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A3 Quattro TDI Re-Shell Into Audi TT225

Discussion in 'A3/S3 Forum (8L Chassis)' started by Airs, Jun 23, 2013.

  1. Prawn
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    Prawn My other car is a MINI!!!!

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    I just can't see it man, as good as they can be.

    I can really appreciate a good soot chucker. Well built / mapped and driven accordingly they can be mighty fast. I'm just not sure a big wave of torque over a short power band could ever replace the sensation of a highly strung petrol motor winding up to well beyond 7k RPM and cracking fire as you grab the next gear.

    I'm open to being proven wrong, but you'll have to let me have a go to find out :laugh:

    :racer:
    Airs likes this.
  2. Airs
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    Airs Member

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    yeah i totally understand where your coming from mate, i used to be a complete petrol head myself and hated diesels, but ever since my first mapped tdi i have been hooked. Once i put the big blower on the bora and felt the power delivery it was crazy and just doesn't seem to tail off at all.

    yeah I'm hoping to do a few track days and stuff this year so i may possibly let you have a blast :p lol just be aware that you might get hooked :p mwahahaha
  3. olethalb
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    olethalb Member

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    awesome build, spoke about doing this with mates - was going to do it but never happened.
  4. foxymk1
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    foxymk1 Active Member

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  5. Airs
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    Airs Member

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    thanks mate :) ahh you should of done it, I've always wanted to do this and the car came up cheap so i couldn't resist :) lol
  6. Airs
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    Airs Member

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    haha cheers foxymk1 :) not your normal kind of colour so thought it would stand out :p lol
  7. Airs
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    Airs Member

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    Another weekend of progress, started off with a plan to get front brakes all fitted and bled up….. but that quickly went out the window with the horrid weather we had up north this weekend, but that didn't stop all play :)

    So my plans changed, instead of fitting the brakes i though why not roll around on the wet floor and fit some new fuel lines :S not sure where my logic came from for that 1 but cracked on anyhow.
    Originally i had started to make a joining piece of fuel line to bridge the gap where the original petrol fuel filter was, unfortunately i couldn't get a good fit with the connectors i was using. So while down the local VW scrap yard i noticed the had a Seat Ibiza PD160 in and up a height, decided to have a little browse underneath and noticed it had different fuel lines fitted to that of the bora ( not thinking obviously its a shorter car lol )
    i took a chance and took them off hoping they where going to be a close fit. i took both lines from the fittings on the in tank pump all the way to the front, including the short piece hat connects the fuel cooler, and low and behold they are a perfect fit :D so i now have factory fuel lines fitted on the TT instead of 'just making something work' and all for under £20, success!! fitting them on the other hand was bait of a pain in the piece!!

    Decided to start mocking up more pipes and header tank for the charge cooler, my initial plan was to use the small coolant bottle from a VW UP but being a little short for space in needing to change my plans slightly, but here is another pic of the charge cooler placed in with some silicone connectors fitted and some heater matrix hoses started.

    [​IMG]

    the pipe between the cooler and compressor housing is slightly to long so will trim it down on final fitting

    [​IMG]

    and closer look at the manifold, turbo and down pipe fitted with a little connecting bracket.

    [​IMG]

    Got a little snap of how the drivers side currently looks with all of the patrol stuff removed and the diesel filter bracket fitted onto the wing mounting.along with new mount and brand new header tank with a BLACK lid instead of the stock blue, the little touches make the difference :)

    [​IMG]

    managed to get a slight break in the clouds and got the front passenger calliper fitted

    [​IMG]

    with the charger cooler being fitted where the battery used to be positioned i had to do some wiring modifications to the fuse box that was located onto on the battery. I decided to strap the fuse box down to the plastic wiring channel and extend the wire connecting the fuse to box to the battery and make it join up with the battery wire located on the starter motor :)

    I'm sure their was more but all i can think at the moment enjoy the read ppl :)
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  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    You are so going to have to bring this to a Badger 5 dyno day... I will organise one soon... I love the concept of this build so much :)

    <tuffty/>
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  9. Airs
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    Airs Member

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    Thanks for the invite <tuffty/> :) i shall have to take you up on that, I'm trying my hardest to get this running for the end of this month but its going to take some push lol

    and thanks for the support its much appreciated :)
  10. FactionOne
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    FactionOne Administrator Staff Member Administrator

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    Only just spotted this thread (as most know, I spend most of my time in the bowels of the server with a flashlight and a canary)...

