A3 Quattro TDI Re-Shell Into Audi TT225

[Airs]

proper love this

haha thanks big ray hopefully it will be alive in the flesh seen and will be hitting up the first show in telford @ ultimate dubs

 

[Airs]

A little more progress at the weekend, finally got the engine somewhere near the bay only to find that the turbo is touching the bulk head so that went away again yesterday after =noon and hopefully should be back with me tomorrow heres a couple of pics of it in

just ignore the rusty starter, thats just their so could bolt box on, thats not the 1 I'm using lol







rebuilt my callipers again swell after them being all stripped and repainted look awesome





I've also been having some thoughts on a colour change when it goes in for paint after christmas but not to sure, heres a couple of examples,

either stay with gloss black like this



or matt black and make it a sleeper


or blue



or personal favourite is this



obviously if I'm going to change to a different colour I'm going to need to change wheel colour to suit it but thats not big issue lol

all opinions are welcome and would be appreciated thanks guys

 

[aragorn]

Pistons in those calipers look very small? They're not rear ones are they?

 

[Airs]

Pistons in those calipers look very small? They're not rear ones are they?

Na aragon its just the pic thats making it like that, if i remember correctly the are 38mm and 40mm, they are bolster s front brakes

heres them before paint

 

[aragorn]

Aye right enough, the rear ones dont have the "bumps" where the pistons protrude on the outside of the caliper!

 

[Gops]

Great thread here!! So much work and I salute you for your epic effort!!

 

[Airs]

Great thread here!! So much work and I salute you for your epic effort!!

Thank you very much Gops i really appreciate it glad your enjoying the read, more updates will be coming soon, I'm itching to get this on the road now lol

you attending Ultimate Dubs??

 

[s3dave]

Loving the project ..... are there some strategic dents in the bulkhead coming or redesigning the mounts?

 

[Airs]

Loving the project ..... are there some strategic dents in the bulkhead coming or redesigning the mounts?

thanks s3dave their has been a mention of strategic dents or cutting the bulk head and re-welding it back abit, but I've gone with getting the manifold re-worked so i can stay away from cutting the bulk head for along as possible, if it comes to that we will see what happens lol

 

[kanecullen89]

I love this project and reading about it. So unique! Good skills

 

[Airs]

I love this project and reading about it. So unique! Good skills

cheers kanecullen89 glad people are enjoying it and to think i wasn't even going to do a build thread lol

it should hopefully be kicking around a few shows come next year for people to have a browse over if they like, maybe tucked at the back of the car park though lol

 

[Sam_]

My vote is for gloss black as is. The rear bumper will get a covering of matte after every drive anyway right

 

[Airs]

My vote is for gloss black as is. The rear bumper will get a covering of matte after every drive anyway right

you are sure roght sam_ so will the bonnet of the car behind aha

 

[Prawn]

Keep it gloss black.

Matt black isn't a sleeper at all, because it'll stand out so much because it's unusual, even if it isn't shiney.

Looks dead smart as it is I reckon, black car, black cage, with the nice alloy TT bits inside.

Going to be very cool

 

[<tuffty/>]

thanks s3dave their has been a mention of strategic dents or cutting the bulk head and re-welding it back abit, but I've gone with getting the manifold re-worked so i can stay away from cutting the bulk head for along as possible, if it comes to that we will see what happens lol

I assume you will be heatshielding the crap out of it too? even with clearence there are a lot of pipes etc in very close proximity to the hotside and where the DP will be... especially the clutch MC... they melt rather well being plastic...

<tuffty/>

 

[Airs]

Keep it gloss black.

Matt black isn't a sleeper at all, because it'll stand out so much because it's unusual, even if it isn't shiney.

Looks dead smart as it is I reckon, black car, black cage, with the nice alloy TT bits inside.

Going to be very cool

your not the first to say keep it gloss black lol

yeah i love all the alloy parts inside, makes it feel nice to sit inside of

thanks alot

=<tuffty/>;2021370]I assume you will be heatshielding the crap out of it too? even with clearence there are a lot of pipes etc in very close proximity to the hotside and where the DP will be... especially the clutch MC... they melt rather well being plastic...

<tuffty/>

yeah I'm going to have to make some sort of heat shield contraption to keep the heat away from pipes and inlet manifold, but its all so tight at the back its crazy.

any suggestions on good materials to use tufty/>??

