superkarls overhaul

How the car currently sits, worked out lambda and egt probe fitment which will be added to the downpipe. Will also need a strategic dent to clear the prop input flange.

And my general feelings toward it all:
 
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What scott said. My mate still hasnt fully welded the dp up, it was only tacked last time i saw it.

Should have some updates by monday, i hope
 
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Downpipe done. Looks like its been made by about 7 people which is awesome. Just got to fit it now, think my dad will give me a hand this saturday getting it all fastened up and in the engine bay once and for all. Heres some pics that i shouldve sent darrens friend to show clearance:Jobs left:Fasten it all inWire it all inStill havent made fuel rail spacers but shouldnt take more than 30minsTurbo oil drain also needs the other AN fitting putting onTIP Fuel pumpBoost gaugeTaxInsuranceMOT
 
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Nice one mate

Did I not send you some rail spacers? If it's the same size as the usual IE ones for dekas....got some in my drawer can send you :)
 
Cheers stace.Theyre genesis 630.I bought an alloy rod that im cutting to size and drilling. Think i measured the gap at 14mm. P.s. This site is full of bugs. Ive no formating toolbar
 
Usual ones are 12.6iirc? Will post you a set if you refresh me on your address :)

Ps I know what injectors you've got....I did order them lol ;)
 
Looking good Superkarl, Clearance is niiiiice and tightish. hehehehehehe My turbo build will have to wait till early next year. Waiting on some cash due to me changing jobs plus my minion, Darren, isn't in the country atm. He is lounging around in SA topping up his tan no less. Also having some small issues that need resolving too. Got me a nice coolant leak and will be replacing the radiator once the slacker gets back.
 
small update:
Had an oil feed made, turned out my dad knew the owner of the place through his bike club, so that's a nice contact to have:


and this is what the turbo looks like installed on the car:


I just have the tedious task of remembering what bolt goes where and get the car back together. I wasn't very organised when I took it apart about 10 months ago

P.s. Gotta love special spanners
 
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Have you checked the actuator won't foul when its extended? you may have to clock the CHRA round a little

<tuffty/>
 
Foul what? The oil feed? I can move that a little.

Youl notice I had to extend the actuator arm, still doesn't open enough for my liking. Gonna be boosting to the moon!
 
My oil feed line was similar to that, it melted and split from the heat. Changed to a stainless hardline fitted to the turbo, then bent 90deg away from the hotside and connected to new turbo oil feed line. Just my 2cent :)
 
To clarify. Oil feed is one going over the compressor. The other braided hose is the egt, which will be routed up to the rocker cover and ran along with the coil packs
 
Been a while, done NOTHING.
been too busy lately.

Bought myself a present though for my recent efforts with my exams:
K&N RU-3620 - Universal Air Filters, Universal Rubber Filter

worked out the size by drawing my old jetex filter on paper, then this one over it. this one seemed to fit the bill being slightly larger, although oval, should be fine, not too big, not too small
 
kwistof said:
Why :think:

What's wrong with the milltek?
Click to expand...
nothing wrong with it as such.
Don't get me wrong, its a quality piece of kit, so well made and the balance between sound at cruise and wot is impressive.
Its just restrictive.

<tuffty/> said:
Mine seemed to sound very restricted at 400hp tbh hence me building a new straight through type back box...

<tuffty/>
Click to expand...
Is that with the 3 inch mid section into the back box as well?
See I've thought about having it 3 inch to the box like you did. But to be honest the restriction is probably more in the back box itself than the 2.75" pipe.

Andrew@A.L.D said:
Even more with me at 500
Click to expand...
It must have been awful at these levels.

I think the solution is 3 inch, with resonator and a 3 inch straight through box mounted sideways.
 
Definitely ditch it man.

Given your reservations about the internally framed setup already, I'd think you want to do all you can to reduce back pressure and exhaust side heat.

Give it every chance to breathe properly, and I'm sure it'll be awesome :)
 
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superkarl said:
nothing wrong with it as such.
Don't get me wrong, its a quality piece of kit, so well made and the balance between sound at cruise and wot is impressive.
Its just restrictive.
Click to expand...

Ohh okay- cheers for explaining that.

I saw that Nicki mentioned on his FB the other day that the Milltek on a mk2 Leon he was mapping was restrictive up to 380bhp. Totally realise it's a different system and car to ours- but chances are the version for our S3s will be restrictive in a similar way.
 
I think you'll need something like this Karl...

120495
 
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superkarl said:
Is that with the 3 inch mid section into the back box as well?
See I've thought about having it 3 inch to the box like you did. But to be honest the restriction is probably more in the back box itself than the 2.75" pipe.
Click to expand...

