A3 Quattro KO4 upgrade, its started

[Paradox1]

I know the feeling. Such a good feeling once you get it back on the road! I may even take a blast down to devon to see ya. my car needs a good blow out

 

[Prawn]

Where did you get the rings so cheap dude?

The same rings Phil got are available special order through any GSF too dude, £11 per piston, it's what I've used in mine and BeachBuggy uses them in his builds too

 

[superkarl]

the legend that is phill miller got me some :thumbsup:

 

[phil miller]

I know the feeling. Such a good feeling once you get it back on the road! I may even take a blast down to devon to see ya. my car needs a good blow out

Ideal marty , once together im gonna drive everywhere so i get the miles on it asap

 

[Paradox1]

you know your welcome my side aswell, i'll even get you a parley/permit (Think of the film worriors)

 

[Prawn]

Drive it up to Ace Cafe next month

 

[phil miller]

Drive it up to Ace Cafe next month

Now that is an Awesome idea and is the best way to get miles under its belt, a fully warm engine being used is better than the warm up cool down run in that it would get using normally round here

 

[phil miller]

you know your welcome my side aswell, i'll even get you a parley/permit (Think of the film worriors)

Ideal will take you up on that dude

 

[Prawn]

you can have Chilli Chips n Cheese with Marty and I!!!

 

[phil miller]

you can have Chilli Chips n Cheese with Marty and I!!!

will do that, be a great day out and be good to meet up with everyone

 

[Paradox1]

you can have Chilli Chips n Cheese with Marty and I!!!

Can you believe I still havent had any Chilli,cheesy chip from there before!!

Its only like 20mins from me and ive never got around to it.

shocking

 

[phil miller]

Can you believe I still havent had any Chilli,cheesy chip from there before!!

Its only like 20mins from me and ive never got around to it.

shocking

I know i live in the sticks but ive never been to ACE, a trip would be a very fitting first long run for Ron

 

[phil miller]

Ok so today i painted the bottom arms (no pics tho ) and ive decided to fit budget poly bushes in the front lower arms

Two reasons for this

first off the engine rebuild has wiped me out, and
Second i do want to fit S3 hubs and bottom arms at some point, so although the camber bushes are worth it, the cheap ones for £26 for front and rear, front arm bushes will do for the time being.

Also ive been looking at my old exhaust valves and the seats on the valve are badly pitted, so i think it was a combo of pitted valves and loads of boost and water in my meth that played its part in the shout lived MAN BOOOOOOOOOST, all in all its coming along nicely

 

[phil miller]

so today i had a plan, when i stripped Ron down i noticed my hot side outlet pipe off the turbo was going black, signs of the hot mani now its running proper boost,

At Christmas i noticed Prawn had made a shield to protect the hose, my plan was simply, Jardo has about 12 heatshields for the cone filter, i asked if he could spare one and as normal he was only to happy to donate one to the cause, so my plan was to stop this getting worse

so i made this

there is a spare M6 threaded hole on the edge of the rocker cover so this is what it will look like bolted up

should help keep the heat off the hose now

 

[badger5]

let me know when you want these rods/shells Phil

 

[phil miller]

let me know when you want these rods/shells Phil

Will be on the phone tomorrow at some point (work has been mental) its all coming together well on the Ron front

 

[bigal 1]

the legend that is phill miller got me some :thumbsup:

What. Two legends in the south west. Well I never!!!, or maybe I did. Actually I've forgotten.

 

[phil miller]

Im hoping for an easier day tomorrow, where i get chance to call you Bill, my boss has been a nightmare, mainly due to one of the other mechanics snapping his leg in 2 at the weekend, so we are a man down with enough work to have kept us all busy, with him not here its just plain mental

 

[badger5]

owch, snapping a leg in two sounds horrific - ewww

 

[phil miller]

owch, snapping a leg in two sounds horrific - ewww

Yeah i spoke to Ash last night and he snapped his tib and fib, he said his foot was the wrong way round (makes me cringe just thinking about it) from what he said he will prob be off work for around 2 months, boss is not happy and is being a little hard on the rest of us thank god for the weekend, although he has been offering OT on friday and monday

 

[phil miller]

Rods and shells ordered from Bill, hopefully start putting Ron back together later this week

 

[Paradox1]

That what I like to hear! good stuff Phill

 

[phil miller]

while i took advantage of the longer daylight, Rods and shells should be here any day, so i decided ive block off the block, make it clean so when i hone the bores i wont get dirt down them, that is now done, i wish id bought my honeing bit home from work today as id have honed the bores aswell, the head is ready, the water pump and stat are fitted, cant wait for the fun to begin

