Prawn and BigAls A3 Track Car

[Prawn]

I looked into both pulling and painting the panel, and also having the whole quarter replaced.

Worked out a lot cheaper to have the panel pulled straight. They'll use a system with tabs spot welded on and a bar threaded through and the whole panel is gently pulled.

its all being done by a local chap from another forum, if his Ibiza is anything to go by it'll be a top job

 

[nightroamer]

Oh yea I have been that process before works really well in the right hands.

Gives a lot of control over the affected areas.

What sort of cost you looking at?

 

[Neru]

3rd gear for the first time on full boost is pretty terrifying

Excited, video soon?

 

[Prawn]

what an AWESOME day.

Thanks to Bill, Tuffty, Tony, Big Bad Dad, and everyone else who came along today for such a brilliant day

had an absolutely cracking day, and the car was 100% faultless. SO happy with it.

I arrived at B5 very early at about half 8, and got the kettle on straight away.

People started to arrive about half 9, and I was put in charge or sorting out paperwork and payment for everyone, which was nci as I got to meet everyone I didn't know too.

Will upload a few more pics tomorrow, but here's a few selfish ones of mine:

Poor Bill got in, and decided he was staying there for good:

Relentless glowing nice and warm:

Car made 291bhp / 240lbft on actuator, and 307bhp / 264lbft on boost. Absolutely over the moon with that

 

[Prawn]

what more interesting, and I'll show this with graphs tomorrow, is that on full boost, the boost curve follows EXACTLY the same values as before, with the same peak at the same revs, same taper down to the same point, yet it's making 16bhp and 20lbft more on the new engine than it used to

Curves from March and now are IDENTICAL in shape to the very last minute detail, just the new ones slightly higher up

 

[<tuffty/>]

Good engine that

<tuffty/>

 

[Prawn]

****** good engine!

Thanks for building it PT

 

[666markyboy]

So 16 bhp down to newness ?? better piston seal etc ?

 

[Prawn]

just general awesomeness I think Mark

On actuator pressure I fully expected more power with it being 2psi higher, but on boost it follows exactly the same curve at just about every singe point. At the point where peak power is developed on old and new engines it's making 16psi. so the gain is at exactly the same boost.

It's a newly built engine, so better compression, the head doesn't have shot stem seals, I've added WMI (although not mapped in), and I've added a full 3'' exhaust.

I'm very happy with the figures it's made, and even more so with how smooth it is and how the fuelling is still bang on

 

[Prawn]

K04 hybrid a3 - 307bhp at badger 5 - YouTube

Relentless manifold glowing red hot! - YouTube

 

[badger5]

thanks for your help yesterday nick

 

[Prawn]

Not a problem Bill, it's the least I can do (quite literally!) after all the help you've given me over the past 2 years of this build

I particularly like the B5 dyno days above others due to the level of monitoring, the seperate plots with boost and fuelling, and the vagcom logs you do whilst running. You never see that kind of detail at a normal multi car rolling road day, and I think it's what makes the B5 ones special Thanks!

 

[Prawn]

So, some graphs! Everyone likes graphs, right?

Old engine, 211k miles at the time, dyno'd at Badger 5 1 week after Niki mapped it:

New engine, forged rods and new rings / shells, but otherwise still stock. low mileage block on this one.

Gains on boost are 14bhp and 21lbft on exactly the same boost, changes made were a full 3'' turbo back exhaust (old system was 2.5''), and the WMI system with very small nozzle installed to keep things cool. the actuator is slightly stronger on the new setup, but due to how the ECU calculates load and duty cycle the boost curve is identical still.

Feels brilliant to drive with the nice smooth delivery too

 

[Oke Phill]

Love it!! Prawn you have done such a good job with this, well done bud. I love the pic of the out side of the car, it looks raw!

Prawn i cant find a clear pic of how you have mounted your cage to thewheel arches at the back. did you make feet for it to bolt to, or did you bolt it straight to the wheel arch?

Cheers Phill

 

[ScottD3]

Relentless glowing nice and warm:

That's glowing more than Reesy's.
Didn't you say it was bad to glow that much?

 

[Prawn]

I can safely say it isn't

It's just the collector glowing a lot on mine, I'm pretty sure on Reesys flat out run all the runners were glowing equally as well!

Anyway, people should do as I say, not as I do

 

[Reesy]

I can safely say it isn't

It's just the collector glowing a lot on mine, I'm pretty sure on Reesys flat out run all the runners were glowing equally as well!

Anyway, people should do as I say, not as I do

Pretty similar to mine, just the pic of mine is a lot clearer Was also my 3rd/4th flat out run

So are you saying we shouldn't all try grass tracking at 130+ mph?

 

[Prawn]

So are you saying we shouldn't all try grass tracking at 130+ mph?

Anyway, people should do as I say, not as I do

 

[bigal 1]

It was great to meet everyone at BB's on Sunday and put a few more names and faces together. There was some amazing machinery there and some awesome engineering. It now is " Rocket Science". All in all a very good day, enjoyed it.

 

[Prawn]

Thanks to Bill for uploading the graphs from the day, I'll post these again so you can actually read them, as my scans were a pretty awful quality by the time I'd laminated the printouts, scanned them as PDF's, then used paint to make them JPEGS

I also have something else which will be hopefully arriving this week and is ultra cool, but I'll wait for it to arrive before posting details

 

[Prawn]

Also of notable worth, on the road my MAF sensor maxes out at 187g/s around 6500rpm, so beyond that I'm blind as to how well it's performing.

