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A3 Quattro KO4 upgrade, its started

Discussion in 'A3/S3 Forum (8L Chassis)' started by phil miller, Sep 17, 2012.

  1. phil miller
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    phil miller Member

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    [Jan 5, 2013]
    Right time for a fresh update, lots has happened and nothing has happened lol

    First off heat shield is here and i will be starting on that very soon, ive got WMI (found thanks to Jardo :)) my 3in dp in cat arrived and is all fitted, heatshield for airfilter all fitted, so here are the pics :)

    My shiney new downpipe and de cat
    [​IMG]
    new and old side by side
    [​IMG]
    [​IMG]

    Now once fitted it was so tight to the prop it was just touching, ive spoken to Sam and he has said ive gotta fit the dog bone powerflex bushes and i should slacken the engine mount bolts and slide the engine over to the pass side a little, will be trying this tomorrow, it took 2 1/2 hours on a 2 post ramp, i dropped the subframe and rack to gain enough clearance to get the DP out, it is also worth saying that one of the bolts for the dp to turbo is a mare to get at, best advice i can give is a ratchet spanner with a double flex head, i also got an S3 cat back exhaust, now this is the funny bit, i would have thought the A3 TQS and S3 would share the same exhaust layout ie mounts, no they dont :( so im left with to choices cut the S3 mounts off and weld them on in the same place as the TQS mounts or try and get the rubber S3 mounts

    My Bargain WMI kit, bought off a lad on VAG parts on FB, paid on nye arrived thursday WINNER
    [​IMG]

    Here is the Heat shield i got from S3dave, fitment is spot on and i have bolted my catch tank to it aswell, happy days
    [​IMG]
    not the best pic but it was dark :(

    Another of Jardos finds
    [​IMG]
    80mm tip V2 i think, should be here soon
    All thats left is to fit the WMI (i havent got a clue) and order a set of Injectors

    Now on the WMI front the injector is in a plastic thing that by the look of it you drill a hole in a solid boost pipe and then this bolts to the pipe??? its this
    Nozzle Mounting Adapter

    can someone explain please :)

    Id just like to thank Jardo for finding me loads of parts, and Prawn for taking me out in his :)
    #81
  2. s3 Hoggy
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    s3 Hoggy Whats going on???

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    [Jan 5, 2013]
    Is that food for de Cat?
    #82
  3. slowcoach3
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    slowcoach3 Active Member

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    [Jan 6, 2013]
    Good work big guy! looking good, i've been after wmi for ages, must find a Jardo detective to find me bits lol!
    #83
  4. phil miller
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    phil miller Member

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    [Jan 6, 2013]
    Russ it was really strange Jardo sorted a group buy on FB for WMI, iirc £235 full kit, so as you do put my name on the list, then within an hour he linked me to a kit forsale, and best of all done the deal for me all i had to do was send payment via paypal :)

    Similar thing with the TIP, he had sorted me a deal, then that one came up, next thing i know its on route

    Whatever you want he will find it

    Anyway, did you have a good christmas and new year dude?
    #84
  5. slowcoach3
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    slowcoach3 Active Member

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    [Jan 6, 2013]
    I'm going stalking on FB then lol! Got some toys in the post for my moneypit, soon as thats all fitted up I'll nip over to Tavi and I'll show you mine and you can show me yours. Actually that doesn't sound great

    Congratulations to you and Rach, having done that myself recently I know how scary it can be!
    #85
  6. phil miller
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    phil miller Member

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    [Jan 6, 2013]
    Defo mate, come over anytime dude, minbe is off to be mapped on the 31 jan, so by the 7 feb i should have awesome power :)

    it was the most worrying thing ive ever done, thankfully she said YES :)
    #86
  7. 16Klappe
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    16Klappe Princess Clap.