 

[phil miller]

Update time

Rods and shells ordered and arrived today Bill you are a total legend

so tomorrow i will be fitting the pistons to the rods and then honing the bores and refitting the pistons, im then planning to lift the head on and torque that down, then saturday evening (after Jake has gone to bed) fitting the cambelt and finishing off, hopefully have it running sunday evening i really cant wait

one question are the bigends 50 ftlbs slacken off 3 times? for some reason i had 55ft lbs slacken off 3 times in my head

They are even more beautiful in the flesh

replacement front dogbone from my very good friend Jardo

Head already

 

[badger5]

55lbft is what I use, 3 times yes

 

[Paradox1]

And to think you were only just going to fit a k04 standard setup.....

now you got the engine scattered around in pieces lol

Loving the progress mate!

 

[A3-Lee]

Looking good mate

 

[16Klappe]

Beast.

Can't wait for the beast to be back on the road

 

[phil miller]

pistons fitted to rods and new rings fitted, pistons all cleaned and everything ready to go, this is gonna be a good weekend

Jardo if you are free i could do with a hand please dude, the head is a fair weight with the mani and turbo on it and my left elbow is still not right

 

[phil miller]

55lbft is what I use, 3 times yes

I thought thats what you had said, but wasnt 100%

They are awesome thank you bill

 

[phil miller]

55lbft is what I use, 3 times yes

<br><br>I thought thats what you had said, but wasnt 100%<br><br>They are awesome thank you bill

 

[phil miller]

ok so after playing in the garden for most of the day with the kids i decided it was time to fit the head

head on

and my fav pic

all thats left to do is fit the tip, injectors and cambelt

i think the 2 heat shields will do a good job

 

[badger5]

I would consider extending the heatshielding along by the servo also phil..

 

[16Klappe]

Geddon' bey!

I'll be seeing you tonight reet?

 

[phil miller]

I would consider extending the heatshielding along by the servo also phil..

ok will get a sheet from merlin Bill I will be calling in to say hi on our way up for the logging that Niki wants to do, be good to put a face to the voice

 

[phil miller]

Geddon' bey!

I'll be seeing you tonight reet?

Ofcourse dude will be over after dropping Jake home

friday when I picked him up he asked what car I had and when I said the black one he didn't look happy and said I want to go in Ron bless him even at 4 he knows what's good and what's not lol

 

[phil miller]

Right not any new pics but tonight ive done a few more bits

TIP is fitted, plugs and coil packs fitted, filled with Anti Freeze

so all thats left is Cam belt kit and oil and re fit the injectors

If all goes to plan i will have Ron running Tuesday evening

 

[badger5]

your Siggys wrong Phil... IE Rifle drilled rods.. not ina...

 

[phil miller]

your Siggys wrong Phil... IE Rifle drilled rods.. not ina...

sorry
but on a lighter note I've fitted a new belt kit and Ron is running

ive just came in and I can't wait to go for a drive, all I can do is

update later

 

[phil miller]

Ok so im BUZZING, ive been out in Ron, only covered 4 miles as im knackered

Also i havent got any pics because i had dirty hands and i wanted to get it done

Ok so i had it running for about 30 mins all was good, i thought then was the best time to stop, let it cool, check for leaks and eat

anyway after going back to it, it cranked over and back fired it then started, so i pulled it out of our garage down the end of our road and drove up to the house, it didnt feel right and the management light came on, my heart sank, i felt that sick feeling again, so i grabbed my laptop and VCDS lead and plugged in, there were loads of codes prob there since i pushed it in the garage 2 months ago with the inlet mani off and everything disconnected, cleared them down and re checked, Cam position sensor ****** idiot i am, i connected it and then disconnected it to fit the top cam cover and forgot to reconnect it lol, so i then went out on a little drive to see how he went, i took it steady, changing gear at around 3/3500 rpm everything seems find, i then remembered what id been told about making the engine work, so i changed in to 3rd and gave it a little more throttle to make it boost, and at that moment, i remembered how fantastic Ron was before the valve issue, it boosted to around 20, only for a second as i changed gear again, but all i can say is its GREAT to have it back on the road.

My Man cave that ive had the head in for the last 2 months is now a dinning room again

i would like to say a massive THANK YOU to Prawn and Jardo (who have put up with me asking silly questions) Bill for sorting me out a with Rods and shell and all the advice over the phone, Dave for being a top bloke, and if it wasnt for the PMs i wouldnt have bothered changing the rods

Thank you all for your help and advice