 

[Airs]

Just a small amount of progress has been made, but feels like a lot of work aha

just got my manifold back last night all re-weorked and welded up ready for final fitting












also managed to pick some fitting up to create my custom oil return over the christmas period, hopefully going for down pipe on the 27th/28th



ignore the ink, i may have silt some at work lol

this also arrived, my charge cooler radiator awesome piece on kit, especially for only £89.99 delivered!!




also had some new goodies turn up like flat bottom steering wheel, made some custom drop links,pink silicon hoses (hopefully more arrive tomorrow) and some other goodies, pics will follow

 

[Westy]

good progress.

I like this pic as it looks like a giant "turbo headed" spider walking around your work bench!

 

[desertstorm]

Looking good but not sure about the charge cooler idea, I get the fact that the charge cooler gives you a shorter inlet tract and less volume so should improve spool and reduce boost losses but I would question how effective it will be at actually cooling the air and whether the actual complexity and extra weight is worth it.

Karl.

 

[Airs]

Looking good but not sure about the charge cooler idea, I get the fact that the charge cooler gives you a shorter inlet tract and less volume so should improve spool and reduce boost losses but I would question how effective it will be at actually cooling the air and whether the actual complexity and extra weight is worth it.

Karl.

Thanks Karl, its not actually that more complex tbh, all you need is a pump, charge cooler, header tank and a pre-rad plus hoses obviously lol with the charge cooler the water is kept cold wether our moving or sat still as its on a separate circuit to the engine, sso the cooling temp is instantly lower.

Larger big core intercoolers and pipe work are quite heavy compared to a charge cooler, once i have all of the charge cooler kit i will be weighing the system and weighing the large core intercooler and pipework i have to see what different their is and shall update,

from the research i have done a lot of people swear by charge coolers, but i suppose every1 has to make their own conclusions on wether it works for them, please see link below for a little more info

Technical : AVT | PWR Chargecooler Systems | Water to Air Intercooler

 

[desertstorm]

So are you having a fan running on the cooling rad for the charge cooler. What kind of pump will you be using and is the diameter of the cooling pipes large enough.
I would also try and avoid too many 90 degree fittings as they pose a big flow restriction to coolant flow.
Also remember 1L of water weighs 1Kg , and I know you are supposed to use straight water in these as it has the best specific heat capacity but it won't be much good if it freezes. So think about that when the winter comes around you will need to put some kind of anti freeze / coolant in or you will end up with a big problem.

Karl.

 

[Airs]

So are you having a fan running on the cooling rad for the charge cooler. What kind of pump will you be using and is the diameter of the cooling pipes large enough.
I would also try and avoid too many 90 degree fittings as they pose a big flow restriction to coolant flow.
Also remember 1L of water weighs 1Kg , and I know you are supposed to use straight water in these as it has the best specific heat capacity but it won't be much good if it freezes. So think about that when the winter comes around you will need to put some kind of anti freeze / coolant in or you will end up with a big problem.

Karl.

Yeah i will possibly be running twin front mounted fans, the rad its self is mounted at the very front with the only thing blocking it is the centre grill so has a lot of airflow to start with. i am running a pair of after run pumps as fitted to the standard bam engine which are identical to this

AVT/Bosch 12v Chargecooler Electric Water Pump EWP AVT / Bosch Chargecooler Pump / 12v Electric Water Pump [CCPUMP] - £109.99 : AVT | PWR Chargecooler Systems | Water to Air Intercooler

I'm running 19mm ID hose throughout the system, yeah i won't be running to many 90's, i will be running G12 in the system so it has no chance to freeze

Airs

 

[Airs]

Hope you all had a cracking christmas and new year, managed to get abit of progress over the festive period in-between the family chaos and getting away snowboarding so heres a little update

I'm finally glad to say that the exhaust manifold is a perfect fit and the engine is now all in place (hopefully to stay)



just ignore the untidy wires and gloves over pipes, just their till things are connected



Turbo sits very close to the bulk head but their is a very acceptable gap between for engine movement, not that their will be much of tat with these engine mounts lol



dropped my bumper off at the body shop to start the repair/smoothing process, managed to do some digging online and found you can buy a plate delete from the DEALERS!! so rang my mate at TPS and turns out it was only £23 ordered 1 of those and made the smoothing job 100 times easier.





Crack fixed







Also had my spare wheel all painted up to match the others



car is currently in getting the down pipe and full system made which i will be going to help with again tonight,along with charge cooler mounted and pipes welded.