    And...

    HOLY ****!

    You dismantled an 8L TDI... 3 Door Quattro. The best 8L package they ever built, and rare as rocking horse muck.

    Banned.

    Seriously though... Epic work, Airs. I don't suppose there's much more I can say. Epic.

    But for the love of the tooth fairy, when you build mine, start with a five door. Jeez. ;)

    R
    Last edited: Jan 20, 2014
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  11. Airs
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    Airs Member

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    Haha yeah i know i struggled for ages to find the A3 aswell and to be honest it wasn't in bad nick for its age and miles, kind of gutted that i did strip it but its worked out for the greater good :)

    ahh **** shall i take my build elsewhere ;)

    thanks alot mate its much appreciated :) can't wait to get it on the road and let people see it in the flesh, hope it goes down just as good.

    :D you provide me the 5 door and we can get cracking :D always keen to help out.
  12. Kave
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    Kave Member

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    Loving the progress, keep up the good work!

    I am curious how do you get it through the MOT? As it will be a 1.8T petrol on the v5 so the test center will be expecting a cat and will the emissions be within spec?

    Whats the score with insurance also ?

    Sorry for the boring questions :p I own a 8L TDI Quatty and considered an S3 and TT shell swap many years ago
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  13. Airs
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    Airs Member

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    Thanks Kave, glad your enjoying it,

    yeah i thought of that too, but i have managed to get it all changed over on my V5 and declared as a TDI :) as far as emissions go, its still down as having 226g/km so i should have no problems passing that with the derv as my bora logbook is only 146g/km lmao only down side is that the tax is still high, but hey ho i can't have everything lol

    insurance isn't bad if I'm honest, I've had very good quotes from adrian flux and sky insurance.

    Oooo someone else with an 8L Quattro :) my original plan was to make my A3 look like an s3 but was going to cost a fortune. its not actually a hard swop to do really just some wiring changes and bits nd bobs and its a good'un :)
  14. Airs
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    Airs Member

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    Morning ladies and gents :) more goodies and more progress lol

    More goodies arrived back end of last week all ready for the weekend, unfortunately the weather was planned to be horrific over the weekend in newcastle so hopes weren't held to high, but thought sod it i want this thing done!!

    Couple of AN fittings turned up for my high pressure fuel line fittings that where welded into my tandem pump

    [​IMG]

    also finished my battery tray for behind the passenger seat, still need to make a cover for it but thats in progress

    [​IMG]

    also been doing little bits and bobs of brackets for things in the bay and for the bottom of the turbo

    fuel filter and bracket fitted onto the wing like a standard derv

    [​IMG]

    started tidying some of the wiring up to clear space for the air filter to sit under the charge cooler behind the headlight, also last night made a bracket for the charge cooler water tank to sit just above the abs pump but behind the strut brace

    [​IMG]

    engine is starting to fill up fast

    [​IMG]

    starting to look bait like a car again :) charge cooler rad mounted just at the front but shouldn't need and bumper cutting to fit

    [​IMG]

    [​IMG]

    inside still looking bait of a tip but not as much in their now

    [​IMG]

    just a little sneaky side on pic :)

    [​IMG]

    If all goes well I'm hoping to get her started this weekend :) already filled her with oil and bolted rocker cover back on just need few little bits and bobs and she should go :) roll on Mr Parcel Man arriving :)
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  15. pablo
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    pablo Member

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    those brakes are just class.
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  16. Airs
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    Airs Member

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    Well Ladies and Gents I'm proud to announce


    SHE'S ALIVE :)

    Managed to get her started over the weekend, ran brilliant then turned her off and wouldn't start again, went through a nice fault process and came across a faulty relay, so bridged the armature and she runs like a dream again, but my god it is loud atm, silencer maybe required lol

    :) will try upload a video for you guys to see :)
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  17. Prawn
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    Prawn My other car is a MINI!!!!

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    Bet it sounds like a right old tractor :laugh:

    Awesome news mate! I look forward to seeing this pouring out smog on a trackday shortly :)
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  18. Airs
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    Airs Member

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    yeah it sounds like a sherman tank mate :p lol

    yeah i can't wait, trying to get it all finished for ultimate dubs :)
  19. s3dave
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    s3dave TFSI Hybrid

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    Excellent mate, fruits of your labour paying off!
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  20. Airs
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    Airs Member

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    Yup sure is mate thanks :)
  21. Airs
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    Airs Member

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    Hey troops, hope every1s weekend went well, or at least better than mine did :(

    started to put the front end back together, got drivers headlight in, slightly touched the diesel filter, so quickly re drilled the mounting for that which was a nice easy fix. Came to do the passenger side light, and OH S**T the headlight won't go in because of the charge cooler :'( turns out the guys i took the idea from don't run full headlights and just use the lenses as their motorsport cars!! can this bloody car get anymore testing!!

    the headlights are tat deep and having the xenon ballast on it swell, makes it sit to far back to re adjust the charge cooler into position without alot of modification, so I'm having to revert back too running an intercooler. Luckily i had a spar THS Twintercooler laying around in my bedroom of all places lol.

    So quick call to the fabricator and off down to the garage i went. We decided that it would be easier to cut half of 1 end cap off and cut off one of the ports to weld onto the other side whilst removing the blanking plate as it was a twin pass cooler, out came the plasma cutter and cracked on.

    Now i have a nice modified THS big core intercooler mounted nicely behind my crash bar, will be making solid boost pipes this week once the parts arrive, i will not be beaten by this car!! :)

    On the plus side, i ordered a stud conversion kit from the local supplier and fitted them friday night, heres a little pic

    [​IMG]

    These things work wonders at keeping my discs on the hub and my hub centric spacers fit on their lovely too :)

    [​IMG]


    will keep you updated with my progress through the week :)
  22. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Unlucky mate... I think going down the FMIC route will serve you better in the long run tbh... maybe a bit of WMI too :)

    <tuffty/>
  23. Airs
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    Airs Member

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    Yeah you could be right <tuffty/> :) a few people have mentioned to me that the cores sometimes fail and drop the water into the charge system, which is the last thing i want to happen!!

    WMI is definitely on the cards :D going to run 2 nozzles into the back of my inlet manifold, unless any 1 can advise wether 2 is too much?? my boost pressures will run at a max of around 40 PSI if that helps :p lol
  24. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Its more nozzle size than the number... need to provide adequate volume to be affective... smaller nozzles work well as they atomise nicely... I currently use one small AEM nozzle and seems to work but that may change after mine has been on the dyno again...

    Not a fan of progessive controllers either... the progressive bit is just to slow the rpm of the pump which of course drops pressure and affects atomisation... pressure switch works better IMO...

    Don't use those **** silicon adaptors for the nozzles either... small amount of alloy weld on the pipe work, file flat and tap... the spray pattern won't be affected by the fitting then

    <tuffty/>
  25. Airs
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    Airs Member

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    So it maybe worth just getting it with 1 small nozzle to start with and then if needed order a 2nd nozzle??

    yeah i was looking at getting it with a boost pressure switch, maybe activating the system and something like 15-18 PSI as car sits on boost at like 5-8 psi whilst cruising lol thats diesels for you.

