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15Degrees-North S3 turbo Race Car build

Discussion in 'A3/S3/Sportback (8P Chassis)' started by 15Degrees, Jan 18, 2013.

  1. S3Alex
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    S3Alex Rarely neutral

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    [Mar 3, 2013]
    Great news.

    Pistons and rods for mine took ages to arrive,but seeing it all come together is just the best.
    #81
  2. 15Degrees
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    15Degrees Active Member

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    [Mar 3, 2013]
    So I started rebuilding the engine today. The block had already been prepared and painted ready for install.


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    Shells fitted ready for crank

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    Engine rebuild paste liberally applied

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    Test fit of crank after a good clean of the journals

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    Bloody thrusts are the wrong ones Dohh. The ones that came out are 2.44mm and these are 2.00mm


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    Ill fit the pistons then as I cant do the crank now :( I had already fitted the rods.


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    Pistons nice and snug


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    Nice :)


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    Ill get new thrusts tommorow so I can finish it off. I cleaned loads of parts ready to go back on.

    Mark.
    #82
  3. S3Alex
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    S3Alex Rarely neutral

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    [Mar 4, 2013]
    That looks superb Mark.
    .
    Considering the state it was in when you got it,you've done an amazing job so far.
    #83
  4. RedDejavu
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    RedDejavu Well-Known Member

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    [Mar 4, 2013]
    epic thread this! Really looking forward to see further progress:D
    #84
  5. 15Degrees
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    15Degrees Active Member

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    [Mar 4, 2013]
    One thing im finding odd.

    On my front subframe there are 4 main mounting holes that are quite large. M10s go in these but the hole is MUCH bigger and thus the subframe can move around as I bolt it up, there dont seem to be any locating lugs so what am I missing here? I want to bolt it up square of course?

    Mark
    #85
  6. KevZA
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    KevZA New Member

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    [Mar 4, 2013]
    Awesome, Awesome work.

    I wish i could be there to assist you. Cant wait for the next post

    When are you looking at getting it completed by ?

    Kev
    #86
  7. 15Degrees
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    15Degrees Active Member

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    [Mar 4, 2013]
    I am hoping to make a test day at Donny on April 25th for the race on April 29th. Let's see how this week progresses. The car should be back from the bodyshop this week and I should be ready by then to put the front end back in with the new engine. I just bought some special ally cleaner so i can clean the gearbox up while its out.

    Then I need to fit the seat, paint the calipers white and bleed the brakes, finish off the inside with the new switch panel we are designing and then its off to NMS for interior loom and map.

    I took the decision to refit the steel doors, tailgate and bonnet to make the car a bit heavier and thus allow me to let the engine breathe a bit more as I am only allowed 200bhp/ton at front wheels.

    Haldex will be switchable on the steering column which will be nice for starts and when it's damp.
    #87
  8. KevZA
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    KevZA New Member

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    [Mar 4, 2013]
    Sounds great, cant wait to see the final product.

    I am sure the engine will be pushing more than that so its going to have a lot of restrictions on the mapping ?

    May i ask why you are going for this class and not something faster ?

    I saw in a previous post that you estimated with the carbon doors and bonnet it would be around 1.1 tons ?

    What are you looking at with the steel doors etc ?


    Kev
    #88
  9. S3Alex
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    S3Alex Rarely neutral

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  10. 15Degrees
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    15Degrees Active Member

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    [Mar 4, 2013]
    The doors tailgate and bonnet I will sell. I am running in Team trophy as it is a natural progression from Track Day Trophy and I know them all and it's great fun and a good paddock.

    Weight wise I think 1.25 with me in it and ten litres of fuel but we will see once it is all back together.
    #90
  11. S3Alex
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    S3Alex Rarely neutral

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    [Mar 4, 2013]
    I may be interested in some of that if the fit and condition are ok for an S3 8P.

    Let me know around sale time maybe.
    #91
  12. 15Degrees
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    15Degrees Active Member

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    [Mar 4, 2013]
    Come and look at them now buddy :) I am in Peterborough.
    #92
    S3Alex likes this.
  13. S3Alex
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    S3Alex Rarely neutral

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    [Mar 4, 2013]
    Not too far.

    Mine is slightly unroadworthy right now as the suspension is in bits. Lol.

    When its all back together it would be great.
    #93
  14. 15Degrees
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    15Degrees Active Member

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    [Mar 5, 2013]
    So I got a bit more done and as you can see the dirty parts from the floor have turned into clean parts on the enigne :)


    Crank looking good all bolted up now.