On the dyno, it saw a max airflow is 176g/s with 307bhp. Inlet temps on the dyno were 21 degrees on full boost, so not too bad at all considering it was 19 degrees in the unit.

I wonder is that 187g/s transpires to be more than 307bhp on the open road?

 

[16Klappe]

You could draw the power curve with a ruler, holy mother of flow.

 

[Lewis583]

As Jardo said that power curve is lovely, nice and linear. Torque curve is good too, bet it pulls like a train all the way to the redline.

 

[Prawn]

it really does, it just pulls and pulls all the way to the limiter, which is currently set pretty low at 7100rpm.

Once it's mapped again, I'd like the limiter a little higher, and to figure out some sort of shift light setup as well

 

[Prawn]

Seeing as the engine is actually looking clean and ok for a change, I decided to treat it to some tarting up.

After fitting the new header tank, the grubby old coolant cap looked out of place, so I sorted out these Porsche caps through a friend

Yes, the paint job on the rocker cover isn't great!

coolant cap:

and the two together for the full effect:

ive also been gathering parts for another little project:

more to come on that later

 

[Andrew@A.L.D]

Seeing as the engine is actually looking clean and ok for a change, I decided to treat it to some tarting up.

After fitting the new header tank, the grubby old coolant cap looked out of place, so I sorted out these Porsche caps through a friend

Yes, the paint job on the rocker cover isn't great!

coolant cap:

and the two together for the full effect:

ive also been gathering parts for another little project:

more to come on that later

I thought this was a track car

Don't turn into a buffty puff because the next thing you know you will be chroming your bay

 

[s3dave]

Stop being a Tart Prawny .......it just isnt you....

We want a propper mans car....baked oil everywhere with battle blood here and there....

 

[Prawn]

Hahaha, don't worry lads, it won't be a regular thing, I just thought that whilst it was all apart it'd be a shame not to paint it, and at £30 for both these caps, they cost sodd all and do smarten it up.

Main reason for it was that my oil cap seal had gone and it was leaking.

Hope to have another update by this evening postman dependant, if not Monday with any luck, then R0tech on tuesday for mapping

 

[Andrew@A.L.D]

Hahaha, don't worry lads, it won't be a regular thing

Thats what they all say, You'll be getting Gold teeth next

 

[Prawn]

HELP PLEASE

Folks, I urgently need a passengers side driveshaft!

Shorter of the two shafts, from any 5 speed 02J mk4 golf / A3, 108mm flange.

Car has developed a really bad shaking, and I think this is all it can be, I've checked everything, hub nuts, all the suspension, engine mounts, dog bone, I've changed the drivers side shaft, but don't have a spare pass side.

Cruises along just fine, but as soon as I apply any torque I get a bad shaking.

Willing to travel if anyone has a shaft I can buy today or tomorrow morning.

Let me know folks!

 

[666markyboy]

Some of the panel pulling they can do these days is amazing.... will they be using this type of system ???

 

[nightroamer]

Good luck finding one buddy.
I have a set of drive shafts in the garage which I think are mk 4 golf. I can have a look and measure.

but in s.w. London (Mitcham) or Reigate.

 

[Prawn]

Good luck finding one buddy.
I have a set of drive shafts in the garage which I think are mk 4 golf. I can have a look and measure.

but in s.w. London (Mitcham) or Reigate.

If they look like this mate, I'm VERY keen:

Let me know dude, 6 bolt flanges on the end, like a star not a solid circle. PCD is 108mm.

Drop me a PM with your number if they're the same ones matey Reigate isn't too far away.

I HAVE to sort this problem today / tomorrow, so I can get to Rtech on tuesday morning!

 

[16Klappe]

Have you got one down here? If you are super stuck pay my fuel and I will bring it up to you.

 

[nightroamer]

Sorry dude appears they are round 100mm must be spare mk2 shafts.

Hope you find some...

 

[Prawn]

Wooooohhooooooo.

Got the shaft out, and it does this:




1 of the 3 rollers is pretty dead, and there were shards of metal in there too.

Thankfully, Bobby "my hero" Singh found me some on e at an hour from home, I messaged the chap, got an almost instant answer, and I'm on my way to pick them up right now

 

[nightroamer]

Glad you have sorted one.

Blimey that's definitely the issue, actually I have the same problem with the polo atm So thanks for the idea!!

Good luck buddy

 

[666markyboy]

I thought it was nearside you had all the problems with last time when it munched the gearbox?? didn't it all get changed for new or was that drivers side ?? is there not a competition upgrade of any kind like the Hardy Spicer joints we used to use on the Mini's ?? as these shafts seem to be a recuring theme

 

[16Klappe]

This is Prawns best option - VW Mk4 Golf/Jetta & Beetle (VR6 / 1.8T) 1000HP Level 5 Axle (right) [RA2292X5] - $799.00 : USRT, Usually Sideways Rally Team

But when the CV's go on them it's going to kill him to replace them.

Not to mention that having sacrificial CV's may well take strain off the gearbox. Don't know if that's true or not but it makes sense in my mind.

Also at least with standard CV's and shafts when it does go the worst case scenario is he has to get one from a breakers or factors, he'll never be more than 24hours away from a fix.

 

[moredoor]

You really got me thinking how come you keep killing these driveshafts