Yeah... mine was 3" all the way to the back box... Bill welded a 3" piece on the miltek to mate with the rest of the system...

I am keeping my 3" mid section but obviously need a new DP for the new setup and building a back box based on the idea I came up with for Stacey's...

<tuffty/>
 
I will hopefully be updating this more often over the next couple of weeks with a little more free time to do stuff.

Its not rotten away yet, but certainly does look it


After fitting the turbo and downpipe and all that shiz and getting the engine in, the downpipe fits alright, only one strategic dent needed by the prop flange, i just need to make a decat section up to meet the miltek, but that will be left till last i think as its a quick job


So i ordered a filter as a reward for myself, and also ordered all the TIP pieces, 90mm and wanted it to be alloy, and will be painted as with all other pipes wrinkle black for subtlety. Mocking up was offer, cut, offer, cut, offer cut, etc etc




I also wanted it future proof, and so my DV inlet is 40mm (forge supersize should it need it), so this required the chargepipe to be fitted and DV mocked up:



Was hard cutting and shaping that DV take off, the N75 port is pretty easy (thanks to stacey), so this lot will be dropped off at the welders:




Will have more updates in a few days, having a hard time finding nuts and bolts n shiz and remembering what goes where due to my own incompetence.
 
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Slowly coming together now! Can't wait for this one to be running again
 
This weeks news:

I turned the engine over by hand randomly as i owed the crank bolt a few degrees. I heard a scratching sound at the gearbox end, so immediately started to panic at what i may have done wrong.
Starter motor came out and it was clear what was wrong:

cover plate was catching the bell housing on the way round, you can see the filings on the cover right where that rivot is.

The black tab you see above had a sharp corner to it, this is what was catching.
So i dremelled all of them to round them off:

Problem solved.
We put this down to manufacture error. Its a LUK clutch. but as far as i know the covers are refurbed with new material, rivots etc, so perhaps a dodgy batch of those black tab things.
This is a better conclusion than fitment error. After a call to my dad about my concerns he came round, and he assured the FW and clutch were installed right as he guided me through it as i used his alignment tool he showed me how to use.

Moving on.

Made some fuel rail spacers out of a bar of alloy.

they're about 13mm. If they dont allow the injectors to seat as snug as they need i can take .5mm off or so.

So i fitted the inlet, began installing, plumbing things, and then set about putting the loom in the bay.
took my time with it, making sure i found the right plugs for their sockets, routed everything as nicely as possible.
Engine bay is starting to evolve:



There were a few things i wish i couldve tidied up and shortened etc, but this will have to be done at a much later date if it still bugs me.

And to end, i have a concern:


The alloy union that comes out of the power steering pump, with the hose attached to it as seen above. This was always loose so it could be swivelled around.
Well i realised that it can pull out very very easily, with no way of locking or clamping it in.
This cant be normal surely? I think i may have knocked it while the engine had been on the floor.
Not sure what to do about it.
Going to remove it and see how it works. Bodge it in somehow if need be. Possibly weld it in. I think its on the low pressure side.

Thats all for now.
 
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That alloy piece is just the feed for the pump so won't be under pressure... that said it should be a tightish fit... I have not looked personally but would suspect there is an o-ring in there somewhere which would allow the movement you describe but still prevent leaking of fluid...

<tuffty/>
 
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<tuffty/> said:
That alloy piece is just the feed for the pump so won't be under pressure... that said it should be a tightish fit... I have not looked personally but would suspect there is an o-ring in there somewhere which would allow the movement you describe but still prevent leaking of fluid...

<tuffty/>
Click to expand...
I consulted with dave who happened to have 2 spare pumps handy. One has a different inlet on it to mine. The other is missing the inlet, but inside is infact an o-ring of some sort.
ETKA doesnt list that O-ring, but il remove what i need and see if i can fix it.
I just wanted confirmation that it wasnt supposed to pull out with the slightest effort really. Glad i've spotted it though.
 
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There are two different pumps listed for the A3 platform IIRC... the S3 and TT get a different pump to the A3... not exactly sure of the differences but seeing as the S3/TT has the quick rack its possibly a heavier duty pump for the quick rack... anyone that has driven a car with a non assisted quick rack will know why... (had a 2.5 turn lock to lock rack on my Mk2 Escort... its why I'm so built yo!... lol)

<tuffty/>
 
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Just had a good read up, been awhile since I have read your build thread great stuff mate good luck with rest :)
 
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What can I say SuperKarl,

Starting to come together nicely :)

Soldier on young sir SOLDIER ON!!!

Starting to put together parts for my turbo build so methinks I might have to get my rear end in gear and post up a build thread.

Darren the slave is back so gotta put him to work!!!
 
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