Stacey's Belated Yo Yo Build Thread

[Sam_]

Well the surge tank was cheap (new, 1/3rd of the price) so I snapped it up. Apparently it helps surpress the noise of it the loud 044 and I'm sure it'll be useful once it eventually sees the track

 

[StaceyS3]

yes indeed they can mate so dont worry!
there is a place up my way, (newcastle) called AlloyFIX Alloy Wheel Repair newcastle rim refurb Specialist in Tyne & Wear that can repair that no problem, but obviously thats a bit far for you! but i am sure similar places exist down your way that can perform similar mirracles!
they basically use a hydraulic ram of 5 ton psi, heat the rim and gently massage the rim back into shape!
it was a joy to watch them fix a slight buckle to my rim! about £50 stace!
check there vids out on the website of theres! its magic!

Cheers mate will have a look around and when i've got a min i will watch their video and pending how envolved it looks may even give it a go myself as got a 20 tonne press at work

 

[StaceyS3]

I did post on here asking what the limitations of the fuel lines and rail

Also asked on vortex and there are a few people running very hight hp with the standard stuff

Dyno lottery i would think.

Thats why i plan to get mine on a hub dyno after the next set of modifications.

Not doubting at all what your setup is capable of mate its immense

Was following that thread on vortex and had some really interesting calcs in there to, but just wondered if when at the higher end of the rpm with high load if the rail and lines start limit things or fuel pressure drops at all as your turbo is slinging a huge amount of air for the 2.1 to consume and the amount of fuel needed must be massive

 

[CHEZ]

Cheers mate will have a look around and when i've got a min i will watch their video and pending how envolved it looks may even give it a go myself as got a 20 tonne press at work

ha! brave man but i would not risk it mate!
the jig he used was a bit specialised and then there is the spiggot to fix the rim to the machine!
plus he has done it for years so made it look easy! lol!
you could actually see the rim bending as he rotated it through the clamp as if it were soft as cheese!
he is also the only place up here in the north east with that equipment!
he did point out that some places use hammers instead though! lol

 

[StaceyS3]

Well the surge tank was cheap (new, 1/3rd of the price) so I snapped it up. Apparently it helps surpress the noise of it the loud 044 and I'm sure it'll be useful once it eventually sees the track

You've really got to get me some of that

Was hoping could fit an IE surge tank in the filter position as looked at the measurements and its not much bigger than the 044

 

[StaceyS3]

ha! brave man but i would not risk it mate!
the jig he used was a bit specialised and then there is the spiggot to fix the rim to the machine!
plus he has done it for years so made it look easy! lol!
you could actually see the rim bending as he rotated it through the clamp as if it were soft as cheese!
he is also the only place up here in the north east with that equipment!
he did point out that some places use hammers instead though! lol

Will have a look into it mate but have straightened a lot of things at work including aluminium castings but for some reason always really wairy with car bits.....suppose because it's my own money if it fcks up lol

Little update to please sam, although not interesting in the slightest

I bored out the spigot rings for the TD alloys this morning as had them removed whilst trial fitting them

 

[Scullies]

What spigot rings? All I can see is BOOOOOBS

 

[Sam_]

What a fine pair of spigots.

 

[StaceyS3]

Little update

Made myself a couple of weld on WMi boss's for if I go from 60-63mm or so pipe work

Not sure how going to have the WMi set up may experiment with a couple of nozzles

Managed to eventually get the crank pinned, went with 2 5mm pins just for extra security

My home made crank holding device mk2.5 as really underestimated how much force is needed to hold crank still when done up the crank bolt on the last build and modified crank bolt so can clamp it all tightly whilst drilling the crank through my timing pulley

Pulley slid back on

 

[BENJAMIN]

I have the vag tool to lock the crank, you're more than welcome to borrow it if you need it mate.

