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2004 A3 3.2 V6 S-line DSG - Progress/Build (pic heavy)

Discussion in 'The Project Room' started by Audi-Rog, Feb 13, 2014.

  1. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 13, 2014]
    Hi and welcome to my on-going progress/build thread.

    A bit of history on the car, it's a 2004 3.2 V6 S-line DSG with 115K on the clock, FASH, Bose, parking sensors on rear, Half Leather and 18" RS6 alloys. It's been Superchipped too, adding around 15 BHP.

    I bought this A3 with the intention of just cleaning it up and re-selling straight away, as it was mis-advertised as a Sport and was underpriced some-what! But after driving it and loving the engine smoothness and power, I decided to sell the wife's car and keep this! (She has my Octy VRS instead, so she's not complaining!)

    I've had to do some mechanical work, replaced the O/S driveshaft, new drop links and put 2 new tyres on the front.

    I've had an A3 2.0 TFSIQ previously, which I restored and added many bits to. But on this 3.2, I've decided to do more to the interior, than the exterior, but you never know.

    So, over the last 3 months, I've been steadily buying bits and bobs to upgrade or replace old knackered parts. This thread will be quite picture heavy and I'll add more as I do more.

    The car on the day I bought it.

    [​IMG]

    Here are few pics of the original condition.



    [​IMG]

    [​IMG]

    Interior isn't too bad at all, but it was owned previously by a smoker, so I will be giving the interior a full detail and clean and feed the leather to freshen it up.

    [​IMG]

    DSG. Bose Symphony, looking a bit tired, but works well.

    [​IMG]

    RS6 alloys need a refurb, they have been poorly refurbed in the past. Missing centre cap!

    [​IMG]

    Not too sure if this is original, but it looks ok, but needs repainting and sticking down properly.

    [​IMG]

    [​IMG]

    Parking sensors, nice.

    [​IMG]

    Aftermarket mirror caps, look ok actually and if someone nicks them I won't be too upset!

    [​IMG]

    Standard pedal set up.

    [​IMG]

    Exhaust tips need a good polish.

    [​IMG]


    Here are some pics of the scratches and defects over the bodywork. These will be corrected at a later stage.

    The classic mark where the wiper hits the boot. I've since adjusted the wiper so it doesn't hit it now.

    [​IMG]

    Some minor and more major marks around the car.



    [​IMG]

    This one is a bit nasty.

    [​IMG]

    Top tip...DO NOT scrub at bird lime....this is what you get!

    [​IMG]

    Front wing.


    [​IMG]

    Rear bumper marks.

    [​IMG]



    ------------------------------------------------------------------------------------------------------------------------------


    So, the first thing to do was to give it a good bath! Boy did it need it!

    This is during and after a good exterior detailing.

    The alloys were given a good de-toxing, AS Smart wheels first.

    [​IMG]

    Then Iron X

    [​IMG]


    [​IMG]


    Then onto the bodywork. APC'd all the nooks, crannies, doors shuts and jams etc, then a 2BM wash.

    [​IMG]

    [​IMG]

    Bodywork decontaminated. First with Tardis, then clayed.

    This fallout was just on the bonnet! The rest of the car was just the same.

    [​IMG]

    Then dryed off , cleansed and sealed with Werkstat Acrylic prime, via DA polisher.

    [​IMG]

    Looks better and is protected from the winter elements.

    [​IMG]

    ------------------------------------------------------------------------------------------------------------------------------------------------------------------
    Last edited: Feb 14, 2014
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  3. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 13, 2014]
    Then I started to replace a few bits. First being the central locking button.

    [​IMG]

    Removed.

    [​IMG]

    Old vs new.

    [​IMG]

    Then replaced.

    [​IMG]

    ------------------------------------------------------------------------------------------------------------------------

    Next little mod was to upgrade the Pedals to the S3 Aluminium set.

    Before.

    [​IMG]

    After! And a dead pedal cover thrown in too by the seller on eBay, nice one!

