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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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    [Feb 21, 2014]

    Well, you promised an update, where is it :laugh:
  2. Airs
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    Airs Active Member

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    [Feb 21, 2014]
    Im sorry I'm sorry :( i have it here lol :)

    Been trying to get all of these damn cooler pipes sorted, but i think finally I'm somewhere near done with them.

    heres a couple of pics :)

    from the outlet of the intercooler

    [​IMG]

    and through the gap under the headlight

    [​IMG]

    [​IMG]

    all in 3' pipe (76mm) its very tight under the headlight so i may end up shortening the upper pipe that runs from under the headlight and use a longer piece of silicone so i get no vibrating from the headlight.

    and this is part of the hot side cooler pipes, has to have a ryt funny bend in because of the turbo mounting and gearbox linkages but it works and will look much better when all painted

    [​IMG]

    unfortunately i couldn't get the car for MOT on thursday night :( i didn't manage to get it finished with home commitments and stuff but I'm pushing and pushing to get it road worthy this weekend, but its still going to miss ultimate dubs which I'm gutted about :( but i think i will still personally be attending just in the bora :) lol
  3. Marshall878
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    Marshall878 Member

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    [Feb 21, 2014]
    What a project. Read through last night. Massive task taken on and executed really well.

    Id love to do something like this but lack self confidence lol
    Airs likes this.
  4. Airs
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    Airs Active Member

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    [Feb 21, 2014]
    Thanks very much Marshall878 :) yeah its been a long has, just down to the fact of what I've been doing to her, but will soon be completed and hopefully every1 will like what I've accomplished :)
  5. Prawn
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    Prawn My other car is a MINI!!!!

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    [Feb 21, 2014]
    What's the reason for struggling to get it all in 3'' mate?

    generally it's thought that 2.5'' IC pipework will support upwards of 600bhp. Surely 3'' will just introduce unwanted lag to the system?

    Hope you have a good weekend on it :)
  6. Airs
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    Airs Active Member

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    [Feb 24, 2014]
    its very tight between the leg and the headlight for a 3' pipe mate, my headlights have xenon ballasts built onto them so it makes the light huge!! lol

    yeah I'm running 2.5 from the turbo to inlet of intercooler and 3" out of the cooler to engine, but think I'm going to change that before long lol.

    But on a plus side…… i drove her at the weekend :D lol

    lets just say she is VERY stiff!! alot of rattling and vibrating but going to be awesome, got a slight little white smoke issue that I'm trying to sort, which i think could be a used injector thing as i never changed the seals when i fitted them, so going to try this first and go from their, fingers crossed its only that because if its anything major I'm just going to cry…. and then rip the engine out and donate the bora engine :p lol

    but lets try seals first ay :p aha
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  7. VAG-Slag
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    VAG-Slag Active Member

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    [Feb 24, 2014]
    There's a surprise!.. lol

    Glad to hear she's mobile tho! . . Good work :thumbsup:
    Airs likes this.
  8. dandam
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    dandam New Member

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    [Feb 25, 2014]
    Are you still planning on getting it to Ultimate Dubs ??
  9. Airs
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    Airs Active Member

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    [Feb 25, 2014]
    Yup, surprise surprise :p lol

    thanks mate appreciate it :) look forward to her being on the road lol

    dandam i don't think she is going to make it to UD :( I'm gutted tbh
  10. Airs
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    Airs Active Member

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    [Mar 2, 2014]
    Hey guys, hope every1s weekend has went better then mine has.

    decided last week that i would do injector seals to see if i could clear up the smoke issue. Ordered new seals and and located new NON stretch bolts for injector rockers and injector hold down bolts. So Saturday morning came and i had to help a friend rebuild his R8 8pot brakes after refurb, spent few hours doing that and then went to set about the TT.

