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Audi S3 - Stroker Big Turbo build.

Discussion in 'A3/S3 Forum (8L Chassis)' started by Scullies, Jan 7, 2013.

  1. Gary_808
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    Gary_808 Member

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    Damn that sounds alot hotter than I thought!

    Inside and outside working in a facility on the airport hopefully they have ac! :(
  2. Scullies
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    Scullies Active Member

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    So I have been suffering with a power steering oil leak. Steering rack decided its had enough, fluid was pouring out the right side when I turned to the right.
    I wasnt looking forward to changing the steering rack, but with the right tools and a car lift, it was rather easy.
    I replaced rack with a used one from a scrap TT and replaced ball joints while the subframe was off.

    [​IMG]

    Took some time to clean all the dirt, grease and oil of the subframe.

    Then I finally got round to fitted the R32 brakes, with braided autotech lines.
    Not the ultimate setup but will do for now.

    [​IMG]

    [​IMG]

    Then got to "test drive" a nice RS5, its damn nice but feels way to slow for my liking. APR supercharger kit would do justice to the RS5 :rock:

    V10 TFSI RS6, MTM tuned still has my number 1 vote :racer:

    [​IMG]
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  3. Scullies
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    Scullies Active Member

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    Little bit of an upgrade.
    Car is off the road for the moment, T3 manifold is off and going to another owner.

    [​IMG]

    With the help of Wayne, I have the first runner tacked onto the V-Band setup. Turbo fitted to check measurements of TIP.

    [​IMG]

    [​IMG]
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Moving it over so the collector is more between cyls 3 and 4 will give you more room for the downpipe

    Nice collector... I looked at those before getting one from Nortech... you using 1.5" NB fittings? make sure the wastegate one is 2" if so... I have a little creep from mine using 1.5" NB

    <tuffty/>
  5. Scullies
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    Scullies Active Member

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    Mine is a LHD, so I have the brake booster on the TIP side. The turbo has to sit in the center for the 4" silicone elbow to clear the brake booster but this also means I have more space on the DP side.

    Yeah, I went for the Treadstone collector as it has the correct size vband for the PTE vband housing, has a locating lip and most important, its a cast SS unit. It needs a little tickle with the porting tools to clean up the inside.

    Thanks for the tip on the WG pipe. Not sure where the new v-band 46mm WG is going to sit. More than likely in the same area as T3 setup.
  6. badger5
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    badger5 RIP S3dave Site Sponsor

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    you making sure the transfer box will clear the runners as they swoop low
  7. Scullies
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    Scullies Active Member

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    Lets hope so :)

    Busy with 4th runner now then will check clearance on the car.

    Im feeling lucky today :)
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  8. