Cawsey's Track Toy

[Danny Cawsey]

Hi Guys, The time has come where i don't need the car on the road anymore so instead of selling it for peanuts I've decided to turn it into a track day car. It will be a slow project but thought it would be a good idea to keep it all in one thread. I bought the car completely standard 3 years ago and has been brilliant ever since.

Here's the spec so far:

1999 Audi S3

AMD stage 2 map, BBS LM 19s, 20mm Momo Spacers, Black Diamond Discs, Ferrodo ds2500 pads, Milltek Exhaust, Pipewerx downpipe and Decat, Custom FMIC, 4 bar Fuel Pressure Regulator, Forge 007p, Forge short shift, Forge DV relocation ,Forge TIP, S2000 Filter, Sachs Race Clutch, Sachs Light weight Single mass flywheel, ForgeOil catch tank, De baffled Charge pipe & Polished, Polished Inlet Manifold, N249 Delete, PCV Delete, Red Engine Mounts, Forge Boost hoses, Angel Eye Headlights, LCR Splitter,

I've spent this weekend repainting the front grills, cutting open the bumper for the FMIC to access as much air as possible, stripping out some of the interior, fitting some carbon panels around gear stick, hand brake and for switches.
Here's a few pictures:

 

[Danny Cawsey]

 

[Dani_B19]

Anymore pictures of the carbon fibre? Also is it real or wrap?

 

[Danny Cawsey]

All the Carbon fiber is real, I build carbon fiber Race yachts as a job so its free for me i plan on lightening everything i can with carbon.

 

[Dani_B19]

Class. What else you doing in carbon fibre?

 

[Danny Cawsey]

Next will most probably be carbon door cards then maybe build a whole new dash, but i have a lot of other things on the list to do first like engine bits and handling.

 

[Dani_B19]

Fancy doing some front wings and wing mirrors ?

 

[Jason.s]

Front wings, doors, roof, boot lid, spoiler, bonnet. That'll do for now lol

 

[s33nyboy12]

Looking good, I like the front bumper cut out...... Have you notice any difference performance wise?

Sean

 

[jcs356]

I tracked my Ibiza when I bought my S3 - like you, not worth trying to sell it so had a good few years fun out of it until rust finally got the better of it. Enjoy!

 

[Danny Cawsey]

Looking good, I like the front bumper cut out...... Have you notice any difference performance wise?

Sean

I havnt really driven it hard yet since the bumper mod as my engine is making a rattling sound so i need to get that fixed first before testing.

 

[Danny Cawsey]

Front wings, doors, roof, boot lid, spoiler, bonnet. That'll do for now lol

I think I'm going to stick to interior parts and brackets at the moment, maybe in the future ill start making exterior panels. It takes so much time and effort to make carbon parts taking a splash from the part then making mold then laying the mold up sanding the painting etc.
i have a lot of other things that are priority first and i work 55 hours a week so time is limited

 

[StaceyS3]

Will be really good to see how light someone can really get an S3

Will be following this one closely

 

[Prawn]

Eeeeeeeeeeexcellent!!!!!!!!!!!!!

You're local too. We need to talk

 

[limbo118118]

looks cool! i like the way youv cut the bumper like that 0-400 s3! i was wondering when i would see another!

 

[vrbob]

Ah its started

Glad to see you have jumped the gun and taken an angle grinder to your bumper already.

If you need a hand one evening/weekend drop me a shout as you know i am only round the corner from you.

Rob

 

[future]

looking wicked! excited to see where this goes i am near to you and rob as well so we should all have a chat and lend a hand!

tom

 

[vrbob]

looking wicked! excited to see where this goes i am near to you and rob as well so we should all have a chat and lend a hand!

tom

Defo Tom you will like Danny`s car its almost the same as yours pre-facelift without ESP.

Will try and sort out meeting up over easter when you are back and we do some late night mechanics.

 

[future]

yay for no esp!! looking forward to some late night mechanics with you guys!

 

[Paradox1]

Finally, someone with a S3 has the guts to take the risk. Good stuff.

whats next on your to do list?

 

[Prawn]

are you keeping it road legal so you can at least enjoy taking it out for a blast around hampshires finest roads Danny?

 

[Danny Cawsey]

Ah its started

Glad to see you have jumped the gun and taken an angle grinder to your bumper already.

If you need a hand one evening/weekend drop me a shout as you know i am only round the corner from you.

Rob

Cheers Rob its always good to have a spare set of hands. That rattle i had at high revs while we were logging has got much worse now, no power and judders like a jcb, I'm pretty sure its something to do with this stupid light weight SMF.
so its going to have to wait until the end of the month until i can afford to put it in a garage to check it. unless anyone local on here fancy's taking the gearbox off and having a look?

 

[Danny Cawsey]

Finally, someone with a S3 has the guts to take the risk. Good stuff.

whats next on your to do list?

