My minor modding thread

Westle said:
Paul, am I right in thinking that you are single or have a very understanding other half! You must have spent a small fortune in time and money on this project?
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LOL... I am indeed married with the usual 2.4 children etc.... I don't know if 'understanding' is the right word, more 'acceptance' :)

Mrs <tuffty/> gets to do what she wants to do and the the <tuffty/> juniors get a look in too... all is good...

I have spent less time on the car more recently as there is less to do but I have been messing with cars since I could drive so she knows what she was letting herself in for... mostly!! LOL

<tuffty/>
 
Not had much to update recently as I have been a bit busy but had some bits through today which should finally finish off this part of the project.

I was looking to get a custom exhaust from one of the many custom exhaust places but after hearing a few horror stories decided I would just build my own.

Received some bits today from Jetex and Speedflow....
20091119_IMG_3901.jpg


The Speedflow pipe is to replace the water pipe from the turbo to the block as this was leaking.
20091119_IMG_3903.jpg


The silencers are 3" bore and the rear box is 3" in and 2 x 2.5" out which will be attached to a couple of slash cut tail pipes.

Shouldn't be any restriction with these babies....
20091119_IMG_3904.jpg


20091119_IMG_3906.jpg


Should be starting work on this at the weekend, just need to order up some clamps.

Once that is done then I can get the mapping finished ready for the dyno in December.

That will be more or less it for now... water/meth injection next I expect ;P

<tuffty/>
 
Been busy today, with the elite fabrication skillz of Tony and Bill occasionally mumbling 'BRAAAAAAARRRRRRRRPP!!' I have managed to piece together the exhaust system.



I have been running the OEM system since I fitted the BT.
20091115_IMG_3896.jpg


3" stainless steel all the way and pretty much straight through...
20091121_IMG_3909.jpg


...only joking ;P

Pics of the progress...
20091121_IMG_3911.jpg


20091121_IMG_3914.jpg


20091121_IMG_3918.jpg


...now needs to be welded and the brackets worked out...
20091121_IMG_3923.jpg


20091121_IMG_3924.jpg


Once fitted I will sort the tail pipes. 2 x 2.5" slash cut is the current trian of thought but will see what looks good when its all on there.
20091121_IMG_3925.jpg


<tuffty/>
 
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20091121_IMG_3909.jpg


Mate, I think you're going to have to chop that down a bit :)
 
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tufftybloke said:
..you think??? I was just going to upturn it a bit DTM style then polish it :)

<tuffty/>
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Corkscrew it :)

Oh, and give it that 'burnt' look at the end like all the ricers have on their exhausts :icon_thumright:

...or a single 'truck stack' :hubbahubba:
 
Loving the exhaust paul, looks so much better than the stock set up. How much has the exhaust ended up costing?
 
Paul,
Im pretty sure you could sell those exhausts !
i like how it goes round the rear diff/hadex jobie rather than under it,
Realy want to hear this now !!
Failing this... stick with the straight though pipe on and fit a flapper on the end !
 
dont think it will sound so oem anymore :undwech:
 
Would you consider making and selling them paul/bill? Think you would be onto a winner.
 
Righty....

Exhaust is on.....
20091122_IMG_3936.jpg


...and here is a somewhat dodgy video...

Exhaust

I have a small rattle which I knew about but will wait for the system to settle before sorting that out. Its not as loud from the outside as we were expecting but tbh it is a little boomy inside the car which may settle down but I may have to consider a different back box....

Does sound good under boost though :hubbahubba:
<tuffty/>
 
Last edited:
It should settle down a bit after a few miles, mine did but I still fitted an extra can to calm it down a bit. My centre can is about the same size as yours but my rear can is about twice as big!.

Looks great though :)

Do you get any popping under load when you change up?. Mine does it a bit but its not too bad, more of a muffled "FOPP".