    [​IMG]

    ---------------------------------------------------------------------------------------------------------------------------

    Next up was to install a K&N panel filter. Very simple.

    [​IMG]

    [​IMG]

    ------------------------------------------------------------------------------------------------------------------------------

    Another detail to fix, was the boot gas struts, as they took forever to raise and made it very heavy to move. So, found 2 new ones for a Tenner each (eBay). Again very simple but an effective fix.

    [​IMG]

    Old struts removed.

    [​IMG]

    New ones installed.

    [​IMG]


    ------------------------------------------------------------------------------------------------------------------------

    The next upgrade to do, was the Symphony 6 CD Bose HU, it was very tired and had pixels missing! I managed to bag a bit of a bargain. A Symphony II 6 CD Bose HU. I needed to buy a Quadlock adapter and after doing alot of reseach here and other forums, I fitted it!

    [​IMG]

    Cover all, for protection!

    [​IMG]

    The new replacement.

    [​IMG]

    Old unit out.

    [​IMG]
    Re-wiring.

    [​IMG]

    After install, works perfectly too! Sounds alot better than the old one!

    [​IMG]

    ------------------------------------------------------------------------------------------------------------------------------
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  4. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 13, 2014]
    So that's some of the interior upgrades.

    I've also done a bit of updating to the exterior.

    And after searching eBay forever, I finally got very lucky and found these MY11 rear light clusters. £60 for the pair!!

    [​IMG]

    So here's before.

    [​IMG]

    During. 50/50 shot!

    [​IMG]

    After, looking much nicer!

    [​IMG]



    ------------------------------------------------------------------------------------------------------------------------------

    I also found a genuine Votex front lip, to put on at sometime in the future. The only thing I've done to it, is prep it for painting. I wil get the bodyshop to do that though, I'm not brave enough to do it myself.

    [​IMG]


    --------------------------------------------------------------------------------------------------------------------------------

    More interior updates.

    As I'm not really a fan of the early DSG gear surround, I decided to change it for the later style version. Here is a little "step by step" of the removal process. THIS IS NOT A FULL GUIDE! Just a little direction if someone else wants to do it too.

    These are the replacement parts. Again, very reasonable price on eBay. This is how they came up, after a good clean up and polish.

    [​IMG]

    The original set up. It's ok, but not for me. It's a little over engineered! (well built though!)

    [​IMG]

    Piano surround removed, by pulling up from the ashtray end.

    [​IMG]

    Next pull down the gearknob sleeve.

    To remove the knob, pull the button all the way out and pull with all your might, try not to smack yourself in the face when it shoots off!

    [​IMG]

    Then use a small screwdriver to push in 2 black tabs on each side, and ease off the chrome surround.

    [​IMG]

    Which leaves you with this. The lights.

    [​IMG]

    This unplugs from the middle right, by pulling out the cable connector from underneath.

    [​IMG]

    Here's the plug

    [​IMG]

    Then remove the gear "runner" cover by pulling 2 tags at the front and rear and pulling towards you and up gently.

    [​IMG]

    Then re-fit the new surround. This was alot easier then taking it out!

    [​IMG]

    With lights on! Much nicer in my opinion, I may do the S3 knob if I can get one cheap enough!

    [​IMG]


    That's where the cars at, at the moment....

    More to come.......thanks for looking

    Comments welcome


    -------------------------------------------------------------------------------------------------------------------------
    Last edited: Feb 14, 2014
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  5. LukeW
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    LukeW New Member

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    [Feb 14, 2014]
    I cannot believe how much better the car is now looking :D Great Job mate. I'll be looking to get one soon, maybe not a DSG one but still a 3.2 :). I'll be messaging you for tips soon, your cleaning technique is amazing, good luck for the future and keep us updated.
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  6. Taroni
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    Taroni Member

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    [Feb 14, 2014]
    Look very good mate . How are you finding the K&N filter ? I was looking at getting a Piper 1 for mine as im sure there not oiled like the K&N
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  7. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 14, 2014]
    Thanks Luke, I will be adding things as I go along :)

    I'll be quite happy to give you any cleaning tips and techniques you may need mate :thumbsup:

    I've really only touched the surface of the exterior restoration. I'll be giving it a full correction detail, when the weather picks up and the wife lets me :laugh:

    I may have a go at refurbing the alloys too....we'll see!


