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Another hybrid conversion thread....

Discussion in 'A3/S3 Forum (8L Chassis)' started by Welly, Sep 14, 2010.

  1. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 11, 2010]
    only time will tell on durability of any of these new manifolds

    wonder what guarantee will be offered.

    the other unknown option is JBS's cast k04 manifold. Their k03 one is a quality casting, which on my wifes 1.8t lupo was reliable unlike so many "other" hi flow manifolds.

    cost = unknown - region £450 inc vat
    reliability = too early to tell, but good if k03 one is anything to go by
    Warranty = unknown.
    Last edited: Nov 11, 2010
  2. Welly
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    Welly VX220 SC Driver :)

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    [Nov 11, 2010]
    Don't worry, using the 034 as a benchmark, it won't take long to find out.... lol
  3. RobbieRolex
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    RobbieRolex Member

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    [Nov 11, 2010]
    LOL, i've had more mileage out of a pair of shoes.
    Inertiauk likes this.
  4. Welly
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    Welly VX220 SC Driver :)

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    [Nov 11, 2010]
    :lmfao:
  5. superkarl
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    superkarl MAN OF STEEL

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    [Nov 11, 2010]
    could it not just be really really unlucky and you had a defected one? maybe they will be able to identify why.
  6. Speedy Steve
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    Speedy Steve Active Member

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    [Nov 11, 2010]
    SH1T the bed thats bad welly sorry for your loss! I think ill have to get Bills Tip fitted and see what figures we get with the stock manifold as 314bhp wasnt to bad. I think the TSR is looking very tempting
  7. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 11, 2010]
    Hmmm. and all the 034 K03 manifolds which also cracked were "unlucky" too I guess. Its a bit of a coincidence. No one can be happy including them that the thing has failed so quickly. Clearly time and effort have been put into them, but there's a fundermental flaw in design and or material choice.
  8. superkarl
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    superkarl MAN OF STEEL

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    [Nov 11, 2010]
    ahhh i didnt know ko3 ones had cracked. shame, everyone was hopefull you had found a winner.
  9. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Nov 11, 2010]
    TSR no brainer really
  10. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Nov 11, 2010]
    Sorry to hear mate, thats a right kick in the c~*t for you. Id try the XS power one, you've modified it to fit and it's not like you've got to shell out again, which ever you do hope you get it fixed mate.
  11. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 11, 2010]
    xs power one is mocked up here on a head.. downpipe wont fit on itdue to angles being wrong on turbo flange.. there is pretty much not a lot right with it. shyte

    tsr one looks good. it would need to be warrantied for that price.
    jbs one is likely to be available before xmas, and judging by their k03 one its quality of material and cast is 2nd to none. £450 likely price its deffo a contender. again warranty will be key, and one without caviats.

    BUT, we saw more gains from my 3inch tip than the 034 manifold on wellys.

    hmmmm
  12. IbanezDan51
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    IbanezDan51 Member

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    [Nov 11, 2010]
    Would a shot of nitrous keep the temperatures right down? Can you even get a 5-10 shot of nitrous?

    Can water meth kits be set up so that it only comes in at WOT?
  13. RobbieRolex
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    RobbieRolex Member

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    [Nov 12, 2010]
    Yes, my WMI is progressive so it starts injecting at 7psi and is on full load by 14psi, this is completely adjustable.
  14. Dane
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    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

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    [Nov 12, 2010]
    JBS have certainly been thorough with their testing, whilst it's a bit of a tease that it's been in development so long at least we know they have put it through it's paces
  15. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    Yeah, I agree. Although when they first drew up plans, Noah was still a boy. There is testing, and then there is testing....
  16. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    Stop talking about WMI - you're making me horny...
    Inertiauk likes this.
  17. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    OK. So, a decision has been made....

    I popped up to Bill's last night an mocked up the XS Power manifold. Bottom line... I just don't think it's going to be worth the hassle to actually fit the thing.

    One of the tubes contacts with the head. Not a huge problem as the bit that it hits can be removed... Or so I thought. Removed that lip, and it still contacts. This makes me think that under expansion, it would cause it to crack somewhere.

    Also, the turbo being fitted to it, means that the downpipe won't actually fit under the runner for cylinder 3... Again, a bit of a fundamental flaw.

    So, what is going to happen is this... Fitting the OEM manifold back on. Bill is going to have a look at porting the collector. There is some material to come out of there as far as can be seen, so it can be made to flow a little better than it does in stock form.

    Weighing up the options on the manifold, as to whether to buy a new OEM one and work that, or use my existing one. The one that's come off has some minor cracks in it, but is still workable. It comes down basically to the cost of a new OEM manifold...

    Watch this space.
  18. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Nov 12, 2010]
    Is there a possibility of reworking the 034 manni if they dont want it back? (pics should be enough)
    ive had good results welding cast.
  19. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    Maybe dude. Although, based on the current state of it, I wouldn't be convinced it wouldn't crack somewhere else.

