing the hot oil as soon as I arrived, at this point the engine had covered 280 miles, and was feeling great.

We filled it up with fully synth, and settled in for a few beers and Ham Egg and Chips, BBD style

Tuesday morning I went to Truro to look at some concrete, you don't care, but I'm including it anyway!

Lovely moulds for pre-cast units:

And the finished product, we have 124 of these units coming at work, and this was the first

After looking at grey stuff, I headed back to mum and dads, packed my stuff, and jumped in the track car to drive the 200 miles home.

All was going well up until exeter, I was on the phone to Frenchman who was asking how the exhaust sounded, so he listened in as I pulled away from a set of lights on the A30.

Through 1st gently, no trouble, into second and full throttle, pulling like crazy, into 3rd, and NOTHING. ZERO psi.

Hmmmmmmmmmmmmm, this seems odd. No lights come up, no visable oil behind the car, no smoke, no smell, it sounded perfect, dipped the clutch and revved it, it revved just fine too.

What the FECK had happened? ARGH.

I pulled off the A30 and found some street lights near exeter airport and using the light from my iphone started having a look over it.

All the boost hoses were fine, the TIP was still on tight, I pulled the front bumper off and checked the hoses under there too, all tight and fine.

I went over the hoses again looking for splits, nothing. I looked down the back of the turbo with my iphone light and saw the retaining nut for the actuator rod tight up against the wastegate arm, all looked well.

Argh.

I tried to call Dan (Beachbuggy) and got no answer, tried again and left him a message asking for some advice.

I prodded a few more things, took it for a drive and it was OK, but zero boost. ******.

I parked up again, and called Tuffty, he asked all the usual questions, hoses, actuator etc etc, all looked OK, so we decided it'd be best to pull the TIP off to see if the turbo was spinning freely or not.

I pulled the TIP off, after burning myself a lot, but couldn't put my hang inside the turbo - too hot still.

Picture attempt #1:

I appear to have missed my target. haha

Attempt #2

Hmmmmmmmmmmmmm, all looks well. ****** it, I'm burnt already,a little more won't hurt, so I stuck my hand in and grabbed hold of it.

No play, left, right, up, down, in out, it was perfect, and spinning freely too.

Hmmmmmmmmm, but this time things had started to cool down, and Dan called me back having listened to my worried answerphone message.

He was adamant it'd be the actuator, despite my protests that I'd already checked it. I checked it again, and D'oh! The nut had come loose! letting the wastegate blow open.

With the problem found, i set about refitting the TIP, which took AGES because the 80mm TIP is very tight against the gear cables on a 5 speed car, that took about 40 mins to shoe horn back on, then I started winding the actuator nut up again.

After about 15 mins of winding it with a tiny ratchet spanner, I got fed up, and tried to remove it to check it out.

To my surprise, it just pulled straight off!

Ok, it all makes sense now. Stripped thread.

New nut was found in my socket set case, wound on with the pre load guessed, and off I went, and my god was it good! Actuator pressure was up to 15psi, and the car felt AMAZING!



All worries over, and I continued on my journey about 90 minutes later, burnt, oilly, and tired, but happy it wasn't something more serious!

If you actually bothered to read all that, you must be REALLY bored!

Roll on Bills RR day next weekend

 

[badger5]

good work prawny

 

[jojo]

my guess is that he was overtaken by a suprisingly quick S3 and prawn had an emotional break down at the side of the road.
the smell of panic was in fact prawns heart dissolving in his tears, pouring out onto the road.
he promptly phoned dan and tuffty for reassurance that this couldnt happen, and speaking from experience they broke the news to him ever so gently....

S3's are faster.

the end

I thought he was overtaken by Jardo, then the world just shrank around him!

 

[Prawn]

I thought he was overtaken by Jardo, then the world just shrank around him!

HAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHA.

Legands never die, they just get banned

 

[superkarl]

i cant believe how much of a bargain that exhaust is! and the fact its so cheap landed in the UK with no charges!
what a find!

the leon looks cool, any info on that?

 

[Prawn]

crazy isn't it? It's only 304 stainless, so it's not absolute top notch stuff, but I had a toyosports 304 stainless exhaust on the dailly that I installed about 2 years ago and it's still going strong and not rusted yet

The tubes also seem to be fairly thin, which has the added bonus of making the system pretty light! haha. it also sounds great. I'm very happy with it

Leon is similar to how mine was this time last year (Not crashed haha), all caged up and stripped, currently on a st2 ko3S. Andy calls it sooty

 

[superkarl]

it also sounds great.

we all need proof of this!
other wise we can only assume it sounds gash

 

[Prawn]

Only clip I have superK, and it's rubbish!



Will try and get an external clip for you when I'm back home on Sunday

 

[moredoor]

That's a lot of exhaust for only £220 sounds the bees knees as well. Have you tested how loud it is yet?