T
 
well i just spent the last hour or so reading this entire build thread from start to finish, a truly immense effort by tuffty and badger, i applaud you!!

i know you acheived 380bhp with a busted fpr pipe and oem exhaust, with those know fixed have you got yourself back on the rollers yet? you gotta be seeing 400bhp easy, i would of thought so anyhow!!

really love the sleeper look of the car mate, which is what attracted me to the purchase of my s3, standard looking engine bay with only my brakes possibly giving the hint of power away, whereas even your brakes are stealthy ;) love it!!

again congrats on the build, now sit back and enjoy :)
 
Thanks mate... doubt it will stop there tbh...

I still have the water pipe to replace as I haven't found the time to do it yet and I want to quieten the exhaust down a little as there is too much drone for my liking atm...

Hoping to get the mapping finished for the rolling road day I have organised at Ajec so we will see then as to if I make 400bhp... would be nice but more interested in getting a decent baseline power output to see if I can tweak some more power out of without going silly...

Couple of minor tweaks in the pipeline and of course water/meth ;)

Roll on the 12th of December...

<tuffty/>
 
Yeah, thats planned although I have no money for that as yet... :)

<tuffty/>
 
No money? After reading this build thread i see money comeing out of your ears! haha.

Awesome build thread tho, Hope all goes well on the 12th. :)
 
S3 HODGE said:
No money? After reading this build thread i see money comeing out of your ears! haha.
Click to expand...

Oh yeah... LOL :)

If I was doing it again or someone else was looking to do this I would seriously recommend saving the extra cash to get the valves in... its a little concerning how easy this can get to the redline and with it slightly raised too its on the edge of reliability.

I don't drive it that hard but seeing as people have dropped valves on an otherwise std engine then its worth the peace of mind to get it all done at the same time...

I'll start saving after christmas :)

<tuffty/>
 
even 380bhp in a daily driver hatchback is seriously impressive, if you could break the magic 400bhp without pushing the engine/turbo too close to its limits then you have truly pulled off something special, think how much time & money companies like mitsubishi spent on developing their engines to produce 360/400bhp in their evo's, you managed to do the same in 2 or 3 months and didnt cost the earth :)
 
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Update....

Slightly disappointing result on the rollers today (the day was good though, well done all who attended)....

Last time I was on the rollers I got 383bhp and that (as it turns out) was with a split vacuum pipe to the FPR which gave a boost leak and reduced the FPRs ability to control fuel properly (which is why the duty cycle on my 630cc injectors was nearly maxxed) and a std exhaust which was affecting the EGT's and stifling the engine at high RPM.

I fixed the pipe and the mapping (predictably) was overfuelling so reverted back to a previous known good one which I have been running since as Bill has had far too much on to sort it properly and I wanted to get the exhaust on before I sorted the mapping out.

As I don't thrash my car within an inch of its life, the map has seemed ok and I haven't done any logging since it was put on. Did some logging today and it seems leaner before boost and then just goes bonkers and dumps fuel from around 5.5k...

Needless to say its back to the drawing board and I will do some more logging to see what's having an effect on the fuelling. I thought it was EGT's initially but using my Liguid gauge on the way home I couldn't get EGT's over 960 degrees... Thinking I will log EGT's vs Fuelling and see if there is any correlation to rule it out, the alternative is to move the EGT probe as it may not be in the right place where it is now.

<tuffty/>
 
315bhp was the most it could muster this time around... the path to power is a long and twisty slippery slope :)

<tuffty/>
 
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oh...does it feel any less powerful from before when you had it on the rollers last??
 
tufftybloke said:
315bhp was the most it could muster this time around... the path to power is a long and twisty slippery slope :)

<tuffty/>
Click to expand...

So you lost almost 70BHP and that's after fixing the leaking pipe?

What rollers gave 383bhp? Wasn't the mapper by any chance?

The map you reverted back too must be very different to loose so much ?! It must feel really low on power in comparison? Unless one of the two rollers was way out!?
 
The map I did 383bhp on was different to this one and was tweaked according to the setup at the time, it was a stage after the current one as I had an issue with overboosting (N75 pipe issue) and MAF readings...