 

[StaceyS3]

Cheers mate will see how it holds up, it managed last time but it was after breaking a stupidly under engineered mk1 and then ended up welding a new handle/bar on this one as broke the first lol

 

[StaceyS3]

Little update, my friend has made my pipe, although he made it a little longer on the flex parts

Old and new side by side

I actually bodged a quick bracket together out of stainless unlke cable tieing the other pipe last time

It feels absolutely amazing to have the S3back again after puttering around in the misses sub 100bhp Ka sport

Also the misses has chipped in to get me a personalised plate but will reveal when it shows up

Happy Christmas all

 

[Sam_]

Rolling out the red carpet for the new hose I see. Looks like a few calendar related stains on it though.

 

[StaceyS3]

Not quite mate the carpet is just to keep me dry as not got quite the joyous weather you have over there, hate to think what's on there as it's what I recieved my alloys wrapped in so would prefer not to think what and who's old fluids I was laying on lol

 

[Sam_]

Haha yeah best not to think about.

What fly/clutch you running? Looking for one at the moment. Was going to go aluminium 034 fly and Southbend stage 3 clutch?

 

[StaceyS3]

Did have southbend stage 2 daily and southbend smf but it was looking rather worse for wear when last looked

Have now got a southbend 6 puck friction plate to chuck in an see how it goes as the fly and pressure plate were rather blue when I last looked

 

[superkarl]

Stop talking about ****** clutches and go and get leathered ***!

Merry xmas guys.
Hope you had an awesome first xmas with the little one stace.

 

[StaceyS3]

Stop talking about ****** clutches and go and get leathered ***!

Merry xmas guys.
Hope you had an awesome first xmas with the little one stace.

Lol Karl, was nursing a sore head from Christmas eve and got stuck driving during the day but just chucked twice as much down my throat in the evening to make up for it

Had a wicked chrimbo and will do for the next few days (joys of split family's both sides you end up with 4 Christmas days) hope you guys have had a gooden

 

[Sam_]

Haha I was getting leathered while posting but not at a pub unfortunately Just at home with a 6 pack and a couple of 40oz'ers. Decided to buy some H&R RSS Clubsport coilovers as a present to myself haha

 

[JoeD]

Little update, my friend has made my pipe, although he made it a little longer on the flex parts

Old and new side by side

I actually bodged a quick bracket together out of stainless unlke cable tieing the other pipe last time

It feels absolutely amazing to have the S3back again after puttering around in the misses sub 100bhp Ka sport

Also the misses has chipped in to get me a personalised plate but will reveal when it shows up

Happy Christmas all

What pipe is that out of interest, is it power steering related?

 

[StaceyS3]

Haha I was getting leathered while posting but not at a pub unfortunately Just at home with a 6 pack and a couple of 40oz'ers. Decided to buy some H&R RSS Clubsport coilovers as a present to myself haha

Haha brilliant mate, nothing better than some self indulgent Christmas shopping

 

[StaceyS3]

What pipe is that out of interest, is it power steering related?

Yes mate it's the power steering pipe that runs from the pump to the passanger side of the rack

 

[StaceyS3]

Plates showed up today just waiting for the docs to go with it and will then transfer it straight over

Would have got my initials at the end like a few others on here have done but I've not got a middle name and having 2 letters at the end isn't a standard prefix type plate so GTX seemed like a sensible way to go

 

[Sam_]

They look like pressed plates too? Cool. Same as ours here.

 

[StaceyS3]

They look like pressed plates too? Cool. Same as ours here.

Sorry mate must have missed this

Yeah are pressed plates mate, have got pressed plates on the current reg and love them

Little update

Have eventually got some more hours in on the engine as had a nice quiet day at work

Block with the N/A headgasket

Head all torqued down with ARP's to 80ftlb and mani nuts also torqued up (well ones can get to) with nordlocks and copper locking nuts

I didn't think could put my back through much more torture lifting the engine in and out of the cupboard and didn't like the idea of leaving it out when i'm not there so have come up with a contraption to shoe horn it in and away

It started as an old tool trolley like mine

Tacked a few bits of scrap metal in to hold the sump

It home safe and sound and was a tight fit

Am now using a hoist in future unless can get someone to give me a hand

I am really undecided on what to do about cams???

Came close to buying some cat cams 3658's but when spoke to arnold at pag parts he said that my inlet mani will really soften the lower end of the rev range and suggested maybe a really mild cam like 3651's and changing to a .63ar hotside?