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    [Jan 6, 2013]
    [​IMG]

    [​IMG]

    Literally the ultimate sleeper.
    #87
  8. 666markyboy
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    666markyboy Well-Known Member

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    [Jan 6, 2013]
    spray the bttm part of the cooler and pipes matt black
    #88
  9. 666markyboy
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    666markyboy Well-Known Member

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    [Jan 6, 2013]
    are 5 door A3's longer than 3 ???? that would explain the S3 exhaust problems as i only had to slightly mod one hanger when i fitted a BAM system to my TQS
    #89
  10. phil miller
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    phil miller Member

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    [Jan 6, 2013]
    The problem is one hanger would bolt up but one would need to be cut off and welded, didnt really have time to do this so i left it for the time being :) may have a go after work tomorrow, wheel base i would have thought is the same, 3dr doors are alot longer than 5dr front doors
    #90
  11. slowcoach3
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    slowcoach3 Active Member

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    [Jan 6, 2013]
    I'll defo come over, i want to see your beast and pick your brains on DP fitting, thought i'd better keep up with you so ordered a dp and front mount, can't get beaten by an a3 eastate lol!
    #91
  12. phil miller
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    phil miller Member

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    [Jan 6, 2013]
    Cool did you get a relentless DP? i found the best way/only way was to undo the 4 main subframe 21mm (iirc) bolts, and the column 13mm bolt and drop it down, unbolt the 3 10mm 12 point bolts on the prop and move that to the pass side a little, undo the dog bone aswell, then when bolting the new DP up i found a double flex head 17mm ratchet spanner made getting at 2 of the dp bolts easier, althou a C spanner would work just aswell :)

    Front mount for yours will be easy as you have the pipe wok on both sides already, i think westy or welly has a list of the pipes need in the FMIC sticky on around page 11ish, mine does touch the prop slightly (on the big round donut) im gonna try powerflex dog bone mounts to see if that helps

    Your more than welcome over anytime dude :) and just cause it has 2 doors more its still not an est lol
    #92
  13. slowcoach3
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    slowcoach3 Active Member

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    [Jan 6, 2013]
    Cheers dude I'll add some flex heads to the shopping list. Managed to get a bargain wellycooler, time for stage 2 map!
    Loving the a3 and your change of mind from just putting a ko3 back on ;)
    #93
  14. phil miller
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    phil miller Member

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    [Jan 7, 2013]
    Cool where did you get the welly from? Have you still got your 312s? if so do you wanna sell um? i need some to help me slow down once its mapped lol
    #94
  15. phil miller
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    phil miller Member

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    [Jan 13, 2013]
    Right so since last week Ron has seen a fair amount of work, the S3 cat back is fitted and sounds spot on

    [​IMG]

    i took the DP off to mod it as i was having issues with my prop
    [​IMG]
    and once off the damaged from the prop :(
    [​IMG]

    so i repaired it and mod it so i have plenty of clearance now

    then the B5 TIP that Jardo found for me arrived to i had to fit it, ive gotta say hats off to Bill, its a better fit than the OE item, looks better and will forever

    [​IMG]
    fitted
    [​IMG]

    Then Jardo found me some injectors, they are 550cc genesis injectors, with the wiring adpators for a bargain price
    [​IMG]
    I started to fit my heat shield
    [​IMG]

    and today Jardo came over and after adjusting his exhaust we started to fit my METH kit :)
    [​IMG]
    [​IMG]
    Ok so the res is a little small, but i will replace it with a larger one in the near future and when i do i will fit a low level sensor, it my meth kit i also had these
    [​IMG]
    [​IMG]


    [​IMG]
    the controller in the left hand side and the single one above is for safety, Prawn has very kindly said he will help me fit them (ok he will fit them while i watch :)) and from what i can understand if the 2 controllers see a meth flow problem it switches boss to actuator pressure, Paul has told me its a wise thing to have so its gonna be sorted :)

    all ive got left to do is get a nut the same thread as my meth nozzle so i can fit that

    then fit my AGU mani, a little more heat shield and Ron is ready for Niki :)
    #95
  16. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 13, 2013]
    Good work Philardo :)

    Not seen that on a K04 DP before... relentless one isn't it? damn their wobbly QA checks..

    <tuffty/>
    #96
  17. 16Klappe
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    16Klappe Princess Clap.