    Arrived at mates house to start stripping the manifold off to get to the remaining inlet bolts (all hidden down the back of block), so i decided to remove the compressor side boost pipe and BOOM, MASSIVE KICK IN THE STONES found a load of oil in the silicon boost pipe straight off the compressor housing :(

    Started looking further into the turbo, i had no oil at all leaking out of the filter inlet, but alot in the compressor outlet. After a little debate i decided i needed to take it off for closer inspection, so today i spent taking it off only to find alot of oil coming from the exhaust side of the turbo aswell :(

    so all in all my BRAND NEW turbo is busted, going to ring the guys that supplied it tomorrow and see what the crack is :( so not been a good weekend at all.
  11. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 2, 2014]
    Bad times dude :(

    Been there myself... not good... hope its not too bad :/

    <tuffty/>
  12. Prawn
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    Prawn My other car is a MINI!!!!

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    [Mar 2, 2014]
    pah.

    *******s.
  13. Airs
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    Airs Active Member

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    [Mar 3, 2014]
    Yeah not a good thing mate, hopefully all will get sorted though :)
  14. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Mar 3, 2014]
    hope all goes well with getting a new turbo sorted and they dont try blame the user, as some do.. Was it a standard turbo? or hybrid
    Last edited: Mar 3, 2014
  15. JimS3
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    JimS3 Active Member

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    [Mar 3, 2014]
    Have you got the breather hose plumbed into the TIP as per the standard setup?
    If you have it's quite normal for the hoses on the TDI to be full of oil.
  16. Airs
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    Airs Active Member

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    [Mar 4, 2014]
    Hey Jim, no this is not connected as per standard setup, its venting off atm but will be into a catch can as oily boost pipes are no good!!
  17. Airs
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    Airs Active Member

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    [Mar 5, 2014]
    Hey guys, hope every1s week is going well :)

    still trying to sort the turbo front, but forgot to upload a couple of other progress pics so here they are :)

    front mount and oil cooler all mounted up

    [​IMG]

    and how bumper sits with both on

    [​IMG]

    [​IMG]

    still got my grill to go into the bumper which will hide the oil cooler, but may still need painted black to make it a little more stealth lol

    so who's attending ultimate dubs this weekend??
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  18. slepy
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    slepy Extremely smart and handsome person. VCDS Map User

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    [Mar 5, 2014]
    Brilliant project mate. What kind of rollcage do you have? Safety devices or something else?
  19. Airs
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    Airs Active Member

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    [Mar 5, 2014]
    Cheers slepy :) its a full weld in one from custom cages, not the easiest job I've ever done in my life and had to do alot of modification to it to get it in their too lol
  20. slepy
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    slepy Extremely smart and handsome person. VCDS Map User

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    [Mar 5, 2014]
    Thanks mate, looking forward to the end result :)
    Webster2001 and Airs like this.
  21. Dane
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    Dane Faster than a V12 Q7

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    [Mar 6, 2014]
    What a project! and what a roller coaster of a thread, stick at it!
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  22. Airs
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    Airs Active Member

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    [Mar 13, 2014]
    Hey guys :)

    Have decided whilst my inlet and stuff is off to get 2 WMI nozzle adaptors welded onto it, think i have worked out a good location to place them but just need a little more advice from the GURU's lol

    Was thinking of fitting them here in the middle of each pair of ports,

    [​IMG]

    and this is the direction it will be jetted in,

    [​IMG]

    Does this angle look ok?? as it will be sucked back on a 90 degree ish angle. It will only be activated at around 15-20 psi and be boosted up to around 30-35 PSI, if this should be ok i will get it drilled and welded today and off to be powder coated before i go snowboarding this weekend :)

    Any help would be great thanks guys :)
  23. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 13, 2014]
    Curious as to why you are considering fitting them in the inlet rather than into the charge pipe work?

    Not fitted a WMI kit to a tdi before but I believe the principles are the same...

    Fitting them directly to the inlet is more for octane boost/knock control on petrol engines... the cooling effect on the charge air will be minimal at that point... for getting inlet temps down you typically fit the nozzle just after the intercooler to allow for the meth mix to absorb the heat

    What are you aiming to get from using WMI on your setup?

    <tuffty/>
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  24. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 13, 2014]
    Airs likes this.
  25. Rice
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    Rice Member

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    [Mar 14, 2014]
    Oh so thats what meth kits are for, reducing the intake temps! Never really thought about it tbh.