    yeah in my bigger inlet I've got a couple of nice positions to tap a port into :)

    you got any advice on which kit to look at <tuffty/> ?? :) thanks
  26. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    The Devils Own stuff is ok... I have a DO pump, check valve and pressure switch... seems to work well... I used an AEM nozzle (removed the in built non return valve) as my kit was some bits Bill had lying about (he's good like that lol) but the DO nozzles work

    <tuftfy/>
  27. Airs
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    Airs Member

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    Yeah I've had a little look at the devils own stuff and looks ok and reasonably priced too. Ahh yeah I've heard he is good like that lol
    i would possibly just run the nozzle that it comes with unless their becomes and issues with it lol

    going to look out for a kit soon so i have it ready for when its getting mapped :)
  28. Airs
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    Airs Member

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    just a little pic of the front mount on, its a heavy sod but mounted up well :)

    [​IMG]

    going to work on hard boost pipes over the next couple of nights :)
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  29. Airs
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    Airs Member

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    hey peeps hope every1 is well :) another couple of updates and opinions needed,

    car is moving along nice, looking good for MOT on thursday night :) just need some more alu welding due on the intercooler tonight to finish the last of the pipes for now,

    quick peek on how she is sitting behind the bumper, oil cooler still to mount at the top behind the grill, bumper has had plate recess removed too, and intercooler is retaining the headlight washers, with 63mm inlet pipes and 76mm outlet pipes :)

    [​IMG]

    New grill ready o go in bumper, new on top old on bottom

    [​IMG]

    need some opinions on a custom badge for my flat bottom TT steering wheel, what you guys think, all opinions welcome

    1
    [​IMG]

    2
    [​IMG]

    3
    [​IMG]

    4
    [​IMG]

    and a few thrown together, the joys of working for a sign company :p lol

    [​IMG]

    will hopefully have more updates tomorrow for you guys :)
  30. kanecullen89
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    kanecullen89 Member

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    Looking good.
    Badge option 2 for me
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  31. micky2 not 1
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    micky2 not 1 Member

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    love it... i've got a spare tt lying around :faint: fancy doing a derv tufty
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  32. VAG-Slag
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    VAG-Slag Active Member

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    I've said it before and I'll say it again, so much time for this build! . . And you've gotta admire how you've thrown your self at it :respekt:

    On the logo front deffo number 4 for me, its the neatest and most OEM looking IMO...
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  33. Airs
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    Airs Member

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    OOO a spare TT have you micky, tell me more :)

    Haha thanks Vag-Slag :D really appreciate it. yeah i quite like no.4 tbh too lol may print them all to try lol
  34. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Hah!!... :D

    I do but on my Mk2 Golf ;P

    <tuffty/>
  35. Airs
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    Airs Member

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    haha well 1 of my mates has 2 mk2's where my TT is, 1 a white syncro and the other a grey auto, where doing 1.8t on syncro at some point and TDI on the auto lol TDI lump bolts straight in with VR6 mounts too :p just gotta fight with the wiring,

    you wanting a derv conversion on your MK2 tufty or a 1.8t??
  36. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Derv ideally as she is my daily/cheap car... I don't want another 20v engined car in my life... one is enough LOL...

    <tuffty/>
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  37. Airs
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    Airs Member

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    yeah thought that was what you meant, its just the wiring side thats abit of a pig i have heard, but bolting it in is a doodle lol
  38. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Was actually considering the 1.4 3 pot tdi lump... keeps the tax low, mapped they are 100hp and 170ish ftlbs... more than enough to propel a little Mk2...

    Wiring should be ok... I am ok with wiring... have fitted a fair few standalone systems in the past so modding or even making a loom won't be an issue... we shall see... need to get the S3 running first :p

    <tuffty/>
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  39. Airs
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    Airs Member

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    the only thing about my conversion is that when i declared the conversion on logbook, they wouldn't change my tax price :( so still being stung with 225bhp tax @ £280 a year :(
  40. micky2 not 1
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    micky2 not 1 Member

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    yep...i dont need another car right now.....but by time my A3's done they may have run out of petrol!

    only tdi that i want is a 330d auto

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