    Rog
    Last edited: Feb 14, 2014
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  8. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 14, 2014]
    Hi Taroni

    Cheers for the compliment :)

    I've never had an issue with a K&N filter and I've used them on many a car! As long as you clean the MAF sensor every now and then you're fine.

    I find they help the throttle response, increase the exhaust note and they last forever (almost!)

    Rog
    #7
  9. omblad0n
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    omblad0n Member

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    [Feb 14, 2014]
    Nice progress mate. Subscribing to this thread.
    2 months ago I got a 3.2 manual 04 plate 66k miles (with loads of optional extras), and have similar plans to you, but I cannot be arsed to do anything till the weather picks up abit. All I did since getting it was engine Oil & filter & Haldex Oil & Filter. Next I wanna to the Chain rails and tensioners for peace of mind when I get the time.

    What other plans have you got for it?
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  10. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 14, 2014]
    Cheers mate.

    I've had a bit of practice with a previous A3, so some of the upgrades I've done before, or at least researched them. So it hasn't taken me long to do some of the mods.

    I'm still learning as I go, for example the install of the Symphony II+, which wasn't too bad, once I understood the wiring. It's very satisfying to accomplish some of these mods, it does make a nice difference to the look and feel of the car.

    It's had alot of mechanical work done in it's history, so I don't have to worry about those things for a little while. So, it gives me a chance to concentrate on the superficial stuff! Which is nice.

    Other plans....., votex lip will be added, maybe new OEM alloys and I'm on the lookout for an S3 or Votex rear valance (maybe?). I'll continue to upgrade the interior with newer parts. These will all be, as and when I can. (And the wife will allow! ha ha)

    The main plan though, is to make it look as good as new!
    #9
  11. MattKeating
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    MattKeating Member

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    [Feb 14, 2014]
    Nice work. Really Interested to see wat you do to the exterior, as mine has a few marks and swirls that I want to get out.
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  12. omblad0n
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    omblad0n Member

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    [Feb 14, 2014]
    Sounds good. I am lucky as to have most of the optional extra, and interior is in really good nick, you wouldn't say the car is 10 yrs old.
    The paint needs abit of atention, and it'll get a full detail when weather allows.
    Has yours had the chain sorted? Mine has no signs of it, but reading on A3Quattro.de, a technical analysis proved that VR6's on long life service are the ones prone to chain failure, which happens due to worn down rails(they are plastic). Mine was mostly on long life all of its 66k miles life, so I'll be doing the rails and tensioners when time allows.
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  13. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 14, 2014]
    I haven't got too many extras, but I'm not too bothered, it has enough for me. There's less to go wrong! The interior is great quality, so it doesn't age too bad, does it. It doesn't take too much detailing either, to make it look new again.

    I would have thought that with only 66K on the clock, your chain and tensioners would be sound. You could have them inspected first to see if they are worn? They should last the lifetime of the engine. If you maintain the engine properly that is. Personally, I don't spend money unless I have to, but that's just me!

    I will change the oil every year in my ownership. I don't do any mileage now anyway, as I have a works van. The chains on mine haven't been changed to my knowledge, there's no record of it. Although, the engine runs and sounds superb. But if I see or hear any symptoms of worn chains, I'll have them sorted. I tend not to read too many forum horror stories these days, as you tend to get paranoid!