    Coming together nicely :)! Do like a good TT, have always wanted a coupe, nice driving position, they look good too. Looking forward to seeing it finished, and hearing how the tdi sounds.
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  26. Airs
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    Airs Active Member

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    [Mar 18, 2014]
    Hey tuffty, was going to mount the nozzles their as i thought it may aid in better distribution of the mix, but after reading that info you provided it doesn't seem like that is the case .im looking for the WMI to help cool some of the temps down as the TDI's run quite hot to start with.

    alot of the TDI engines suffer from cam wear which has been suspected to be caused by the oil/engine temp being to hot, so I'm looking to reduce temps and potentially gain abit more power from the engine if possible.

    sorry for the late reply lol



    thanks Rice :) i can't wait for it either, hoping to crack on some more this week with her :)
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  27. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 18, 2014]
    My nozzle is post FMIC...
    [​IMG]

    Fit a lot this way

    <tuffty/>
  28. Airs
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    Airs Active Member

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    [Mar 20, 2014]
    This looks like good place to fit it mate, alot of room to do it and a nice flowing pipe too :) ordered myself some new IC pipes last nigt and going to redo the cold side of the IC this week i hope :)

    also ordered these little goodies too,

    Fumoto drain valve for my sump, going to be doing lot of oil changes and the seems like a much easier, cleaner and faster option,

    [​IMG]

    ordered this adaptor so i can make use of my 1.8T sump, will use this where the standard 1.8T oil return normally goes as a point for my oil temperature gauge

    [​IMG]

    just going to drill and tap an adaptor plate to fit this into and eventually an oil temp gauge, an recommendations on any good gauges people?? I've already got a new south indigo boost gauge installed that i took from the bora, was thinking of their oil temp gauge to, but its only in degrees F, not sure if that will just bug me :p lol

    Another quick little question but has any1 had any dealings with TSR performance?? potentially interested in purchasing 1 of their baffled sump inserts, please see link below, all advice and opinions welcome :)

    TSR 1.8t baffled sump insert

    cheers guys :)
  29. superkarl
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    superkarl MAN OF STEEL

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    [Mar 20, 2014]
    LOL Sam will chime in when he wakes up on his side of the world
  30. Airs
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    Airs Active Member

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    [Mar 20, 2014]
    HAHA is that a good thing or bad superkarl?? lol
  31. Rice
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    Rice Member

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    [Mar 20, 2014]
    I dont live that far from TSR, and so i know a lot of people who have used TSR performance... I hear that they used to be very good. But recently not so good. I would personally stay away from them.
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  32. Airs
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    Airs Active Member

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    [Mar 21, 2014]
    thanks for the advice Rice, what makes you want to stay away??
  33. Sam_
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    Sam_ Down under

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    [Mar 21, 2014]
    I'm pretty sure it's run by people that are new to running a business. Customer support is pretty lacking. I ordered a manifold/downpipe and a line kit totalling about 1500 quid from memory. You'd think for that you'd get top notch service and no problems. Firstly they forgot to weld in the EGT probe into the downpipe after specifying several times that I had a wideband car and needed the mount (the picture on their site also shows it). They also sent the line kit with an incorrect banjo fitting on one of the coolant hoses (probably the same person that "checked" the downpipe before it left?). Neither of these two issues would be a major problem if they actually replied to emails or treated the issue like it was their fault. They agreed to send me a EGT probe mount but with no mention of them covering the cost of the probe being welded in. Their response to the issue with the line kit was for me to get it sorted here. I went to a local hose specialist who said they'd have to make a new fitting and it'd be $100 as it wasn't something they stocked. TSR agreed to send me a new line eventually. It's still not sorted though. It's not like I am waiting on it to complete the build or anything but it's just frustrating that they could have just checked what they were sending before they sent it. It seems a bit "that'll do" to me.