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    [Jan 13, 2013]
    i love this car so much.
    #97
  18. phil miller
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    phil miller Member

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    [Jan 13, 2013]
    Yeah its a relentless one :(, when i first bolted it up it was very very tight, id gone about 1 mile and thought i heard it touch, anyway the hotter it got the worse it got, it seems the DP expands alot on first warm up, if it was Fwd i wouldnt have a problem at all, just bad luck really, but we got all the work completed by just after 3 on tuesday and my boss let me sort it, so thats another job ive been paid for to do on my own car ( i love my boss :))
    #98
  19. phil miller
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    phil miller Member

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    [Jan 20, 2013]
    Ok so i had tuesday off work so i planned to get my meth controller mounted, nozzle boss welded on and nozzle fitted, also my dog bone mount fitted

    so i was trying to decide the best place to mount the controller so its easy to get at but not in my way, so i put it here
    [​IMG]

    i dont use the cubby hole so it made perfect sense as its easy to get to :)

    then i decided where to mount the nozzle, marked it up and took the pipe off

    [​IMG]

    now 1/8 NPT is a very hard pitch thread to find in a normal auto motive garage, so after asking everyone i could think of if they stock that thread, one of the lads at work said to have a look thro his box of random nuts and bolts, hes in to motor bikes and as he said, you never know
    so i got lucky and found a nut with the correct thread (WINNER) i used my cut off air grinder to cut the nut in half, i then welded this to the pipe
    Due to the pipe being thin it was awful to weld, couldnt get a good flow, so after id welded it i used the smoke machine to check for leaks, had a very slight leak so added a little more weld, cleaned the weld with a carbrid bit and sprayed a little paint over it to protect it

    here it is mounted up
    [​IMG]

    so after taking with Prawn i set the start psi on the controller to 8psi, as im running act pressure it shouldnt cut in, but if it did the pump wouldnt run dry as id put a little water in the res
    But wed morning i started Ron up to go to work as i pulled away i had a slight misfire and smoke, so i stopped, switched the engine off and then started it again, everything was fine, got to work (1/2 mile away) had a quick look went right to the res and saw it was empty :(, id put enough water in it so the level was about an inch above empty, so over night it had sipponed out as my nozzle is lower than the res and pump :( ive gotta get an inline check valve from devils own, so at the moment i disconnected the controller and left the res empty

    so the dog bone, easy to do, although i used the vice and 2 pairs of pump pliers to get the bush compressed enough to catch the centre bolt
    [​IMG]

    as i thought i have a slight dash rattle now, nothing to worry about but its there

    all is going well, but ive had a reminder that the 288s arent up to the job, even at 6psi, ive gotta do something pretty quick as its booked in to be mapped a week thursday, and i dont think i will last long if i dont uprate the brakes before the map
    #99
  20. phil miller
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    phil miller Member

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    [Jan 23, 2013]
    Right so Ron is booked in at R Tech aweek tomorrow :) im excited but also realise i have loads left to do, the AGU inlet manifold needs to be cleaned and fitted, Prawn is sending me some injector adapters as the AGU injectors are longer than ARY standards and the 550cc genisis injectors, ive gotta get some Meth, which is turning out to be alot harder than i thought and a meth check valve, the only update picture wise is a pic of my new injector along side an AGU injector and my AGU inlet manifold

    [​IMG]
    [​IMG]

    so the next update will prob be some figures/videos of the car at Niki's

    wish me luck :)
  21. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 23, 2013]
    I cannot wait to see what the Burgandy Destroyer produces on the dyno, it's going to be hilarious :) so standard looking, and not far off double standard output :)

    Have you asked Niki if he has any meth he can sell you whilst it's thrre?
  22. phil miller
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    phil miller Member

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    [Jan 23, 2013]
    Thank you mate :) im still trying to decide what to do to hide the FMIC a little so it looks even more standard, will give Niki a call tomorrow that way he can mix it and fill it when he needs it rather than me doing it before :)
  23. s3dave
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    s3dave TFSI Hybrid

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    [Jan 23, 2013]
    Good luck Phil , does the WM nozzle have no check valve or is it an AEM failed one?
  24. phil miller
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    phil miller Member

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    [Jan 23, 2013]
    Its a snow performance kit and from what i can see it doesnt have a check valve in the nozzle holder :( so im gonna get one from Devils own, £28 inc p&p :)

    Thank you Dave so much for getting the heat shield out to me that was spot on esp as it was over the christmas break
  25. beachbuggy
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    beachbuggy Well-Known Member

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    [Jan 23, 2013]
    Oh joy another beachbuggy turbo heading to r-tech to be ragged senseless... One day I might rebuild one for someone that wants to run 225bhp like it was designed...

