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Another 8L Track Car - Lets get ready to 'Ruuuuuuuumble'!

Discussion in 'A3/S3 Forum (8L Chassis)' started by Welly, Oct 22, 2012.

  1. Welly
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    Welly VX220 SC Driver :)

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    [Nov 5, 2012]
    Dude, sorry I meant to PM you. Budget is a bit tight to stretch to getting seats just yet. I've spent mostly all of what I have on the engine.

    I'll have to leave them for now.
  2. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Nov 5, 2012]
    I will most likely still have them when you have the cash anyway lol
  3. Welly
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    Welly VX220 SC Driver :)

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    [Nov 9, 2012]
    OK mate, I'll bear that in mind.
  4. Welly
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    Welly VX220 SC Driver :)

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    [Nov 9, 2012]
    OK then.... did a few bits and bobs whilst having 3 days off this week.

    Firstly, removed most of the air con pipework from the A3's engine bay. A PITA frankly, but does give much more working room so worth doing.

    The rods turned up from China at my office whilst I was off - so I went and grabbed them!

    [​IMG]

    They just are the same as the IE rods to be fair, or at least as close as damnit. Here are my old IE 20mm Non RD rods:

    [​IMG]

    Anyway, very happy with them for the money to be fair. Would have been better had they been EDM Rifle Drilled - but I didn't have the dosh and am aware of the potential consequences...

    Fitted up to the pistons nicely - a nice tight fit onto the wrist pin I must say...

    [​IMG]

    [​IMG]

    Also started mocking up the manifold and turbo for fitment. Started by giving the head a cleanup to remove all the old skanky bits of gasket etc. Looking good now it's clean:

    [​IMG]

    Nice large inlet ports is what we want... (Yellow cover has to go though...)

    [​IMG]

    Adjusted the manifold flange to make it actually fit the head correctly. It has also now been ground flat as it was a few mm out of square as most Chinese manifolds are! Then fitted up the 38mm wastegate to get an idea.

    [​IMG]

    [​IMG]

    So that fits then.

    Next on went the turbo to try and get an idea of sizes. Lots of measurements taken of the dimensions for the whole assembly together. It's Big. VERY big and it is going to be a tight fit.

    However based on measurements it looks like it physically will fit into the engine bay which is a bonus...

    [​IMG]

    [​IMG]

    [​IMG]

    More to come this weekend...
  5. burns3
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    burns3 Member

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    [Nov 9, 2012]
    Coming along nicely mate, i'm sure it will be a tool when it's all up and running.
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 9, 2012]
    tight fit into wrist pin = bad wellyboots

    How tight were they to push in??

    it should slide thru easily by light touch else splash lube wont get there and they will wear rapidly and do this>


    Last edited by a moderator: Aug 15, 2014
  7. Welly
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    Welly VX220 SC Driver :)

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    [Nov 9, 2012]
    Reasonably tight dude, didn't push in easily. Not mental tight though - thoughts? They weren't that bad...
  8. Welly
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    Welly VX220 SC Driver :)

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    [Nov 9, 2012]
    Very close to what I remember the IE ones being to fit on the first rods I bought back in the Jurassic period.
  9. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 9, 2012]
    I bought a small honing tool to get the pin fits "nice" as the variance on rod bushes and pin (used) often made for some being tighter than others, then a customer brought some used rods, pistons in for fitting into his new block, and looking at them (the video) they were shagged completely... Explanation being they were too tigh, unsifficient lube able to splash in there (which is the RD point which I wont labour any more).. The pins were ribbed.. oh err, such was the consequent wear, and so much friction had picked up and spun a bush in a rod.

    I hone them so you can easily push the pin thru with light touch.. slide in and out.. no effort required.

    the finishing diameters on all rods seems to vary compared to pins... new and used..

    IE rods often on the tight side..
  10. Maz
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    Maz Moon is made of green cheese

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    [Nov 9, 2012]
    I'm impressed, not just by the speed in which you are tackling this but how Mrs Welly is cool with you using the dining table as a work bench.
  11. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 9, 2012]
    lol @ mrs welly comment.


    shhhhhh
    its hush hush
  12. Welly
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    Welly VX220 SC Driver :)

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    [Nov 9, 2012]
    What they don't know won't hurt them....

    Also, the top is made of glass so I have to go a bit steady....
  13. kwistof
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    kwistof South East Events Moderator Regional Rep

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    [Nov 9, 2012]
    :whistle2: It's Friday and yes I'm being childish :)
    (I'll get my coat)
  14. coatesy
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    coatesy poking badgers with spoons

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    [Nov 9, 2012]
    ahahaha quality its good to see some one out there has the same humor as me lol.


    looking good welly dude!
  15. Welly
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    Welly VX220 SC Driver :)

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    [Nov 9, 2012]
    Just for reference, I have borrowed the aforementioned honing tool...
  16. ReDBull
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    ReDBull Member

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    [Nov 10, 2012]
    I know what you mean about AGU cylinders heads being hard to find! I've been looking for one for a while now. I think I may have to buy a complet engine. The builds looking good so far and good luck when your Mum finds out.
  17. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Nov 10, 2012]
    AEB heads seem to be so much easier to get an they're just as good.
  18. Jason.s
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    Jason.s Active Member

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    [Nov 10, 2012]
    Yeah sold mine for 70quid!
  19. s33nyboy12
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    s33nyboy12 Well-Known Member

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    [Nov 10, 2012]
    I am impressed too, very speedy looking good.

    Lol at using your kitchen for the work! Love it
  20. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2012]
    AJH ones also work as far as I know - large port as well.
    Westy likes this.
  21. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2012]
    Not as much progress as I hoped over the weekend to be fair. In so much as there was none at all!

