Stacey's Belated Yo Yo Build Thread

...and on the subject of vents I wouldn't be putting non baffled ones at the back of the engine where the exhaust lobes aren't covered and where all the oil pools... thats just asking to chuck all your oil into your catch can every time you hit the loud pedal from the oil shifting back and being thrown off the cam

<tuffty/>
 
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<tuffty/> said:
...and on the subject of vents I wouldn't be putting non baffled ones at the back of the engine where the exhaust lobes aren't covered and where all the oil pools... thats just asking to chuck all your oil into your catch can every time you hit the loud pedal from the oil shifting back and being thrown off the cam

<tuffty/>
Click to expand...
looks like he's put plates under the rear vents to try to stop that
 
Dubster5 said:
looks like he's put plates under the rear vents to try to stop that
Click to expand...

Hopefully its enough but I doubt it will prevent oil slopping in... VAG put the breathers at the 'top' end of the cover for a reason

<tuffty/>
 
badger5 said:
why so many vents in the rocker cover?
you expecting that much blow by after your build? :p
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TBH am a little concerned that the bottom end won't be to brilliant as the piston to wall clearance is right on the upper limit following some wear on the lower part of the skirt that occured in the earlier running of the bottom end, But will see how it goes.

The other thing to remember although is 4 lines an AN10 line internal daimeter is 14mm giving it a CSA is just under halve that of the OEM 19mm which then makes my 4 AN10 lines less than 2 19mm breathers.

Last time i had two AN10 lines T-ing into 1 like onto the catch tank bit like the OEM system and suspect this could have contributed to my low oil pressure, thus now have over engineered it unlike before.....AS SOME WOULD SAY, ITS ALL ABOUT THE FLOW ;)

<tuffty/> said:
...and on the subject of vents I wouldn't be putting non baffled ones at the back of the engine where the exhaust lobes aren't covered and where all the oil pools... thats just asking to chuck all your oil into your catch can every time you hit the loud pedal from the oil shifting back and being thrown off the cam

<tuffty/>
Click to expand...

I hope it works ok with the plates i've put in over the holes, this should stop oil directly flicking off of the camshaft and up there.

Regarding all the oil sloshing to the back on the loud pedal, i haven't heard of any of the drag boys complaining of it as have noticed a couple with cam covers like this, FFE are running a very simular setup with breathers at the back and over 1000hp which seems to work for them, i'm not sure if he's done anything special to his?

Only time will tell, if so will have to revisit it
 
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On a slightly more positive note i got a couple of hours outside before preparing for my monday night shift

Went back to the boost pipework. I started by looking at where to take the boost reference for the N75, i do prefer it off of the comp cover tucked away a bit.

Cleaned the casting up so was flat to start with as had a raise symbol where i wanted to mount it.



Drilled and tapped a hole ready for a 90 degree fitting had bought, i stuffed the comp housing to catch filings etc as well as using the hoover as i drilled into it.



Now i continued on the hotside piping path, originally i'd planned to run the pipework parallel to the side of the engine but decided it would look to wierd and involve to many unnecessary bends so went with the more direct approach

Parallel with 45's



Direct









That's as far as i can get really with the hot side until I get the cooler shipped over in the next few weeks to work out where the next 90 will go.

I still had some more time and now my silicon reducer had arrived i started on the cold side.



Its quite tight between the head light and chassis/ oil cooler so have had to start mitering the pipework joins to try and get it through there.



Looking up from underneath gives you a slightly better view





That's as far as have got for now and probably not able to do to much more until have the cooler to work out the overall positions.

On another note Si dropped in for a chat with some car porn to show off for his mk1 golf and a customers car.



+1mm valves :) His mk1 will be insane, still can't get over the fact he will be aiming for more power than me in a car potentially weighing nearly half a normal S3!
 
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StaceyS3 said:
TBH am a little concerned that the bottom end won't be to brilliant as the piston to wall clearance is right on the upper limit following some wear on the lower part of the skirt that occured in the earlier running of the bottom end, But will see how it goes.

