My minor modding thread

[Prawn]

to be technically correct and factory, which way should the writing be on the cambelt?

Not that I'm going to change mine if it's wrong of course

 

[badger5]

I presume viewed from #1 end it should read correct?

good question..

 

[aragorn]

The Audi service manual makes no mention of belt installation orientation.

 

[Vex182]

That made me laugh! I have no idea which way mine is facing, but I do care about it staying tensioned and on!

 

[Scullies]

the cambelt is an easy fix, just paint it black
no writing = no problem

 

[Sam_]

It should be covered up anyway....

 

[<tuffty/>]

It should be covered up anyway....

It will be once I have decided if I am just painting the old cover or getting a new one

<tuffty/>

 

[chaz20vt]

I like how much detail you go into with this
Spot on...

 

[<tuffty/>]

Little something turned up at the Badger Cave today

...project manifold is a go then

<tuffty/>

 

[Westy]

Thought you were making a Pegani Zonda exhaust

 

[Andrew@A.L.D]

Where and how much please.

 

[<tuffty/>]

Where and how much please.

Here ->collector info

<tuffty/>

 

[superkarl]

Where are you sourcing the tubing Tuffty? and what schedule?

 

[badger5]

+

 

[CazzaVR]

Oooh- looks very interesting! Very nice car mate- been working my way steadily through your thread- it's a real credit to you 8)

 

[<tuffty/>]

Been a little while since my last update as I have been helping Bill catch up on stuff and had to send the collector back as they had made it in 1.25" ID tube rather than 1.5" ID tube... in the mean time I got the 70mm TB blasted ready for having beads welded on and of course painting

I also painted the cam belt cover and modded it for the manual tensioner

The new collector turned up Friday so game on...

...Nortech (the stars that they are) even did the final capping run on this one...

...and of course the obvious difference between 1.25" and 1.5"...

...it begins...

So tomorrow I am gonna make a start and see where I end up... what is evident from my initial faffing is that its not as easy as you would imagine to work out where all this goes and to keep it all away from stuff that could melt...

I have not discounted going underslung either...

Hopefully some progress pics tomorrow...

<tuffty/>

 

[Broken Byzan]

I have not discounted going underslung either...

actual YAY !!!

 

[<tuffty/>]

Long but productive day...

rigged up a bracket to hold the collector in place as its next to impossible to hold that and tubing etc at the same time...

Started with cyl 1 runner as this would have to tuck close to the block..

Unfortunately some idiot had put a transfer box in the way and both the runner and the collector was too low to get anything else in so pulled it apart and started again... moved the collector a little higher and re-did runner 1

runner 2 in weld tape (tm) stage...

Runner 2 coming together...

Now clears stuff and fits nice...

Runners 3 and 4 were pretty straight forward comparatively...

Had to make some adjustments to the bends to allow clearance (not loads of course but hopefully enough)

Need to trim the transfer box bracket though...

...but it seems to fit ok and looks pretty good all things considered...

...so of course I had to try it on the new engine...

...and of course I made sure that all the studs were accessible... the most "awkward" ones being..

...and

The manifold should be easy to fit in situe which of course is the next thing I have to do and once fitted to the mock up engine in the car I can work out where the wastegate will go

All in all not too bad considering its my first attempt and I have never used a welder before... started just after 10am and finished up around 7pm... rather tired now to say the least lol..

Plan to grab a couple of days off work to finish it off and then it can be welded up...

<tuffty/>

 

[badger5]

Superb

 

[micky2 not 1]

like it paul. Personally id want it a little higher purely to stop it cooking the TB. bt mines more track than road so you'll have lower temps. Great job....i got competition ;]

 

[jojo]

Superb

x2

 

[Gops]

Looks absolutely brilliant! Was following this all day on FB!

 

[Lewis583]

That looks the nuts Paul. Easily on par with some of the professional manifolds available.

 

[s3dave]

Nice... you will be making TFSI Quatrro Downpipes soon...

 

[superkarl]

How did you figure out where to mount the turbo? I mean whats the thought process behind the collector being in between 3 and 4? Youl obv have loads of room for the downpipe

 

[Sam_]

Awesome work. Placement looks close to TSR but lower and more central between 3 and 4 whereas TSR is closer to 3.

 

[Prawn]

Fantastic work PT!

Drilling into that with a big holesaw to add the waste gate will be a scary moment!

I assume the WG take off HAS to come from the very top of the collector so as to divert gasses from all 4 runners?

 

[<tuffty/>]

Thanks guys... I was quite surprised how well its gone so far... didn't expect to be this far along... of course the tricky bit now is getting the weld sequence right so as not to 'paint yourself into a corner' so to speak...