    If you're local to them it might be less of an issue but on the phone and email, their customer service is pretty ****. Dealing with them remotely is painful to say the least.
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  34. Sam_
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    Sam_ Down under

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    [Mar 21, 2014]
    Grab the forge sump if you can. Forge seem to be much better to deal with and their sump is said to be better anyway :)
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  35. Airs
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    Airs Active Member

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    [Mar 21, 2014]
    Jesus dude sounds like they just want to take your money and thats the end of it!! yeah it would be alot worse if it was your last parts swell, but they rant coin much for our "foreign relations" are they. i don't live especially close to them but t least I'm in the same country, but no asking myself is it really worth the hassle to save £55 ($91 USD ;P lol)


    yeah forge have a very good nam no matte who you ask which is a good hint, thin i will just bite the bullet once the time comes and buy a forge baffled sump :) thanks for the help, hows the build coming on?? :)
  36. Sam_
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    Sam_ Down under

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    [Mar 21, 2014]
    I have a forge sump to go on. They use pattern sumps but mine looks ok. The only thing with pattern sumps (and pattern parts in general) is that quality can vary as I'm sure you know.

    I'm just trying to get the cash together to buy a clutch setup so the block can be balanced. Going for a Clutchmasters FX850SS (like their top twin disk but using a single disc, bit more road friendly) just incase I get the urge to stick a GT35 on later (as seems to be the trend now). GT30 is soooo last year!!
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  37. Rice
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    Rice Member

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    [Mar 23, 2014]
    I can't really remember specific problems that people have had, but it basically runs down the same lines as what Sam is saying, all they want is your money, the customer service is ****. I also went there when I was about 17/18 for a job when I was just getting into engineering and they were total dicks!
  38. Airs
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    Airs Active Member

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    [Mar 24, 2014]

    Yeah totally understand what you mean sam, so of the quality can drastically vary lol hopefully when i buy 1 i get a decent quality sump lol

    yeah from what I've been reading GT30 is old hat now, strange isn't it lol never heard of those clutches before but will have a look at them online, never really been into petrol stuff so reading through this forum helps me learn a little more :)

    yeah can't stand companies like that, it should always be about the customer service and after care then just being about the money, jesus just shows they must be dicks in general if they where like that with you Rice
  39. Airs
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    Airs Active Member

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    [Mar 28, 2014]
    Hey dudes :) hope every1s week has been good, mine has been hectic with work but looking forward to the weekend on the car.

    Since posting in here a little while ago, I've had a re think on my boost pipe situation and decided to redo the cold side of the cooler in 2.5" pipework after receiving a few peoples advice :) you know who you are lol

    so i went and chopped the 3" outlet pipe off my cooler and started mocking up the 2.5" pipes, heres a few pics with the precision mounted screw drive :p lol

    [​IMG]

    [​IMG]

    [​IMG]

    Since doing this conversion I've been looking at how the 167 relay works as it sits exactly where the diesel 103 glow plug relay sits, been toeing and growing and decided to go with this option up to now, since the glow plugs are only on for a few secs on start up i decided i would just put them onto a switch of some sort and the WHOLLA i found this in the shed and thought it would be ideal :)

    [​IMG]

    Located

    [​IMG]

    and on position

    [​IMG]

    so this is going to be my option for now until the car is all up and running properly and if it causes no issues i may well keep it lol

    Fitted my FUMOTO drain valve too, will come in very handy with these short milage oil changes coming up

    [​IMG]

    Hopefully the last bits on silicon turned up today, finds crossed :)

    [​IMG]

    and a couple of none related car pics that I've been up too lately, been playing in aviemore

    [​IMG]

    and really need to get back out on the bmx as i miss it, roll on the summer, heres a little pic from last summer

    [​IMG]
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  40. Airs
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    Airs Active Member

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    [May 15, 2014]
    Hey guys, sorry i aint been updating for a while ha alot going on lately but its all on the up :)

    Since last posting i had to remove the car from where it was parked in my friends back garden and have nicely relocated to this indoor space :)

    [​IMG]

    Still havent bought my water meth as of yet, but a few more purchases have been made, biggest 1 being a full elevel air ride setup and this is the little build i have done :)

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Fully carpeted the boot floor and wheel well

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    I did have a problem with engine smoking quite alot, which turned out to be the injectors overfueling alot and not burning enough of it lol

    Manage to get a hold of some new standard injectors and now its all fixed :) woop woop

    This sunday we are re-wiring the fuel pump relay and glow plug relay into the correct positions and then it should all be running perfect and 95% ready for MOT :)

    More updates to come again very soon :)

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