The other thing to remember although is 4 lines an AN10 line internal daimeter is 14mm giving it a CSA is just under halve that of the OEM 19mm which then makes my 4 AN10 lines less than 2 19mm breathers.

Last time i had two AN10 lines T-ing into 1 like onto the catch tank bit like the OEM system and suspect this could have contributed to my low oil pressure, thus now have over engineered it unlike before.....AS SOME WOULD SAY, ITS ALL ABOUT THE FLOW ;)



I hope it works ok with the plates i've put in over the holes, this should stop oil directly flicking off of the camshaft and up there.

Regarding all the oil sloshing to the back on the loud pedal, i haven't heard of any of the drag boys complaining of it as have noticed a couple with cam covers like this, FFE are running a very simular setup with breathers at the back and over 1000hp which seems to work for them, i'm not sure if he's done anything special to his?

Only time will tell, if so will have to revisit it
Click to expand...

quite how a positive displacement oil pump vs any potential back pressure on an open pipe is going to effect oil pressure is beyond me. Clutch at straws imho. +0.001" bearings etc were not a good idea... You cant compare 9 sec cars with ones which will see different use imho....
Reality is you wont know what Ed actually did, as he does'nt share details from what I've ever seen of his work..
Seems like a of of effort to end up reducing the overall CSA vs std... Kinda begs the question WHY?
 
badger5 said:
quite how a positive displacement oil pump vs any potential back pressure on an open pipe is going to effect oil pressure is beyond me. Clutch at straws imho. +0.001" bearings etc were not a good idea... You cant compare 9 sec cars with ones which will see different use imho....
Reality is you wont know what Ed actually did, as he does'nt share details from what I've ever seen of his work..
Seems like a of of effort to end up reducing the overall CSA vs std... Kinda begs the question WHY?
Click to expand...

If there's any positive pressure in the block then surely this will counter act against the pressure the pump produces? I'm not saying that this was the main factor to the low oil pressure at all as the bearings was the main reason but suspect it really wasn't helping matters as oil pressure still wasn't that good after they were changed. Are you still running +1 thou on the big ends on the badger wagon? The engine was also breathing heavy during its life as cylinder 1 had got hot to which all valve guides and seals were replaced again.

I was only using Edd's as a reference for where i placed my breathers as he's done the same and like i said earlier may have done something special to counter act splash from oil, i know the application is different but hopefully the same principles will surfice

On the old setup I had with the 2x-10an lines branched into 1 (simular to the OEM 2x19mm), I suspect this was dramatically less efficient than OEM with less than half the CSA, it was venting to atmosphere on a long pipe to the underside of the car to reduce smell like many, but this would have also made it less efficient than OEM with the long breather.



The new setup with 5x-10an lines will have just over double the CSA of the OEM single 19mm and be very simular size to Prawns 2x19mm pipes.

I can't see why not increasing the breather flow capabilities is not a good thing? I know that obviously we don't want our engines breathing but they will a certain amount, we are quite happy putting over twice the flow and air pressure through these engines with obviously higher cylinder pressures but not worth uprating the breather systems proportionally??

I've also read that when running to atmosphere you should also be looking at increasing the size of pipework compared to a vacuum supported system?

These are my reasons for choosing to do what i have and i can't see any issues of having an overspec'd breather system if that's what i've done?
 
StaceyS3 said:
If there's any positive pressure in the block then surely this will counter act against the pressure the pump produces? I'm not saying that this was the main factor to the low oil pressure at all as the bearings was the main reason but suspect it really wasn't helping matters as oil pressure still wasn't that good after they were changed. Are you still running +1 thou on the big ends on the badger wagon? The engine was also breathing heavy during its life as cylinder 1 had got hot to which all valve guides and seals were replaced again.

I was only using Edd's as a reference for where i placed my breathers as he's done the same and like i said earlier may have done something special to counter act splash from oil, i know the application is different but hopefully the same principles will surfice

On the old setup I had with the 2x-10an lines branched into 1 (simular to the OEM 2x19mm), I suspect this was dramatically less efficient than OEM with less than half the CSA, it was venting to atmosphere on a long pipe to the underside of the car to reduce smell like many, but this would have also made it less efficient than OEM with the long breather.