    I forgot to mention there is a second crack on the manifold, which was located last night.

    It's on the underside of runner 1 (typically as it's inaccessible). It's a much bigger crack as well, you can physically feel gas coming out of it.
  20. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Nov 12, 2010]
    ahh right, waste of time attempting it then,
  21. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    Honestly dude, the thing is an utter lump of wasted space. 1 crack is bad - 2 very large cracks is just awful.

    I simply wouldn't fit another one. End of.
  22. Lemon S3
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    Lemon S3 Alex

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    [Nov 12, 2010]
    Are these 034 mani's sh1te then? I've got one I bought from Issam in america, ready to be fitted when the hybrid arrives but reading your problems makes me think to not use it n wait for JBS to release theirs.
  23. RobbieRolex
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    RobbieRolex Member

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    [Nov 12, 2010]
    I hope not, i have one fitted now for nearly 1000miles(said hugging a tree), i think the only thing saving mine is the lower EGT's, i hope.At the same time, i am keeping my stock one on standby!
  24. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    I'm not saying don't use it dude.... However the facts speak for themselves...

    Fitted for less than a month. Covered less than 1000 miles. Result of which: 2 huge cracks making it completely unusable.

    The decision is yours....
  25. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    Ultimately, my gripe isn't the cracking, thats just a pain, and the results of a badly made product. Nobody was to know that at the point of fitting.

    The issue is the f**king pain in the ass of taking it off to fit another.

    A ball ache. One that I didn't need.
  26. RobbieRolex
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    RobbieRolex Member

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    [Nov 12, 2010]
    Check your private messages, it might ease the ball ache!
  27. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    Thanks is deserved. Muchly.
  28. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 12, 2010]
    034 mani's in k03 fitment crack and many of them have cracked.
    The new k04 manifold has also cracked.. and given the track record of the k03 ones, is a poor reflection.
    I have no faith in 034 manifolds period as a consequence.

    Jokingly last night, we thought maybe the 034 Motorsport k04 manifolds were recycled and remelted k03 ones such is their familiar cracking tendancy.

    I would need a LOT of convincing to trust such a product again. Its not like the track record on k03 mani's was good..

    JBS's is due out this side of Xmas with target pricing of £450 I believe
  29. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 12, 2010]
    righto - other non-cracky related:

    3 INCH TIP:

    to prove the 3inch tip can go onto std airbox (not that this is what I would reccomend) I fitted the version 2 to a car with std box last night. It fits, is tight and fiddly to do, but is doable.
    My advise is this is for people with open cone induction kits not std airboxes, but those who would want to retain their OE airbox can, its possible but will be a fiddle.

    The kits will go with one bend precut and the others left for users to trim to suit their particular installs of induction.

    turbo intakes are done, need slight remachine on bore as it seems not all k04's are consistent in their OD (dammit)
    fabricated alloy section will be quoted and work commence next week. I will confirm exact pricing next week for people.

    pictures:
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
  30. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    OK, so it would appear that WMI has just appeared on my list of bits to fit.... :). Maybe this week isn't so bad after all....

    A new mani is too pricey for me at the moment, so Bill is going to attack my OEM one and port the collector.

    I am sure there will be photos to follow....
  31. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Nov 12, 2010]
    looking good bill....
  32. RobbieRolex
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    RobbieRolex Member

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    [Nov 12, 2010]
    You know its the right thing to do :yes:, This is really gonna help your setup.If you have questions, let me know, my install is still very fresh in my mind.
  33. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    Cheers matey, I will bear that in mind.

    Getting a working manifold back on the car has to take priority though.... :(
  34. Welly
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    Welly VX220 SC Driver :)

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    [Nov 12, 2010]
    LOL @ this thread. Like most of my threads it has become and epic tail of highs and lows...
  35. Speedy Steve
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    Speedy Steve Active Member

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    [Nov 13, 2010]
    i think we need a group buy on wmi
  36. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Nov 13, 2010]
    I have suggested this before... happy to sort it out if the interest is there...

    <tuffty/>
  37. Speedy Steve
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    Speedy Steve Active Member

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    [Nov 13, 2010]
    me me me me me me me me me me me me me also clutch group buy lol
  38. Welly
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    Welly VX220 SC Driver :)

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    [Nov 13, 2010]
    OK, news....

    034 are sending out a replacement manifold for me.... The ceramic coated one this time.

    I am still in 2 minds as to what is best to do with this really. I'm not personally convinced that ceramic coating something which is fundamentally flawed to fix the problem will work.

    I've booked off Weds and Thurs next week to do the work, so I've got time on my side to decide...
  39. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Nov 13, 2010]
    Velco HG mate, Told ya didn't i ? LOL
  40. voorhees
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    voorhees Moderator Staff Member Moderator

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    [Nov 13, 2010]
    It'll be nice and cool though :/

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