Think i may just get it up and running and mapped on standard cams and then make a decision from there with where want to lift/shift the power band and maybe the IE cams may eventually be available by then?

Whats your guys thoughts?

Cheers

 

[badger5]

arnolds saying the IE mani will "soften" - aka "loose" low end power?

 

[StaceyS3]

Yeah pressume that's what he means by it or possibly just create some more lag due to being a bigger volume?

Was just emailing about for prices on cams and also asked of his views or opinions on what to go for and am now very unsure of what to do as originally leaning towards the 3658's but he was leaning more towards the 3651s?

Here's a couple of pics of the turbo mocked on there so can work out how lines are going

Bill what's you opinion on having the oil drain go between the runners on the mani in stainless hard pipe? Can you see anything adverse due to doing so?

Can just about see my finger in the pic roughly where would be looking to run

Edit: forgot to say that the pipes will have around 10mm clearance to the runners

Cheers

 

[badger5]

Bill what's you opinion on having the oil drain go between the runners on the mani in stainless hard pipe? Can you see anything adverse due to doing so?





Cheers

personally I would'nt do this no.

 

[StaceyS3]

Cheers Bill my only worry is that to get it to the sump i have to do a really long line around the mani near cylinder 1 or run along the transfer box which will end up being nearly parrellel to the floor in some areas?

Heres a couple of pics with fitment with the old box on and the tial wastegate placement as when me and Bill spoke many moons ago he was concerned as james's was tight and mine has obviously also got the prop to contend with

As a comparison here you can see james's with his mani which obviously sits the turbo an inch or so lower than mine

Whats everyones (especially bill with first hand experiance with the TSR mani) thoughts with fitment issues with this?

Main ones i can see is gear change cables and coolant pipes that run to the bulkhead? Does the A3 have different shaped coolant pipes to the K04 equiped cars?

 

[badger5]

coolant lines are different between k03 and k04 cars yes.. hardline and outlet elbow from head differ between models
tial looks better positions on yours to james' are his angled downward also and wedged the gate into the gear cables. not ideal.

you could look to do part hardline to get away from the runners and weld a -10 fitting on to the end of that line to then enable a well wrapped flexi to route to the sump. the ones I have done have varied but are based on the same theme.. Stock sump pipe return line, which is cut at the top of the vertical section where I weld on a -10 fitting.. sometimes 45deg sometimes straight.. Onto that the flexi line goes on with either 90deg fitting or 45deg. It snakes under the manifold up past cyl 4 and tial and loops round the back and onto the hardpipe I made off the turbo. It allowed fitment ogf turbo with part oil drain already bolted up (an access thing) and flexi went onto that. Its close to stuff and heatshielding is muchos given it passes by the tial and its outlet (which is also wrapped)

I'm just not keen on running a drain thru the runners.. Hardpipe is fine, its just the thought of oil baking to the sidewalls of that pipe where it passes the uber hot runners, and over time reducing the bore.. Maybe I am worrying too much but its my reason for being a little apprehensive about it.

 

[Prawn]

So much goes into builds like this! I don't think people fully appreciate the knowledge and experience that goes into making them work well.

very much looking forward to seeing this one come together when it's mapped

 

[StaceyS3]

coolant lines are different between k03 and k04 cars yes.. hardline and outlet elbow from head differ between models
tial looks better positions on yours to james' are his angled downward also and wedged the gate into the gear cables. not ideal.

you could look to do part hardline to get away from the runners and weld a -10 fitting on to the end of that line to then enable a well wrapped flexi to route to the sump. the ones I have done have varied but are based on the same theme.. Stock sump pipe return line, which is cut at the top of the vertical section where I weld on a -10 fitting.. sometimes 45deg sometimes straight.. Onto that the flexi line goes on with either 90deg fitting or 45deg. It snakes under the manifold up past cyl 4 and tial and loops round the back and onto the hardpipe I made off the turbo. It allowed fitment ogf turbo with part oil drain already bolted up (an access thing) and flexi went onto that. Its close to stuff and heatshielding is muchos given it passes by the tial and its outlet (which is also wrapped)

I'm just not keen on running a drain thru the runners.. Hardpipe is fine, its just the thought of oil baking to the sidewalls of that pipe where it passes the uber hot runners, and over time reducing the bore.. Maybe I am worrying too much but its my reason for being a little apprehensive about it.