    Was expecting head gasket and shells to turn up on Saturday morning and they sort of didn't. Rather annoying.

    Anyway, they're here now so I can get on and fit the pistons and rods one night this week.

    In other news I used the honing tool to give a bit more clearance to the small end bushings on the rods. Now they slide in and out very nicely indeed - much like warm apple pie. No photos of that sadly as I didn't have enough hands. My missus also came home and found me doing it on the glass hob in the kitchen - not impressed.

    Popped up to the Dyno day at Bill's on Sunday - I couldn't stop long as I had to get to my daughter's birthday party... However I did get this from my crustacean friend... Prawny :)

    [​IMG]

    Many many thanks again Prawn - much love.

    Also here is today's deliveries...

    [​IMG]

    Now need to get some gas for the tig welder and we'll be cooking.
  22. ReDBull
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    ReDBull Member

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    [Nov 12, 2012]
    Thanks for that I'll get searching! I've just been quoted £350 from a chap on eBay for a AGU head!
  23. ReDBull
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    ReDBull Member

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    [Nov 12, 2012]
    She cought you doing what the pie or the rods?
  24. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2012]
    I can't guarantee that as a fact as I've never seen one. What I do know however is that the AJH inlet manifold was the only large port OEM manifold that suited the S3 TT with the TB on the right hand side.

    If the manifold is large port - then lets be fair, the head is going to be as well.

    You can buy a whole engine for about £250 delivered - VW SHARAN SEAT ALHAMBRA 1.8 T TURBO 20 V ENGINE CODE AJH | eBay

    For reference, the AJH engine came in the 1.8T Sharan and the 1.8T Seat Alhambra only as far as I know.
  25. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2012]
    The rods. I don't do pies. I have a missus for that exact purpose. :D
  26. Speedy Steve
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    Speedy Steve Active Member

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    [Nov 13, 2012]
  27. scoobyra
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    scoobyra It's not f@cking ORANGE!!!!!

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    [Nov 13, 2012]
    Just read this thread through and its funny as feck! Nicky said "Mike, our daughter's out, come upstairs"....I was like eff off, this is serious stuff on here and much more exciting :whistle2:

    Good to see you at the weekend Welly and keep up the good work....at this rate, I won't have to shag the Missus for a good few weeks yet! LMFAO :eyebrows:
  28. Welly
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    Welly VX220 SC Driver :)

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    [Nov 14, 2012]
    You too mate, always a pleasure. :thumbsup:
  29. Welly
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    Welly VX220 SC Driver :)

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    [Nov 14, 2012]
    After giving it some thought I have decided I want to do something different this time.

    Thus I shall be fitting the WellyCooler V2.

    Which is this hossing beast of a thing.

    MASSIVE TURBO 4" THICK FRONT MOUNT INTERCOOLER SUBARU STI WRX 700x300x100mm | eBay

    I shall be cutting the bumper up literally to fit it so that the end result looks something like this:

    [​IMG]

    Some of you may remember I considered doing this to Bumble. It's in my usual subtle, understated style... :)
    Westy likes this.
  30. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Nov 14, 2012]
    You'll freeze the engine with that beast :faint:
  31. Welly
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    Welly VX220 SC Driver :)

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    [Nov 14, 2012]
    Should be interesting to see how it performs vs the original core. I can't see there being much difference really. Same inlet size and outlet size, there is just more core.
  32. Speedy Steve
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    Speedy Steve Active Member

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    [Nov 14, 2012]
    Its going to look epic!
  33. ScottD3
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    ScottD3 I want your faulty electronics Supporter

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    [Nov 14, 2012]
    Mount a beer cooler in the back to cool the water down even more and spray it on the cooler.

    To much?
  34. Speedy Steve
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    Speedy Steve Active Member

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    [Nov 14, 2012]
    na mount a beer cooler in the back and spray passangers with beer more like
    Westy likes this.
  35. ScottD3
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    ScottD3 I want your faulty electronics Supporter

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    [Nov 14, 2012]
    Get a twin outlet one. lol
  36. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Nov 14, 2012]
    Big is not always better of course ..then pressure drops..
  37. Welly
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    Welly VX220 SC Driver :)

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    [Nov 14, 2012]
    Agreed there is more volume to physically fill, but in the grand scheme it's not a massive amount. However there is more cooling area.

    Bigger certainly was better for the original type B core, I'm going to apply that principle again and keep my fingers crossed.
  38. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 14, 2012]
    wonder what airflow manages to get to the water radiator after its passed thru the deep fmic
    we will see in due course no doubt.
  39. Welly
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    Welly VX220 SC Driver :)

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    [Nov 14, 2012]
    Yes, that is an interesting thought. I will also be removing the aircon rad from the A3 as I have now completely destroyed the pipework... That should allow additional flow the rad shouldn't normally see.

    With regards to the 'it's not that much bigger' statement, working out the maths it actually is.

    The WellyCooler core is 600 x 300 x 76mm. Cubic volume is 13,680,000 mm.

    The proposed WellyCooler 2 core is 21,000,000 mm. It's over a third as big again.

    I shall fit in the name of testing. If it doesn't work I shall use it as a washboard or something....
    Westy likes this.
  40. Prawn
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    Prawn My other car is a MINI!!!!

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    [Nov 14, 2012]
    if you've removed the aircon condenser welly, you can trim the slam panel back to set the IC back another inch or so if you so desire to keep it all inside the bumper.

    Obviously, if you'd rather not then go nuts!

    I've been considering an offset stick on plate and more holes in mine recently....
    Speedy Steve likes this.

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