The new setup with 5x-10an lines will have just over double the CSA of the OEM single 19mm and be very simular size to Prawns 2x19mm pipes.

I can't see why not increasing the breather flow capabilities is not a good thing? I know that obviously we don't want our engines breathing but they will a certain amount, we are quite happy putting over twice the flow and air pressure through these engines with obviously higher cylinder pressures but not worth uprating the breather systems proportionally??

I've also read that when running to atmosphere you should also be looking at increasing the size of pipework compared to a vacuum supported system?

These are my reasons for choosing to do what i have and i can't see any issues of having an overspec'd breather system if that's what i've done?
Click to expand...
I dont know why you think badgerwagen runs +0.001" bearings. It does not.
 
badger5 said:
I dont know why you think badgerwagen runs +0.001" bearings. It does not.
Click to expand...

You said on the phone when was discussing my spec years ago before i purchased mine that your badger wagon had them on the rod big ends and was fine, and is reasonable for higher power levels
 
badger5 said:
nope I did not.
its never run oversize EVER!
Click to expand...

Sorry Bill but your memory must be going! You did say that to me when I disscussed my build spec with you years ago and also said that your badger wagon runs them on here to another user??

 
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It does't run them... /END
Never has!

I dont know why that was said.. Pretty 99.99% sure its on std size calicos
 
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Maybe a full paragraph typo then! Haha it might be on calicos now but in 2013 it might have been a different??

Good progress Stacey!!

with regards to the breathers on the back I do think you'd have to have a lot of flow to lift the oil up those lines but in fairness I haven't had the cam cover off while the engine is running to gauge the amount of 'pooling' and splash!

It's good to see some thing different with the steering pump and it'll be good to have that space with all of the standard pipes that get in the way all the time!

Just thinking aloud here but if the crank case is positive through bad breathing would this affect oil flow rather than the oil pressure?

Those valves look good!!
 
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Prengsi said:
Maybe a full paragraph typo then! Haha it might be on calicos now but in 2013 it might have been a different??

Good progress Stacey!!

with regards to the breathers on the back I do think you'd have to have a lot of flow to lift the oil up those lines but in fairness I haven't had the cam cover off while the engine is running to gauge the amount of 'pooling' and splash!

It's good to see some thing different with the steering pump and it'll be good to have that space with all of the standard pipes that get in the way all the time!

Just thinking aloud here but if the crank case is positive through bad breathing would this affect oil flow rather than the oil pressure?

Those valves look good!!
Click to expand...
been on std size calico's for years.... 6 and counting :p
 
I'm sorry Bill but i'm not a liar and am 100% sure on what we discussed before i purchased them bearings and what you had said regarding them, plus even in above in black and white, a whole statement, not a typo.

None the less back on topic

Got a couple of hours outside after my night shift wednesday.

Managed to finish off all the fuel lines



I'm a bit concerned that the hose will rub on the fuel rail making it not look so pretty so will fix it in place some how.



As can see in the picture also refitted my modified header tank with the support bracket.

Modified PS pipe



I did lots of other boring non picture justifying stuff like fitting the wishbones, driveshafts, ARB links etc.

Hoping to get back on it monday but am now going to be held up by my intercooler, ecu and a few other bits that are still sitting over in the USA, so not sure how well will progress apart from tieing up loose ends.
 
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Prengsi said:
Maybe a full paragraph typo then! Haha it might be on calicos now but in 2013 it might have been a different??

Good progress Stacey!!

with regards to the breathers on the back I do think you'd have to have a lot of flow to lift the oil up those lines but in fairness I haven't had the cam cover off while the engine is running to gauge the amount of 'pooling' and splash!

It's good to see some thing different with the steering pump and it'll be good to have that space with all of the standard pipes that get in the way all the time!

Just thinking aloud here but if the crank case is positive through bad breathing would this affect oil flow rather than the oil pressure?

Those valves look good!!
Click to expand...

Thanks mate do like to be different and try some of the ideas that float around in my head.