    [​IMG]



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    Oil pump fitted

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    Let's start on fitting and timing up the cams then


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    My parts pile seems to be getting smaller :)

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    Ill get some more done tommorow as the selant turns up at Audi for doing the sump and new studs for the exhaust manifold. I am going to fully build the engine and gearbox up so i can just slot it back in in one movement. Then I only have to connect the exhaust and gearbox shafts up :)


    Mark.
    #94
  15. S3Alex
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    S3Alex Rarely neutral

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  16. RedDejavu
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    RedDejavu Well-Known Member

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    [Mar 5, 2013]
    ok have to say i have a h... on from looking at this amazing progress:]
    #96
  17. OCD-A3
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    OCD-A3 Member

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    [Mar 6, 2013]
    Check out Tyrol Sport subframe collars. They are made to fill the gaps and keep the subframe from shifting.
    #97
  18. bmh.01
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    bmh.01 Member

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    [Mar 6, 2013]
    Sealey VS3900 - Subframe Locating Pin Set 4pc --- Sealey & Draper Tools - CCW-Tools

    To the book the idea being that these are fitted before you remove the subframe then you can replace it in the same position and not loose the suspension alignment, but they can be used to centrally align the subframe in your case.

    They are repros of VAS tools, not something someone has cooked up.
    #98
  19. 15Degrees
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    15Degrees Active Member

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    [Mar 6, 2013]
    They look to big buddy. My Sub is ally. If that's all you need though ill get some custom ones made up by Radical precision, my mate owns it. They are modifying my sub so my power steering rack fits anyways by moving the rack mount holes.

    I wonder why Audi made it such a daft design? Unlike the Germans that. I mean why not just have an M10 in err like and M10 hole.
    #99
  20. bmh.01
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    bmh.01 Member

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    [Mar 8, 2013]
    Should be spigot'd and bolted imo. But its probably done as you can get small camber equalisation by moving the subframe.
  21. 15Degrees
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    15Degrees Active Member

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    [Mar 8, 2013]
    Yeh I agree. Ill get Mik to make me that brass bush kit up while he is modyfying my rack mount points.
  22. 15Degrees
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    15Degrees Active Member

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  23. 15Degrees
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    15Degrees Active Member

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    [Mar 11, 2013]
    Also

    Can I get a sequential box for an 8P? We are looking at taking this to 24 hour spec after this years racing.
  24. 15Degrees
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    15Degrees Active Member

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    [Mar 16, 2013]
    Here we go car back fromthe paint shop :)


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    Mark.
  25. 15Degrees
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    15Degrees Active Member

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    [Mar 16, 2013]
    The car is slowly coming together. The engine has been a ***** though, so many mis matched parts on this engine it's a joke to get the right parts for it but im nearly there! The timing belt is off a Mk2 golf gti 16 valve LOL. 147 teeth.


    Sump dry fit and also nice and clean thanks to Ally clean :)

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    Manifold being tidied up

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    Sump fitted

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    My bottom pulley had a knackered key in (fault number 50) it so I bought a new one.

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    Now that engine looks better huh?

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    Fitting the fire supression system in. 4 nozzles to the engine bay

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    My subframe being modified

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    My mates rather large lathe, this is one of 3 this size!!

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    My modified cam pulley to bring it out 3.5mm so the belt dont lip. This is because the Audi 80 head does not line up correctly with the bottom pulley. The cam pulley was on the wrong way around to counter this but that was not an elegant solution for me.

    [​IMG]


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    Peddle box fitted with some anti slip flooring.


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    More to come :)
  26. AndyA3170
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    AndyA3170 Guest

    [Mar 16, 2013]
    Makes me want to get my car re sprayed
  27. S3Alex
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    S3Alex Rarely neutral

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    [Mar 17, 2013]
    You might give Sadev a try but they will be shockingly expensive and I'm not sure the 4wd version will fit.

    Also Quaife don't do one.

    Another thing you could do is drop Backdraft and AMDTuning a line and both may have some advice.
  28. jaydav2306
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    jaydav2306 Member

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    [Mar 17, 2013]
    You guys are in pboro that awesome I'm down the road may have to pop in some time
  29. A3SBQ
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    A3SBQ A3 SportBack 2TFSI quattro DSG

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    [Mar 18, 2013]
    Subscribing.
    Great work.
  30. Josh williams
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    Josh williams Member

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    [Mar 18, 2013]
    Wait this is in peterborough?! What the heck how havent i noticed that, its where i live!
  31. 15Degrees
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    15Degrees Active Member

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    [Mar 18, 2013]
    Pop over to look at it this week if you like.

    Mark
  32. 15Degrees
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    15Degrees Active Member

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    [Mar 25, 2013]
    Man there are a LOT of jobs on this rebuild. It has been more work that I thought simply because I remove something and see it needs redesigning so its taking a lot longer than a normal reuild would. Anyway here are some parts I had made:)

    My stainless subframe mount kit, a much better solid dogbone and a nicer cap for the hall switch.