Fuelling was about right at the time but on the way to the dyno the FPR pipe must have finally given up the ghost and the N75 pipe came off (again!!)... The N75 pipe was put back on and 383bhp was the result but there was still a problem as the boost gauge was only reading a little over 1bar and the injectors were close to fully on. When I looked into this, it was due to a split FPR pipe which the boost gauge is tee'd off so causing a small boost leak, lower than usual fuel pressure under boost (rising rate regulator) and incorrect reading on the boost gauge. Fuelling was tweaked to suit and once the pipe was fixed meant that the tweaked map was overfuelling so reverted back to a previously known working map and all was ok.

My new exhaust has made things a little leaner off boost but still not sure why its dumping fuel. Its totally possible that the current map is still a way off with all the little red herrings we have encountered while mapping so before doing anything else I am going to give the car a once over making sure all pipes are sound with no boost or vacuum leaks before proceeding with the next round of mapping.

Its possible the ECU is falling back on protection maps as there are so many sensors and variables that control a std ECU thats its difficult to know what the ECU is actually doing sometimes...

I went over to Ajec knowing that the map wasn't the finished one but was hoping to get some good logs from it to see what needed tweaking to get it finished... the fuel dump is a new one and on the way back from Ajec, my boost is now showing 1.4bar... Testing the actuator leads me to believe that its now relaxed a bit as its opening at 12psi (0.83bar) which is a little less than the 1bar its rated at. This is fairly typical and the 1.4bar I am seeing on the gauge is actually correct as this is what the map is requesting.

The map had a lower requested boost set as it was overboosting to over 2bar which was due to the N75 pipework, now its sorted and the actuator was relaxed a tad, it needs putting back up to 1.8bar in the map which will happen when Bill gets a chance to spend some time on it.

<tuffty/>
 
S3 Rav said:
oh...does it feel any less powerful from before when you had it on the rollers last??
Click to expand...

A little but thats more to the actuator relaxing a tad... bear in mind I did 0-60 in 4.8secs the other day, the power is there but I did notice a small amount of hesitancy when I went for third during that run...

I don't drive my car hard and the time on the rollers is prob the hardest its been run since I had the map put back on...

Just not had the time to sort it out properly yet... all be done for the next RR day though ;P

<tuffty/>
 
Did a quick pipe check today, all seem good. Also did a charge system leak test and held 30psi no probs.

Bill looked through the logs and the fuel dump does indeed look temperature related. Prob never noticed it before its my daily driver and I don't really drive her hard... the dyno has proved useful though as the logs appear to show that the fuel dump didn't happen during some of the initial calibration and warm up runs (where power wasn't being logged) but by the time the actual runs occurred, the EGTs were already up and the ECU was having a moan hence the dumping of fuel.

The dyno is probably the hardest she has been run over a short period of time. Also because the actuator has relaxed a bit as the boost is holding at 1.4bar which is actually what the map is requesting explaining the low figures.

Next steps are to look at repositioning the EGT probe, tweaking the fuelling and upping the boost.

...when either of us can find 5 mins to do that of course :)

<tuffty/>
 
Can the pre load on the actuator be adjusted? or would that void the warrenty??
 
S3 Paul said:
Can the pre load on the actuator be adjusted?
Click to expand...

It could but wouldn't achieve anything... 1 bar actuator is pushing the limit of capability of the N75/ECU to control requested boost as has been evident since my car has been on the road. The file I am currently running is set to 1.4 bar as due to an issue which turned out to be the N75 pipework, I was getting too much boost. This was thought to be because the actuator was a little too stiff but as previously said it was a pipe popping off.

A stiffer actuator is always going to be more difficult to control as it slows down the reaction time of the whole setup... 9-12psi is said to be a sweet spot and now the actuator is there, the boost I am making is spot on the requested boost... as said, next step is to turn it back up :eyebrows:

S3 Paul said:
.... or would that void the warrenty??
Click to expand...

...think I am a little past that now :whistle2:

<tuffty/>
 
hi tufty,
hope you dont mind me asking nut how much did your exhaust cost you all in?
thanks
 
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