Karl... most of the mani's I have worked with or seen tend to place the turbo centrally between cyl 2 and 3 or just over cyl 3... they also stick the turbo high up which on smaller turbos works ok but they all still make the DP a challenge... most manis are made for the US market and they don't have servo's and other stuff in the way so I wanted the turbo in a more OE position so it gave me more room there...

<tuffty/>

 

[<tuffty/>]

Fantastic work PT!

Drilling into that with a big holesaw to add the waste gate will be a scary moment!

I assume the WG take off HAS to come from the very top of the collector so as to divert gasses from all 4 runners?

Yeah pretty much... this is why it will be measure twice and cut once

Will have a faff at the weekend

<tuffty/>

 

[Prawn]

can't wait until it's all done mate, getting the mani out of the way seems like a massive step

 

[Scullies]

Thanks guys... I was quite surprised how well its gone so far... didn't expect to be this far along... of course the tricky bit now is getting the weld sequence right so as not to 'paint yourself into a corner' so to speak...

Karl... most of the mani's I have worked with or seen tend to place the turbo centrally between cyl 2 and 3 or just over cyl 3... they also stick the turbo high up which on smaller turbos works ok but they all still make the DP a challenge... most manis are made for the US market and they don't have servo's and other stuff in the way so I wanted the turbo in a more OE position so it gave me more room there...

<tuffty/>

Awesome work meneer :thumbsup:

When the guys welded my mani together, they started with the runners, once they were all done, its was a calculation game to see which runner to weld at what time to the collector. But im sure you know all this by now after welding for a day


LHD and RHD manis both have their issues. RHD has more space on the TIP side, where LHD has limited space on the TIP side. On mine, a 4" to 3.5" silicone reducer just fits past the valve cover and brake servo and my turbo sits higher up. Would never fit if I mounted mine at your level. I would have to go TIPless
Then on the exhaust side, RHD is limited by brake servo and LHD could fit a 5" DP


Also with the turbo being lower you have tighter angles to work with for the downpipe VS the turbo being a bit higher up you have a bit more room, not much but every ball hair counts

S3 with longitudinal setup FTW

Interested to see where you route the wastegate pipe? Similar to what Bill did on Stacey's?

 

[<tuffty/>]

Awesome work meneer :thumbsup:

When the guys welded my mani together, they started with the runners, once they were all done, its was a calculation game to see which runner to weld at what time to the collector. But im sure you know all this by now after welding for a day


LHD and RHD manis both have their issues. RHD has more space on the TIP side, where LHD has limited space on the TIP side. On mine, a 4" to 3.5" silicone reducer just fits past the valve cover and brake servo and my turbo sits higher up. Would never fit if I mounted mine at your level. I would have to go TIPless
Then on the exhaust side, RHD is limited by brake servo and LHD could fit a 5" DP


Also with the turbo being lower you have tighter angles to work with for the downpipe VS the turbo being a bit higher up you have a bit more room, not much but every ball hair counts

S3 with longitudinal setup FTW

Interested to see where you route the wastegate pipe? Similar to what Bill did on Stacey's?

I am no stranger to the awkwardness of making a DP for a low turbo... my last setup was underslung remember ;P

I might look at using 3.5" out the turbo but tbh 3" serves Bill's Ibiza ok so rather than try to fit large stuff in a small place I may just stick to 3" all the way... not chasing numbers with this so its down to whatever is practical...

<tuffty/>

 

[s33nyboy12]

Very impressive mate!

you must have the patience of a saint.........I'd be dying to drive it , clucking to get it finished lol

Sean

 

[badger5]

I am no stranger to the awkwardness of making a DP for a low turbo... my last setup was underslung remember ;P

I might look at using 3.5" out the turbo but tbh 3" serves Bill's Ibiza ok so rather than try to fit large stuff in a small place I may just stick to 3" all the way... not chasing numbers with this so its down to whatever is practical...

<tuffty/>

feck that lol... biggest we can fit in there dude

'because we can'

 

[<tuffty/>]

feck that lol... biggest we can fit in there dude

'because we can'

Well... thats the down pipe plans sorted LOL...

<tuffty/>

 

[<tuffty/>]

Very impressive mate!

you must have the patience of a saint.........I'd be dying to drive it , clucking to get it finished lol

Sean

My patience is a side effect of my OCD... I do want to get it done and it kills me not being able to drive her but it needs to be done right and it would kill me more if I rushed anything for the sake of it and it wasn't right

<tuffty/>

 

[scotty_24]

Awesome work mate, this is some car!

 

[Sam_]

feck that lol... biggest we can fit in there dude

'because we can'

Forward planning for the 40 psi

 

[Scullies]

Forward planning for the 40 psi

Thats pretty low

 

[Andrew@A.L.D]

Thats pretty low

for me would be very low lol