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Another hybrid conversion thread....

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

  1. finesse
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    finesse Active Member

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    sell the coated 034 & OEM to fund the other one, cannot remember the name....
  2. RobbieRolex
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    RobbieRolex Member

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    Well fair plate to them, that is good customer service at least. Why would you say the coating is fundamentally flawed?
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Welly was referring to the manifold being flawed not the coating mate....

    Applying ceramic coating to it won't prevent something that is likely to crack from cracking...

    <tuffty/>
    JimS3 likes this.
  4. badger5
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    badger5 RIP S3dave Site Sponsor

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    well, lets see it happen first folks..
    words are easy, seeing one arrive is believing!

    watch this space

    the ceramic coating i get done on my tubular manifolds and downpipes is to reduce rediated heat and keep the heat inside the tubes, so they do no rapidly expand/contract which is a stress fatigue scenario.. I dont do ceramic coating on the manifolds to make them reliable, they are already reliable, this adds to it..
    coating something which has inherant flaws in design or material choice will not in my opinion and experience fix a thing.

    IF they warranty their manifolds and stand behind the product then it will prove if "they" believe they are selling ticking time bombs or not.. We will have to see how this ends up.
    they have everything to loose if handled badly.
    Last edited: Nov 14, 2010
  5. Welly
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    Welly VX220 SC Driver :)

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    Morning all, and welcome to another week.

    I can't be arsed with waffling on today so....

    I'm fitting the OEM manifold back on, once it's been ported.

    I'm doing this solely for reliability, as my OEM manifold has has a million hidings, and is still OK.

    I think that, despite ceramic coating, the 034 will still crack after a period of time.

    I don't want to have to change the manifold a third time.

    Work commences tomorrow night. This will be the 5th head gasket this year. :(

    :thumbsup:
  6. RobbieRolex
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    RobbieRolex Member

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    Will you be porting the OEM manifold before it goes back on?
  7. Welly
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    Welly VX220 SC Driver :)

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    Yes mate, Bill is porting my OEM for me tonight and that will be going on on Wednesday.

    I'm sure he will photo before and after for reference.
  8. RobbieRolex
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    RobbieRolex Member

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    Must get the dremmel out to my OEM one for when the time comes!
  9. Welly
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    Welly VX220 SC Driver :)

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    My experiences not filled you with confidence dude? :(
  10. RobbieRolex
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    RobbieRolex Member

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    LOL, not really, from what people are saying its the inevitably of the failure, we will see, that and i always wanted to port a manifold.
    Last edited: Nov 15, 2010
  11. s3dave
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    s3dave TFSI Hybrid

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    Just a thought, it is not uncommon for the oem one to crack....ive seen 2... isnt the porting going to weaken it further....
  12. Welly
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    Welly VX220 SC Driver :)

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    Bill has been very careful of where he's taken material from from within the manifold's collector. There has only been material removed from the parts which are thick, the thin bits have been left alone.

    In all fairness, how much worse than the 034 can it be?
  13. s3dave
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    s3dave TFSI Hybrid

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    hmmm good luck with it anyway
  14. Welly
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    Welly VX220 SC Driver :)

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    Well mine has taken much more abuse than most, and is still good. So IMO, that stands it in good stead. I'm pretty sure bill wouldn't have ported it if he didn't agree.

    Time will tell....
  15. RobbieRolex
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    RobbieRolex Member

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    Does porting make much of a measurable difference though, would you say its worth doing? Also mine has had a torrent of abuse and is still solid.
  16. Welly
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    Welly VX220 SC Driver :)

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    Wait until you see the photos dude. On your photos, where was the heat being generated from? The collector. Why? Because it's very restrictive.
  17. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Bill has only attacked the collector and not touched the runners.... the collector is a bit of a bottle neck and Bill has removed some material around here to prevent build up of heat from choking at this point... pics should follow as I am pretty sure he took some earlier before Welly picked it up...

    As for a difference, this is yet to be seen but the main advantage the 034 mani gave was it ran cooler as exhaust gasses didn't back up at the collector... if the porting work Bill has done is to do anything then it should reduce EGT's a bit from std and hopefully not glow yellow hot like it has done in the past...