Cheers bill my thoughts were simular knowing full well that the hardpipe will more than survive the heat but wasn't sure how it'll effect the oil, i will look at routing the route mentioned next time i've got it all back out at work (probably next weekend), have also been playing with one of the k03 oil drain lines and was going to be using the flanges minimum from these with either my hydraulicy hose friend making up the rest or using AN fitting as have been compiling a shopping list

What do you tend to use for oil feed and coolant feed return as i know all the thread sizes etc but can't make my mind up between banjo-AN adaptors due to access or just normal straight AN-metic adaptors (suppose will need some flare spanners)

The coolant hard lines off of the block do you think i will be better off with A3/K03 ones(cant remember what shape they are)? IIRC will they pass under the comp intake rather than over/in front of them?

Cheers

 

[StaceyS3]

So much goes into builds like this! I don't think people fully appreciate the knowledge and experience that goes into making them work well.

very much looking forward to seeing this one come together when it's mapped

Cheers mate

Like we said before its all the little things that are an **** and get forgotten about cost wise, its also a lot easier whilst the car is running and can do it at leisure unlike last time when i bent a rod

One thing to also not forget although i have a general engineering knowledge, up until i came on this forum i hadn't ever even peformed an oil change or changed my own plugs so goes to show what you can learn on the net and over the phone to bill lol

 

[badger5]

The coolant hard lines off of the block do you think i will be better off with A3/K03 ones(cant remember what shape they are)? IIRC will they pass under the comp intake rather than over/in front of them?

Cheers

lower hardpipe to heater on k03 ones... closer to tial and g'cables but well below turbo intake.
I use hardlines and M14 (I think) stainless banjos with 3/8" stainless tube welded to them and then hoses from them once they have gone past all the very hot stuff.. I've not ever liked or had reliability from flex's straight off the CHRA.. Its so close to something 1000'c, I dont care what braiding is on it.. its not going to like those temps.. lol

 

[superkarl]

Stacey, when you bought your pistons did it state the CR with an X thickness gasket?
Usually they say X:1 CR with XXX thickness gasket.

 

[<tuffty/>]

You planning on getting the manifold ceramic coated or at least wrap it? gonna be a lot of heat there... looks good though dude... well jell...

<tuffty/>

 

[Sam_]

Looking awesome. Can't you use a bit of fire sleeve on the turn drain? Have you seen the 034 kits?

 

[StaceyS3]

lower hardpipe to heater on k03 ones... closer to tial and g'cables but well below turbo intake.
I use hardlines and M14 (I think) stainless banjos with 3/8" stainless tube welded to them and then hoses from them once they have gone past all the very hot stuff.. I've not ever liked or had reliability from flex's straight off the CHRA.. Its so close to something 1000'c, I dont care what braiding is on it.. its not going to like those temps.. lol

Sounds perfect.....love it.... hadn't thought of doing hard lines on the others then onto AN fittings, apart from on the oil drain

Think I may be better off with the k03 pipes? Will see what I can dig out

Cheers

 

[StaceyS3]

Stacey, when you bought your pistons did it state the CR with an X thickness gasket?
Usually they say X:1 CR with XXX thickness gasket.

No just stated 9.0:1 on IE's website and as far as I know they generally only push going for standard thickness gasket as they sell them to except the 83mm bore for a healthy $100 rather than an N/A one?

Any reason why you ask?

 

[<tuffty/>]

Looking awesome. Can't you use a bit of fire sleeve on the turn drain? Have you seen the 034 kits?

...to allow it through the runners?? not really mate... radiant heat is a fecking killer... if you can keep stuff away from the hot stuff then there is no reason to compromise... have done a fair few builds like this now so can say from actual experience (including my own car of course) that all the heatshielding in the world is not as good as keeping it out the way of heat in the first place... at the very least the manifold would need ceramic coating anyway as this thing will glow big time when use on a track day...

<tuffty/>