    [​IMG]



    I decided to fit the H&R anti roll bars I had lying around. For this of course you re-use the standard mounts.

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    If you are careful you can drill out the riv nut using a 13mm drill and still use the nut part again :)

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    This is my modified subframe so the mount for my rack does not push the gaitor off the end like it was before!

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    My bushes fitted. 1mm stainless. You have to loosen the whole subframe for these to fit nicely

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    This is the engine just about complete

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    And back in the car

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    LOADS more to do :) This is a tentative list of jobs left over!

    1. Doors need rehanging
    2. Door upper window frames need putting in doors
    3. Plastic windows need fitting to door frames unless you use the frame the window is in if those frames are as good as the other frames that came out of the good steel doors.
    4. Rear steel tailgate needs fitting
    5. Front steel bonnet needs fitting
    6. Rear tailgate plastic window needs taking out of carbon tailgate and fitting in steel one
    7. Front bumper support black panel needs fitting. This might need a lot of fettling and cutting so it fits and the rad and intercooler fit underneath it. The other front panel (The one without the ally bumper bit on it)
    8. Front bumper needs fitting securely to front panel and wings
    9. Front bonnet pins need fitting, these can be taken from the carbon bonnet
    10. Rear bumper needs fitting (this was held on with wood chip screws LOL)
    11. Exhaust needs fitting. There is a bit on the back box that needs cleaning and welding as it is leaking there. Just a dab of mig should do it
    12. Front callipers need balance pipes making and fitting on the bottoms.


    1. Carbon door cards need fitting by using M6 riv nuts and M6 blue counter sunk with blue washer I guess one in each corner, Door centres can be cut out but leave room for mounting door card and door frame mounts
    2. Carbon door handles need fitting to top centre of doors with M6 riv nuts and blue fixings
    3. The two screen heaters need fitting so they point up at screen as close the screen, then a small cut out needs making in dash panel so they just poke though each side.
    4. Brakes need bleeding front and rear.
    5. Clutch needs bleeding


    1. Headlights need fitting if they arrive (I ordered new ones as again the other ones were cut etc)
    2. Seat needs fitting
    3. Caliper's need painting white with Foliatec kit
    4. Drain diff oil
    5. Drain haldex oil
    6. Replace haldex filter
    7. Clean engine loom



    Repair the other driveshaft with kit in box
    Fit both shafts tourque to 70Nm and I think 140nm outer bolt (need to check)
    Pipe up water system and intercooler system with cleaned samco hoses and mikalor clips
    Fit water expansion tank lower down left side so bonnet shuts
    Fit catch tank system right side so bonnet shuts
    Fit dash
    Fit centre console
    Fit switch panel to centre console with M8 riv nut
    Fit rear fuel pump and filter back underneath car on the hangers
    Run pipe through car secured with M5 riv nuts and P clips
    Pipe in swirl pot in engine bay and high pressure fuel pump in engine bay
    Fit engine loom
    Get interior loom made
    Map car
    Corner weight car

    Win races!!!!


    Pheww not much left to do then
  33. 15Degrees
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    15Degrees Active Member

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    [Mar 25, 2013]
    PS

    It's an Audi S2 head by the way.
  34. S3Alex
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    S3Alex Rarely neutral

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    [Mar 26, 2013]
    The engine work is looking superb....you've done an amazing job of cleaning that up and sorting it out.
    .
    The whole thing is completely transformed,and I hope it goes as good as it beginning to look!
  35. 15Degrees
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    15Degrees Active Member

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    [Mar 26, 2013]
    I have done my best :)
  36. S3Alex
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    S3Alex Rarely neutral

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  37. KevZA
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    KevZA New Member

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    [Mar 28, 2013]
    Keep checking this post daily always egar to see your progression.

    Had a look at your S3 Alex must say AMD tuning did an amazing job. I wish we had high quality work like that in ZA.

    Kind Regards,
  38. Josh williams
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    Josh williams Member

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    [Mar 28, 2013]
    Where abouts in peterborough are you mate?

    Pm me if better :)
  39. sliced
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    sliced Drive safe, stay alive.

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    [Mar 28, 2013]
    whats gonna be quicker, this or s3alex's s3?!
  40. S3Alex
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    S3Alex Rarely neutral

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    [Mar 28, 2013]
    They're very different cars to be honest.

    Despite the power difference that 15Degrees will run for the track,I'd expect his to be quicker around a track as it's going to be lighter,and purely focussed to the track,rather than carrying around air-con,leather,rear seats and all that sort of stuff.

    There's also the matter of the drivers...my track experience is zero!


    What I'm really interested in is seeing how different people put their cars together,and how we all get around similar problems in different ways,so we can all find answers that others use.

    Many thanks Kev......thats very kind,and I can only say I agree with your comments about AMD.
    big harty likes this.

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