 

[Airs]

Small update, but quite a lot of progress

exhaust is all finally completed full custom down pipe and full custom system, and a few pics of how it looked underneath until i painted it lol







decided to keep the tail pipes from the stock back box and polish them back up as they where already stainless, plus it kept it looking deceivingly stock





also started my aluminium welding for the charge cooler and boost pipes last night, will be finishing this off tonight



all mounted to the gearbox so it moves with the engine



plus a 3.5'-3' reducer welded onto the end to go with my 3' boost pipes



will hopefully upload more pics tomorrow with the boost circuit all complete keep your eyes peeled, its gutting close

 

[<tuffty/>]

I like that alloy reducer... sad but true

<tuffty/>

 

[Prawn]

This is awesome. So much love for this.

Apart from possibly the pink wheels, but I think you ride a BMX, so that explains the questionable choices

 

[kanecullen89]

Amazing!! I'm guessing it's still quattro? Couldn't see the driveshaft under the exhaust on my phone

 

[Rainbird]

Just read this from the start of the thread - this project rules!

 

[Airs]

This is awesome. So much love for this.

Apart from possibly the pink wheels, but I think you ride a BMX, so that explains the questionable choices

Thanks dude

aha i actually ride MTB and BMX lol but a lot of people have said that about the pink, its not just a standard pink mat its perlescent, plus its to annoy all the haters too lol

Amazing!! I'm guessing it's still quattro? Couldn't see the driveshaft under the exhaust on my phone

yeah this is still quattro, the propshaft is up above the exhaust

Just read this from the start of the thread - this project rules!

thanks Rainbird was hoping people would like the read, just got slatted to death on the TT forum for it so i removed it from their.

 

[vala]

was hoping people would like the read, just got slatted to death on the TT forum for it so i removed it from their.

Shame about this, although I'm on that forum quite regularly and didn't come across your thread. Still loving this project though! Great work mate!

 

[Airs]

Shame about this, although I'm on that forum quite regularly and didn't come across your thread. Still loving this project though! Great work mate!

yeah i know, thought they would of had bait interest in it tbh, it wasn't up for very long mate only day or so.

 

[Silky]

People hate things like this as it's different from the norm. It's a fantastic project, looks great and at the same time you get to learn a hell of a lot from doing it. Well done for taking it on

 

[Airs]

People hate things like this as it's different from the norm. It's a fantastic project, looks great and at the same time you get to learn a hell of a lot from doing it. Well done for taking it on

Thanks alot Silky yeah its helping me learn he bits that i didn't know or understand before

 

[VAG-Slag]

So much time for this build, even more time now I've just read it's going to be your daily... LEGEND!

Although I was a tad confused when I skipped form page 1 to 3 and it had turned into a TT

 

[superkarl]

I've got so much time for this too!
I think diesel tuning could be the future. how does it compare cost wise to petrol BT build? For a build of this sort of extent and power goal?

 

[Airs]

So much time for this build, even more time now I've just read it's going to be your daily... LEGEND!

Although I was a tad confused when I skipped form page 1 to 3 and it had turned into a TT

Haha thanks Vag-Slag yeah going to be my daily for sure, maybe a little struggle putting the bikes in the back so may end up with roof bars lol, just cant wait to drive it tbh, my last TT drove so well hence why Ive bought this 1 and it was a bargain lol

I've got so much time for this too!
I think diesel tuning could be the future. how does it compare cost wise to petrol BT build? For a build of this sort of extent and power goal?

Thanks superkarl , yeah diesel is definitely the future,

you can buy and off the shelf big turbo kit for a standard 130bhp tdi engine off the shelf for around £2500, with stock injectors can take you up too 230BHP, but if your buy the uprated injectors you can get up to 290BHP, the turbo its self is capable of around 320BHP possibly more with the correct supporting mods, i.e gas flowed head, uprated cam, correct exhaust, map etc….. plus the torque is through the roof

 

[16Klappe]

Now you have changed your profile picture, I know who you are. Haha!

 

[Airs]

Now you have changed your profile picture, I know who you are. Haha!

haha is that rite 16Klappa, is that a good thing?? lol

 

[Prawn]

I think diesel tuning could be the future. goal?

I also love this build, because it's a bit different, and will be ultra cool, but tdi's being the future? no. not a chance.

 

[Airs]

I also love this build, because it's a bit different, and will be ultra cool, but tdi's being the future? no. not a chance.

Hmm im not so sure Prawn, their is alot more diesel cars coming into the race scene, and the weight saving they have from carrying less fuel could be a big part of that