When researching I found data proving that under load on the engine tested that an engine driven PS pump zapped 8hp where as and electric driven one was taking >1hp from the extra load on the alternator.

Will wait and see on the breather as not seen a 1.8t running with the cover off to see how much pools to slosh about
 
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Thanks Nick :)

Got a few hours here and there on the car over the last week or so. Managed to get the loom all pretty much sorted and in place in the engine bay as well as most of the WMI system.

First up i looked where I could mount the solenoid to be as close as possible to the manifold and outlets. I made a little ally it off





Mounted to the top of the oil filter housing



Now that the throttle body is on the other side i've got to extend the wires to make the extra distance, they had already been extended marginally in the past for the IE inlet manifold but just chopped this out rather than having to many joins.



Apart from the MAP sensor cable hanging in the middle and some tidying/changing of the coilpack loom its all in and complete.





That's it for now and i expect a little while as things are getting busier and extra work is starting to come back, but I'm probably going to book some time off the permanent job to crack on some more.

On a different note the team has now got another sponsor for this coming season. Thanks to Opie Oils, will be a great help

 
Got a few hours here and there on the car :)

I'm really starting to run out of things to really sink my teeth into until I send my intercooler and ECU over, I'm hoping to have the intercooler by the end of next week.

None the less i made a bit more progress on odd jobs as such.

I went to fit the window wiper motor to try and complete the scuttle panel area but very quickly hit an issue



Once in the motor would only rotate this far as failing on some scaffold pole that someone had put in the way



A bit of creativity with the grinder soon solved that issue :)





My friend from Wickham swung by and dropped this off the other day.



I threaded it all through roughly where i wanted it and started by fixing it at the rack to then pull the slack back to the fuel cell area.



I'm currently waiting on some p-clips to fix it to the underside of the car as didn't have the correct ones knocking about. I'm also currently waiting on my 8AN hose to complete the link between rack-cooler and cooler-pump.



Next up i made some headwind on the dash, I'd originally planned on waiting till i had the ECU to have access to run cables etc through the bulkhead but needs must decided to press on.

Sorry didn't actually get to many pics during the many adjustments and cuts i made to the panels but will get the general gist

I had to cut away all the left hand hinged area so an addition of a little hinge from the local DIY store was welcomed to keep it together





Next up was driver side, i made adjustments to the WMI loom and added a relay for the solenoid but sorry forgot to take pics



More adjustments to the side support as i moved the fuse box slightly



Clocks and few other little bits followed



Now was time to play with my steering wheel that has sat in the cupboard for what seems like eternity

I had an adaptor boss as well as a quick release boss to fix to it, I'm quite set on having a quick release for ease of access and quite frankly like it as a security feature.



Next i come across an issue with the horn contacts foul on the quick release adapter, the adapter has no recess for these contacts.







Options are to get over this at the moment are
1. New snap off boss
2. No snap off boss
3. Spacer between snap off boss and wheel
4. No horn on steering wheel

Out of them options the spacer seems like the easiest and retains the central horn but as i found when testing with the seat in it just felt a bit to close to me for my liking even with the column retracted fully.





Sadly enough I did really enjoy sitting in my car pretending to be a racing driver with the seat and steering wheel bolted on :D
 
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Its Alive!!

After doing some more work here and there I got to a position where I could potentially start and run the motor.

Si popped round as always better having two sets of ears in these crucial moments.

First video is literally just after it fired with temps etc still low



This one was once was fully up to temp and revs had dropped a touch



Am quite chuffed as had feared of some wiring glitches/issues where had ripped out so much, plus this was on an old unadjusted map with the 3660 catcams and the GTX3071.

I dropped a load more bits off down to AD fabs yesterday to be welded so hopefully should be on the road in the next 2 weeks.
 
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Exciting stuff mate!

With regards to the steering wheel, I realise i've said this elsewhere, but I'd advise getting a ball bearing one rather than that splined one.

Of all those that I've seen, every splined one has developed play over time.

Not so much an issue in a racecar that does no mileage, they could last for years, but every one I've seen that's seen any road mileage has gone sloppy over time.

It'll be a better solution, and also give you the recess you need for the horn button.