    Good luck Paul.. Looking for some good figures please..
  26. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 23, 2013]
    not likely dan, you can just rag a ko3s senseless to get 225bhp :laugh:
  27. JudderMan
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    JudderMan Active Member

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    [Jan 23, 2013]
    This is such an awesome thread :) Keep it up dude.
  28. phil miller
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    phil miller Member

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    [Jan 23, 2013]
    Dan i cant wait to see how it gets on, it seems ages ago i sent it off to you to have it rebuilt, it took ages before i got it all back together, ive done about 500 miles so far, everything feels great, sounds great, just looking forward to the updates from Mr Gower thro FB while its with him :)

    Dan ive had a few people message me on facebook about who built my turbo, i hope you dont mind but i passed your number and a glowing review about your work to them :)
  29. beachbuggy
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    beachbuggy Well-Known Member

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    [Jan 23, 2013]
    :thumbsup:

    What bhp you heading for 300?
  30. phil miller
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    phil miller Member

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    [Jan 23, 2013]
    Thank you mate, the funny thing is Ron was just gonna have a new engine fitted and sold on, then when it became clear the turbo was knackered and i spoke to Dan i decided to play with petrol turbos for abit of fun, so i got the standard mani and DP, funny thing is i never actually drove it for more than 50 miles on the standard mani before changing it for the relentless (prawns old manifold) and since the day i bought the mani its kind of gone from there, a case of, ive got a good mani so i better get the 3in DP to make the most of the turbo and mani lol

    Its been alot of fun :) but once back from nikis ive gotta set to work on making it go round corners (to get the most out of the power) and a good brake set up

    Its never ending but because of Ron ive made some great friends, Jardo, Nick, Paul, Russ and Bill, to name a few, all have been great, helped me out endless times when ive asked silly questions, hoping for great useable power without any major hiccups when its being mapped
  31. phil miller
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    phil miller Member

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    [Jan 23, 2013]
    I havent done Rods so i will be happy with 285/290 above 290 and i will be OVER THE MOON :)
  32. Paradox1
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    Paradox1 Active Member

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    [Jan 24, 2013]
    Wow phill,wasn't long ago you got started when I sold you the boost gauge,now look at ya!

    Hope all goes well at Rtech.I've never left rtech unhappy or not grinning for at least an hour straight so I know you'll be chuffed.
    Is he keeping the car for a week or isit all in a days work?

    Also the nozzle on the inlet manifold that connect to the brake servo hose.what size replacement do I need?
  33. Paradox1
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    Paradox1 Active Member

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    [Jan 24, 2013]
    Wow phill,wasn't long ago you got started when I sold you the boost gauge,now look at ya!

    Hope all goes well at Rtech.I've never left rtech unhappy or not grinning for at least an hour straight so I know you'll be chuffed.
    Is he keeping the car for a week or isit all in a days work?

    Also the nozzle on the inlet manifold that connect to the brake servo hose.what size replacement do I need?
  34. phil miller
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    phil miller Member

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    [Jan 24, 2013]


    Hiya Marty, thank you mate, yeah I looked back thro this thread and it was only sept I bought the gauge and ic brackets from you, it's amazing how much has happened since then :)
    im really looking forward to going to RTech they are gonna have the car for a week which is fine give me chance to take my golf out as I haven't driven it yet this mmonths he servo outlet on the inlet manifold is 12mm dude

    having been thro this thread again I smiled when I saw i was after 250ish bhp how things change lol ESP about mani and 3in dp
  35. phil miller
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    phil miller Member

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    [Jan 30, 2013]
    Tomorrow is drop off day :) ive painted and fitted the AGU inlet mani and fitted the injector adaptors that prawn sent me, all systems go :)

    so anyone wanna have a guess at what BHP Ron will have after the Rtech visit????

    i will start the ball rolling


    a massive 268 bhp :)
  36. Jason.s
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    Jason.s Active Member

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    [Jan 30, 2013]
    292.8bhp
  37. superkarl
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    superkarl MAN OF STEEL

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  38. JudderMan
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    JudderMan Active Member

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    [Jan 30, 2013]
    295.5

    :) Can't wait to hear what it is :)
  39. phil miller
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    phil miller Member

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    [Jan 30, 2013]
    If i get that i will be over the moon, my guess at 268 is prob my way of not getting carried away, if i hope for 290 and its say 285 i could be a little disheartened, :) will post up here the videos that Niki puts on my facebook so we can see the updates :)
  40. slowcoach3
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    slowcoach3 Active Member

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    [Jan 30, 2013]
    Good luck with it mate, at least you know its in good hands!
    For what its worth I reckon 291.8...

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