    Do you detail your car yourself?
    #12
  14. omblad0n
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    omblad0n Member

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    [Feb 14, 2014]
    Thats true, but done research on the car before buying it.
    Quite a few 3.2s popped their chains in pre 2006 A3s and Golf R32s (BDB and BUB engine codes mostly).
    I like to know what problems to expect with any car I own, especially since a dealer would charge 2k-4k(depending how many valves are bent) to rectify.
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  15. LukeW
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    LukeW New Member

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    [Feb 14, 2014]
    As I have been looking into these a lot lately and was wondering what you guys paid for your just go have something to go off especially omblad0n as I will be looking something around that year an mileage hopefully a bit lower thanks :)
    #14
  16. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 14, 2014]
    I did the same research before, i bought my 2.0 tfsi, as originally I wanted a 3.2. But after reading all the issues with the 3.2, I went for the tfsi. Then, I had one of the rarest issues with the tfsi and the oil pump chain failed! Go figure! Got it fixed and it was as good as new, but I couldn't have prevented it.

    This time, I've been more relaxed about it, my 3.2 has had an audi health check all the way through its history, so I'm not too worried. But in fairness your approach is the right way to go. :thumbsup:
    #15
  17. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 14, 2014]

    I'm not going to divulge how much I paid :ninja:

    But with a good low mileage, high spec example, I would expect you need to pay over £5K - £6K.

    There are some bargains out there though, as people want more effecient cars. Keep looking you may get lucky!
    Last edited: Feb 15, 2014
    #16
  18. autolatry
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    autolatry Active Member

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    [Feb 14, 2014]
    Il do you a deal on mine. Virtually everything in the engine bay is new. Including the chains.
    #17
  19. Kali
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    Kali New Member

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    [Feb 14, 2014]
    Love all the interior changes you're doing! How hard was the DSG surround?
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  20. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 14, 2014]
    Thanks Kali

    The DSG surround wasn't too bad to do, I took it easy. Not forcing anything! I worked it out as I went along.

    It looks a lot scarier than it is to do.

    Rog
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  21. Andy1608
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    Andy1608 Active Member

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    [Feb 15, 2014]
    Amazing what you can do with a good clean some well thought mods.
    you've done that car proud. Good job
    #20
  22. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 15, 2014]
    Thanks Andy :)

    I know, it doesn't take an awful lot to transform the car really, does it.

    That is my main aim, just to bring it back to life, show it's been cared for and give it the respect it deserves! Afterall it was a £26K+ car new!

    The previous owner had neglected the look of the car, but did add some upgraded brakes and serviced it etc. So he did look after it, but you wouldn't know it by looking at it.

    I can't drive around in tired looking premium motor, I wouldn't feel good at all! Afterall, all it takes is a bit of effort, a little know how and a modest amount of money, to turn the clock back a bit. This forum is a godsend for the knowledge too, which has helped me massively over the years.

    I'm also trying to do these things for the least amount of money possible, as I get a kick out of finding bargains and making the most out of them.

    I'll keep searching for various bits on eBay etc, for the next mod/upgrade.....

    I'll keep you all posted..

    :icon_thumright:



    BTW If you are on FB you can see the full progress pictures by following this link:

    https://www.facebook.com/FreemanDet...10151981583166672.1073741843.522406671&type=3
    Last edited: Feb 15, 2014
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  23. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Feb 21, 2014]
    *update*

    The aftermarket roof spoiler wasn't doing it for me, it wasn't fitted very well anyway, so it had to go!

    DSCF8400.jpg

    So the spoiler just pulled off, easy! Leaving the sad tape, that was trying to hold it on!

    DSCF9131.jpg

    Then on, with an original S-line roof spoiler from eBay, for £60 delivered. It's the same colour code as my car too, so I don't even need to have it sprayed. Awesome!

    This is a test fit at the moment, but it will be stuck down properly later.

    DSCF9133.jpg

    Looks so much nicer and it was cheap as..

    DSCF9134.jpg

    More to come...slight change of plan on the DSG surround...