 

[Prawn]

That's a lot of exhaust for only £220 sounds the bees knees as well. Have you tested how loud it is yet?

I havn't yet nando no, I'd really like to test it before I next head to a trackday, but I don't know where I could go to have it tested, short of calling up goodwood or combe and asking them if I can pop along for a sound check.

Any ideas?

 

[coatesy]

I havn't yet nando no, I'd really like to test it before I next head to a trackday, but I don't know where I could go to have it tested, short of calling up goodwood or combe and asking them if I can pop along for a sound check.

Any ideas?

A calibration company will have a db thingy I know my mates last to companies he has worked for did.

I don't suppose it would hurt puting something on vag talk to see if any one on there has one.

 

[666markyboy]

don't they do a rudimentary decibel reader app for the iPhone ??? i'm sure i saw Clarkson using one on Top Gear

 

[Prawn]

yea, it's a load of crap from the ones I've seen, readings just seem to bounce around too much

 

[phil miller]

prawny couple of things, first off if your down near truro why did you go thro the tamar tunnel, surely A30 past Okehampton to exeter is less miles and a faster road rather than A30 bodmin, A38 thro plymuff on to the M5?

Also love the concrete, true Art at its best

Glad it wasnt anything major, im looking forward to meeting you and having a look at your car at the RR next weekend

 

[Broken Byzan]

Ask the Badger.... Shhh nuff said

 

[superkarl]

From that short clip I like what I hear!

And he prob went through there just for the clip :thumbsup:

 

[phil miller]

From that short clip I like what I hear!

And he prob went through there just for the clip :thumbsup:

yeah could be that, but i know that bodmin to plymuff is 37 miles ish and then 42 from there to exeter, thats 79ish miles, but bodmin to exeter is 64 miles, all dual carriage way, and you dont have to pay a toll lol

 

[coatesy]

what did you do with the k03 dp and de cat pipe from your 3" exhaust kit

 

[phil miller]

what did you do with the k03 dp and de cat pipe from your 3" exhaust kit

LMAO your a magpie, anything that shines you want lol, fair play mate

 

[Prawn]

Ask the Badger.... Shhh nuff said

As they said only smarties have the answer


Phil: parents live near Plymouth so I stay with them to break the trip up Be good to meet Sunday, I'm REALLY looking forward to it now!

 

[Prawn]

what did you do with the k03 dp and de cat pipe from your 3" exhaust kit

Sold it to you I thought (sexy carbon bonnet not included)

pm me

 

[ScottD3]

Only clip I have superK, and it's rubbish!

Will try and get an external clip for you when I'm back home on Sunday

Its better than Karl's clip.


Prawn, if you are ever passing bristol, take a blast down the cattle market and under the train tracks.
I love that tunnel!!

 

[coatesy]

Sold it to you I thought (sexy carbon bonnet not included)

pm me

does it come with butt plugs to fit in the second lambda hole?

I pm'd you

 

[Prawn]

Yes, AND a lambda bung, and a gasket, and bolts! Pro job

 

[coatesy]

Yes, AND a lambda bung, and a gasket, and bolts! Pro job

Interesting it comes with butt plugs are they used ?

 

[badger5]

I havn't yet nando no, I'd really like to test it before I next head to a trackday, but I don't know where I could go to have it tested, short of calling up goodwood or combe and asking them if I can pop along for a sound check.

Any ideas?

I have a db meter

 

[Dane]

Great work prawny!

 

[Prawn]

I have a db meter

Awesome, if you wouldn't mind me using it to test my exhaust that'd be great Bill! So long as it's clearly under 100dBa then all is good

 

[slappy_dunbar]

It's been a day. Where are the logs?

 

[Lewis583]

It's been a day. Where are the logs?

I'm sure Prawn will be along soon enough with some to share.

In regards to noise, I was concerned with the system I am building for the MK2, being 3inch right through. So as an experiment i will be making some removal exhaust tips, so that when i get to the track i can put some down-turn tips on and see if it makes much difference.

The Eggsauce does sound nice and seriously cheap for a complete system, top work chap.

 

[badger5]

In regards to noise, I was concerned with the system I am building for the MK2, being 3inch right through. So as an experiment i will be making some removal exhaust tips, so that when i get to the track i can put some down-turn tips on and see if it makes much difference.

The Eggsauce does sound nice and seriously cheap for a complete system, top work chap.

I have built a few 3" turbo back systems, and none of them have exceeded 89db(A) at 4500rpm from new. When they are used for a while they get quieter too.

not saying this is the same as I used 3 box systems on all of these to keep noise down as these cars are all subject to track day noise regs.. Nothing more frustrating than not being allowed on track when you get there.. been there, suffered that.. Donington Park and also told I was "too fast and scaring other track users!!!" ***... They were in fact Morons running that day.. Bitter and Twisted.. Yep.. I still am. Never going there again.