The engine isn't running right at the moment so i need to spend some time getting that sorted first and a few small things like replace window clips etc then ill be focusing at getting all the handling perfect suspension, arbs etc and fitting some Brembos.

 

[Danny Cawsey]

are you keeping it road legal so you can at least enjoy taking it out for a blast around hampshires finest roads Danny?

Don't worry Prawn ill be keeping it road legal for that very reason as soon as i get the Engine running properly again ill have to head up to yours to steal some of your ideas.

 

[Sam_]

I've been doing something similar but need to drive it daily. I notice no mention of suspension in your list but here's a few shopping items:

IDF tubular front control arms - not necessary but won't deflect like bushes and last well (they use decent rose joints). Mine have arrived back in Aus, keen to get them fitted.
Solid subframe and rack mounts - USRT sell both
Front camber mounts - ground control, h2sport or prawns ones
Decent coilovers - KW V3 or H&R RSS Clubsport
Decent tyres - speak to prawn
Light rims - enkei are good
R32 rear arb might be enough - many of the auto-x guys run no arb and say it improves turn in.

 

[Prawn]

I think the key to handling is making the geometry adjustable or at least correct for your intended use. My recent addition of a shimmed rear end, and caster correction front bushes and adjustable top mounts has really transformed my car totally.

 

[vrbob]

Cheers Rob its always good to have a spare set of hands. That rattle i had at high revs while we were logging has got much worse now, no power and judders like a jcb, I'm pretty sure its something to do with this stupid light weight SMF.
so its going to have to wait until the end of the month until i can afford to put it in a garage to check it. unless anyone local on here fancy's taking the gearbox off and having a look?

Cool well just give me a shout either PM me or drop me a text (i think i gave you my number) if you want a hand. Am reasonably handy with a spanner set but just lack some of the knowledge thats all. So if you think you know how to get your gearbox off am willing to be your spanner monkey

Have you got a new clutch setup to go in if we took it apart?

 

[Danny Cawsey]

Yea I have your number Rob, I haven't a clue how to take the box off but I'm sure it won't be rocket science. I'm just limited with space as my garage isn't very big. I may just wait till payday and take it into a garage. Where's good near Southampton? And no I don't have a new setup to put in, It's pretty annoying as I'm running a sach smf and updated clutch, two weeks after having it fitted a bit of metal snapped off the clutch letting one of the springs come loose. so i had it sent back which they wouldn't replace under warranty so I bought a new one which was solid, this was all re fitted about 5 months ago. So far it's cost me an arm and a leg. Here's a pic of the old clutch that broke.

 

[Danny Cawsey]

Also this little gem turned up in the post the other week 40quid from eBay, quite happy with it.

 

[Danny Cawsey]

While cleaning the engine bay I came across this cable and can't work out where it goes, any ideas?

 

[s3dave]

secondary Air injection connector, or after run pump?

 

[Danny Cawsey]

Ahh that makes sense as I deleted the SAI, it was doing my head in trying to find where it went.

 

[Danny Cawsey]

Which engines use the large port head? It's it just AGU and AEB as I'm thinking of buying a second engine completely stripping it for a stroker 2.1 big turbo build.

Next week I will be wiring up the ignition and push botton start and fitting some more carbon parts. Pics will be added as I go along. Also I will be building a flush carbon bonnet vent that will slot into a carbon heat shield box for the air filter when closed.

 

[Dani_B19]

Yes agu and aeb although the aeb engine wont fit so your have to buy a new block seperately.

 

[Prawn]

AEB and AGU yes.

Would it be rude of me at this point to point out that building a track car is much more about the whole package than the engine? Big power is not what you need chap, you've got many thousands to spend before you're needing any more power

 

[Paradox1]

haha prawns thread should be enough to make you think twice.

I think it all depends on how are you want to go with it. its a slipery slope. Prawns car was leathal with just a k03s, now look at where he's at. Personally, as you already have a stage 2 map, your car is quick so I would leave the engine alone and work on shedding weight, braking and handling.

 

[Dani_B19]

Id say a 2.1 would be **** for track, youd be better off with a high revving 1.8 or 1.9, look at bill, hes running a 1.9.

 

[Prawn]

yup, st2 ko4 and 4wd is PLENTY to make a very, very fast track car, stripped and lightened, with some choice handling mods, and you will have a very serious weapon indeed.

The last thing you need on track is some silly 500bhp+ unreliable big turbo motor

 

[Jason.s]

Yup you don't need big power for a fun time on track. Even standard power could be fun if braking and suspension are ood. Look at all the people that drive mx5s...115/130bhp but love every second because of the way it drives. Brakes suspension and make it all last as long as possible on track with decent cooling and stuff like that.

 

[<tuffty/>]

...The last thing you need on track is some silly 500bhp+ unreliable big turbo motor

Don't worry about getting it on the track, it won't make the event without breaking down on the way there

<tuffty/>