    :salute:
    Last edited: Feb 22, 2014
    #22
  24. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Mar 6, 2014]
    *update*

    I decided I needed the S3 gearknob in my life, as the standard style ones weren't doing for me, so I grabbed myself a used bargain on eBay. The S3 gear knob bad piano black surround.

    It took me two attempts at twisting the gear linkage shaft, to get it right. After I damaged the springs the gearknob button, by over stretching them trying put the gearknob on the shaft! I then had to put the old one back on! :keule:

    But, after a mountain of faffing, i.e taking apart the whole gear knob, to repair it, and heating and twisting the gear linkage shaft, (again!!) burning my fingers and getting angry! I finally fitted the S3 dsg gearknob :yahoo:

    image.jpg

    I must say say I love the way it looks and feels. It does make the car feel more sporty somehow. Anywho...

    I've now bought the ashtray delete, as the existing ashtray doesn't match the S3 surround. So I'll be fitting that when it arrives.

    Another update will putting the front Votex lip on the bumper. It is at bodyshop as we speak...


    :thumbsup:
    Last edited: Mar 6, 2014
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  25. foxymk1
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    foxymk1 Active Member

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    [Mar 13, 2014]
    mate that an amazing job on cleaning the car ,, well done it looks awesome
    #24
  26. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Mar 13, 2014]
    Thanks Foxy:icon_thumright:

    I've now got the Votex lip back from the body shop, so I'll be fitting that pretty soon, can't wait!
    #25
  27. Ashmcblue
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    Ashmcblue Active Member

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    [Mar 13, 2014]
    This is bloody brilliant. I am subscribing!
    #26
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  28. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Mar 16, 2014]
    *Update*

    I've had a slightly mad moment, after looking for months, I took the plunge, whilst on eBay and bought some Alloys! I had a nice long trip down to Bath to collect them. So, took the wife and kids and made a day of it! (Kept her reasonably happy!)

    Anyway, I haven't mucked about, cleaned them up a bit last night and fitted them at 7.30am this morning!

    Here are a few pics :cool:

    The alloys I've gone for are genuine BBS Calito 18" split rims, (with Goodyear F1 tyres all round). These are one of my most favourite alloys for the A3, (for this year model). They're a pretty clean, they do need some work on the polished lip and inner rims (worming and laquer lifting), but the centres are in fantastic nick!

    DSCF9274.jpg

    Fitting the alloys.

    DSCF9289.jpg

    Old vs New!

    DSCF9290.jpg

    One side done.

    DSCF9292.jpg

    RS6's, still like them alot (Dumb & Dumber style)

    DSCF9295.jpg

    But, I like these alot better, BBS Calito's:yes:

    DSCF9296.jpg

    DSCF9298.jpg

    DSCF9293.jpg

    (The suspension is still settling, after fitting, in the pics above, it's not sitting that high really...)

    Took it out for a spin to check for any balancing issues and all is well!

    I think it makes the car look a bit more unique, as you don't see these alloys about too much. I must say, they look better than I imagined.....:happy:

    What do you guys think?
    #27
  29. Ashmcblue
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    Ashmcblue Active Member

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    [Mar 16, 2014]
    I like it.
    #28
  30. stetheo
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    stetheo Active Member

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    [Mar 17, 2014]
    Looking really good, I like the new wheels a lot.

    Does ever so slightly look like it's on stilts currently haha, although as the suspension settles it'll look even better.
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  31. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [Mar 24, 2014]
    *update*

    Votex Lip Installed. This my debut at doing this, but after some good advice from the Merlin Bodycraft, bodyshop guys, I was feeling brave enough to have ago myself. Looks easy, but it aint!

    First, I took the bumper off to make it easier for me to seal it down on my own.

    DSCF9377.jpg

    First thing was to clean up the bottom of the bumper, then scotchbrite the area to be glued, to give a better key for the sealant.