    <tuffty/>
  18. RobbieRolex
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    RobbieRolex Member

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    LOL, i couldn't see the collector Welly and on my pics the whole frickin thing looked red hot. Saying that looking at my OEM mani as below, it is a big bottleneck alright, hhhmmmm, Where's that dremmel. Seriously though it looks like they casted this using the same cast i used to make those lead toy soldiers with many years ago, there is room for improvement, DIY style.:rockwoot:

    [​IMG]

    Apols for the **** picture, some cnut robbed my iphone 4 at the weekend so i am stuck with my crappy BB.I am sure Bills will be nicer.
    Last edited: Nov 16, 2010
  19. badger5
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    badger5 RIP S3dave Site Sponsor

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    Following on From Wellys unfortunate experience with the 034/INA K04 hi-flow manifold, and his urgent need to get his car on the road again, he wante dhis old K04 manifold reworked to help with the higher airflow it now achieves..

    Pictures below..
    Std (other) k04 manifold
    [​IMG]
    Ported
    [​IMG]

    [​IMG]
    [​IMG]
    [​IMG]
  20. Lemon S3
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    Lemon S3 Alex

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    Is the ported one cracked on the inside or just an imperfection?
  21. Welly
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    Welly VX220 SC Driver :)

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    There are a couple of small internal cracks mate, yes. But nothing drastic. A cracked K04 manifold looks like the first photo of Bill's - that K04 mani is cracked!!
  22. Lemon S3
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    Lemon S3 Alex

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    Yeh didn't think it would be a problematic crack as that part is pretty thick. The std mani looks exactly like mine but I've also got a crack on cylinder 1 head side I think.
  23. JD09
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    JD09 I'm not modding, I'm improving

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    Wow, well what a rollercoaster fella! Just read the last few pages as have been a tad busy recently!

    Great work on the TIP Bill, loving your progress! And so quick to production!! OEM sounds like a good move for the mani at the moment Welly.

    Bring on the WMI!!
  24. badger5
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    badger5 RIP S3dave Site Sponsor

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  25. Speedy Steve
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    Speedy Steve Active Member

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    expect my phone call bright and early tomorrow Bill !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
  26. badger5
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    badger5 RIP S3dave Site Sponsor

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    okies steve
  27. Welly
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    Welly VX220 SC Driver :)

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    OK, ported OEM manifold is now on. Hit it hard today and got the whole lot done in less than 6 hours, so really pleased with that...

    Initial results are pleasing, feels like it drives really well. I will do some airflow logs later on and let you know how that looks.

    The 034 manifold that's come off is looking a little bit sorry for itself, pics of the cracks below...

    [​IMG]

    [​IMG]

    More later... :)

    EDIT: Pics don't seem to be working for some reason, think my web server is having a spaz.
    Last edited: Nov 17, 2010
  28. Speedy Steve
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    Speedy Steve Active Member

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    woohoo my TIP is on order

    I see no pics Welly?
  29. RobbieRolex
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    RobbieRolex Member

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    Hows it coming along there Welly? I've been busy to, porting my OEM manifild for when the time comes.Not bad for a novice.Still a bit more to do but this is it so far. No as good as Bill obviously.

    Can't see your pics BTW.

    Before:
    [​IMG]
    After
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Last edited: Nov 17, 2010
  30. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    Hmm i see the links alex, but no pics, odd....


    How does it feel compared.. First impressions?

    I am trying to work out whether to skim my mani or port an OEM one for it?
  31. Speedy Steve
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    Speedy Steve Active Member

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    I might just buy the tsr:moa:
  32. Welly
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    Welly VX220 SC Driver :)

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    Feels good mate, spot on. I haven't given it the full right foot really yet, but feels as responsive, if not better than the 034.

    I'm not convinced that the big step from the manifold's collector (which was much bigger) to the turbo helped matters, it must have been disrupting air flow quite substantially.
  33. Welly
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    Welly VX220 SC Driver :)

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    By all means do mate, but I'm not convinced you'll see much, if any gain for £700.

    Buy it and see what it's like dude, would be good to know.
  34. Welly
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    Welly VX220 SC Driver :)

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    All my pics are broko :(
  35. Speedy Steve
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    Speedy Steve Active Member

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    I was only winding mark up theres no way im forking out that kinda money for a K04 manifold ill just get WMI
  36. Welly
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    Welly VX220 SC Driver :)

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    Agreed, it is A LOT of dosh to part with.
  37. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    Meh, some people have more money than sense...... HA HA HA:tapedshut:

    :p:p:p

    XS power FTW...

    N
    O
    T
  38. s3dave
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    s3dave TFSI Hybrid

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    Millteks should be available soon..
  39. Dane
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    Dane Faster than a V12 Q7

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    hey hey, spanner in the works! dont suppose you have a link do you Dave?
  40. s3dave
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    s3dave TFSI Hybrid

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    No link but i called them a month ago, and they said it was due december/jan around £350....

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