I bet you can't wait to finally drive it out of the tent!
 
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the typical chug chug of those cams.. lumpy.. wont be a problem for aem ecu but me7 will be throwing misfire codes from the lumpyness

at least its alive again. always a nice point to achieve.
 
Prawn said:
Exciting stuff mate!

With regards to the steering wheel, I realise i've said this elsewhere, but I'd advise getting a ball bearing one rather than that splined one.

Of all those that I've seen, every splined one has developed play over time.

Not so much an issue in a racecar that does no mileage, they could last for years, but every one I've seen that's seen any road mileage has gone sloppy over time.

It'll be a better solution, and also give you the recess you need for the horn button.

I bet you can't wait to finally drive it out of the tent!
Click to expand...

Haha should be alright on this with the little miles it does then lol, TBH i think i'm going to leave the snap off unit for now and bolt it direct to the adaptor. It is one of the many jobs i will have to revisit when time and money permits.

Will be brilliant to get it out of the ****** place its rested for so long! The mrs is already trying to get me to take the tent down! Was on supposed to erected for winter 2014 through to Jan/feb 15 :D

badger5 said:
the typical chug chug of those cams.. lumpy.. wont be a problem for aem ecu but me7 will be throwing misfire codes from the lumpyness

at least its alive again. always a nice point to achieve.
Click to expand...

Cheers Bill does feel like i have really reached a milestone and is driving me on to complete now.

ECU wise at the moment its still running on the GTX30 map on the OEM unit, no misfire fault codes or anything of that nature as of yet but will have to wait and see.

AEM ECU has been backtracked a bit with many financial hurdles lately including purchasing the remaining 75% of the house, recent job change and Mrs redundancy this week! All off which have dramatically changed the plans for the car over the last couple of months. I will be seeing how it runs on the old map with a bit of tweeking with unisettings and go from there for now.
 
<tuffty/> said:
Redundancy money should pay for the ECU surely? ;)

<tuffty/>
Click to expand...

Haha I wish, she had luckily made the 2 year payout window by two weeks otherwise would have been zero. On a plus side just got a bonus from the new job through :) only got 10% pro rata as started in Nov, but am well chuffed with that.
 
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Have you checked out the Link/Vipec TTLink ECU Stacey? I'm going to be ordering one for mine shortly. Seem to be all the rage over here (3 other S3s I know of here with them).
 
Sam_ said:
Have you checked out the Link/Vipec TTLink ECU Stacey? I'm going to be ordering one for mine shortly. Seem to be all the rage over here (3 other S3s I know of here with them).
Click to expand...

It's definitely another option which can add to the list, have had a little read and appears to be a nice option of ECU to use. Only thing is I am really quite set on the AEM Infinity but tbh i can see me limping around (littlerally due to no MAF) on the ME7 until at least June due to financial commitments.

Madmax199 said:
Dropping by to say Hi!
Click to expand...

Hi Max didn't expect to see you around these parts....going to be in touch soon regarding suspension setup once my house etc is sorted freeing up £££££'s :D

Been slacking lately with the updates as lots been going on but little/no time and forgot to take pictures of most bits....DOH
 
Been slacking on here really!! Some time laid up on the sofa with a bad back seems like an obvious time to fill in a tad.

Big gap in progress updates.....Quite a few changes here and there and over 3000 miles have been put on the car now with well over 2500 with N75 connected.

None the less some more interesting stuff....Pics and videos :)

TIP, boost pipe and Simons screamer for the mk1



Driveshaft that gave up after just over 1000 miles on first launch :D



Few pics of under the bonnet







Nice solid gear shifter linkage and slider to compliment steel shift forks



Inside the car







Outside the car (cars good side lol)





Nice shot of mine and Simons Golf MK1 at Bug Jam 30 at Santa Pod raceway this weekend



More to come :)
 
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Bug Jam at Santa Pod, probably one of the biggest if not biggest VW/VAG event in the UK.



First time the car has hit the strip apart from some runs at Bruntingthorpe around 5 years ago, it performed better than i had hoped with it looking promising of a 10.xx if i can get some practice and make some adjustments.