    DSCF9379.jpg

    I used 3M window bonding sealant (given to me by Merlin Bodycraft), which once it goes off is bulletproof!! And after a mountain of clean up with Tardis and many adjustments. It looked like this. Taped down at the edge to help it cure in the right place.

    DSCF9385.jpg

    I left it to to cure for a good 4-5 hrs.

    DSCF9380.jpg

    Then back on with the bumper and it's complete!

    DSCF9388.jpg

    Here are some after pics.

    DSCF9389.jpg

    DSCF9390.jpg

    DSCF9394.jpg

    DSCF9391.jpg

    I'm very happy with the result, I think it looks great. Makes the car look more aggressive and desirable (to me anyway!). I think it finishes off the look of the car nicely, without going down the S3 wannabe route (not that there's anything wrong with that!), just not for me.

    Next to come......enhancement detail to turn back the clock a little.

    Cheers for looking

    :icon_thumright:
    #30
  32. stetheo
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    stetheo Active Member

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    [Mar 25, 2014]
    Nice mate, looking good.

    Definitely gives it a more aggressive look on the front end doesn't it!
    #31
  33. Audi-Rog
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    Audi-Rog "Fire up the Quattro!"

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    [May 26, 2014]
    This is probably the last update for this progress thread, as I'm pretty much there, in terms of where I want the car to be :yes:

    Mechanical updates: The car has had new tyres fitted all round (since these pics) and an interim service, so the car is running beautifully and smooth!

    The main update:

    I had a small window of opportunity (around 5 hrs), a couple of weeks ago, to give the VR6's bodywork an enhancement detail and soften down or remove some of the larger, deeper scratches and marks around the car. It's not 100% with the time allowed, but it's more than good enough finish, as a daily driver.

    Here are a few progress pics.

    Before:

    DSCI0036.jpg

    The car had undergone the usual wheel cleaning processes and pre-washes, before the 2BM safe wash.

    DSCI0040.jpg

    I had already clayed and de-contaminated the bodywork previously, so there was no need to repeat that.

    Here are some of the defects around the car, that my aim was to remove or reduce.

    DSCI0044.jpg

    DSCI0031.jpg

    DSCI0032.jpg

    DSCI0046.jpg

    The plastics and rubber sills were taped up for protection from the rotary polisher. Then it was treated to a single stage polish using Scholls Concepts S17+ using a Flexipads waffle polishing pad.

    DSCI0052.jpg

    DSCI0054.jpg

    Bad scratch after polishing, looking a bit better.

    DSCI0057.jpg

    The plastics,tyres and rubbers seals were then dressed.

    DSCI0088.jpg

    The polished finish was then sealed with Auto Finness's Tough Coat, leaving this stunning deep gloss and shine.

    DSCI0056.jpg

    Wheels sealed and tyres dressed.

    DSCI0066.jpg

    The finished result!

    DSCF9474.jpg

    DSCF9468.jpg

    So here's a reminder of where the car was, when I first bought it. A rather tired and mis-treated premium motor! Waiting for some love and attention!

    DSCF8841.jpg

    This is after a few quid spent, some subtle OEM mods and more importantly, many hours of effort. And after all that, my A3 3.2 VR6 S-line, has been transformed back to somewhere near it's former glory. Hopefully, I've given it a good few more years yet, of tearing up the B roads, which makes all the effort worth while, for me anyway.

    DSCF9463.jpg

    I will continue to work on some other little marks around the car (touch in stone chips etc),coz as we all know, all car care is on-going. But that's it for this thread!

    Thankyou for taking the time to read and comment on my thread, I really do appreciate it !

    Rog :thumbsup:
    Last edited: May 26, 2014
    #32
  34. Ashmcblue
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    Ashmcblue Active Member

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    [May 26, 2014]
    Absolutely fantastic. Really enjoyed reading all this.
    #33
    Audi-Rog likes this.
  35. CunniBlingus
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    CunniBlingus New Member

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    [Aug 17, 2014]
    Nice turn around!
    #34
    Audi-Rog likes this.

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