The friday i ran 4 times to which all were very consistant within 0.2 sec of each other, this was with launch control at 5000rpm on the lowest map with boost up on full.

I have 3 maps on my car all with vairiable boost via a pot, 1 map for petrol, 1 for petrol and WMI and last 1 for higher octane fuel.

Time slips for this day as follows









Feeling very pleased with Fridays results I turned the launch control up 500rpm, changed the fuel and turned it to Map 1 for the higher octane map feeling keen to see more out of it and chase closer to the distant 10.xx second run.

First result was absolutely lit up the tyres off the line and missed 2nd, whether this was driver error or more to the fact that revs were to high from bouncing on the hard cut and syncros didn't want to shift that high who knows but this is the relevant timeslip.



Next run i thought i'd try plugging in my TMAP controller to run 4wd instantly to aid grip rather than my ECU programmed haldex lock of 7 psi.

Result was even worse, the car wheel hopped and bounced so hard it bounced out of first gear about 10m from the line.The time really reflects this in comparison to others



I went over some of the logs and its not suprising i had absolutely lit up the tyres!! I had built 1.88bar before launching on the first run on saturday :D



That was all the run what you brung out of the way, first round of qualifiers coming up for VWPro. I took some revs out of the launch to try and aid the start but after everyone saying about the extra grip as track would be prepped and freshly glued i put it straight back on hoping that with the extra grip the car would hook with the power in it still.

Well it did spin again and was prepared for it, just let of a little to regain traction, flatshifted to second, all was going well when then flatshifted to 3rd and well there was nothing there, tried again with lots off grinding and noises as a result. :( Went into 4th and slowly cruised to the end of the strip.

Turns out i lost 3rd and 5th with 4th having to be persuaded to go in gear. The car made it home from pod but made some nice noises in the lower gears and when ever put any load through it.

It has steel shift forks so not quite sure what i've done unless i've bent the steel ones? Will have it apart once my back heals.

Next to come is some videos....
 
To the videos.... I'm trying to collect more up from friends as only got 2 on the go pro and nothing of saturday (one of which car side stepped and lots of me hitting the hardcut lol)









Will try and see if i can get my friends to email some more over especially of the fails :D
 
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the missed gear and crunching stacy describes is the usual outcome. synchros aint overly happy with high revs and flat shifting.. le crunch
 
badger5 said:
the missed gear and crunching stacy describes is the usual outcome. synchros aint overly happy with high revs and flat shifting.. le crunch
Click to expand...

Probably not wrong, did suspect killed the syncro but can't work out why lost 5th as well? Can't wait to find out what's wrong, killing me being at home just seeing it sitting there and not working on it. Lot of self restraint to not mess the back up further.

Dog box and few more changes required me thinks followed by more revs :D
 
Hi Stacey I was also at bug jam this weekend (I'm a bit of a veteran I've missed one bug jam since 1990) I think I saw all your passes up the strip, I didn't realise it was a forum car at the time otherwise I would of come and said hello, you ran some good times though, there was some cool drag cars there this year, the Bentley was crazy but for me Wayne allmans mental breakdown takes some beating will you be attending vw action in September
 
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Forgot to say if you contact someone called VeeDubRacing on Facebook or you tube he should be able to sort you out with videos of all your runs
 
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audi upgrades
dusty said:
Hi Stacey I was also at bug jam this weekend (I'm a bit of a veteran I've missed one bug jam since 1990) I think I saw all your passes up the strip, I didn't realise it was a forum car at the time otherwise I would of come and said hello, you ran some good times though, there was some cool drag cars there this year, the Bentley was crazy but for me Wayne allmans mental breakdown takes some beating will you be attending vw action in September
Click to expand...

Thanks Dusty, I was chuffed how it went for my first time :)

There was some very impressive cars there, the bentley was good but for me the Current racing Electric beetle that run 8.47s took it for me.

Should be going action belongs nothing catastrophically fails lol, you should swing by for a chat and a beer if you see us anywhere.

Will send VeeDub a message on facebook as wpould love some videos and i'm sure they've got some fantastic quality ones
 
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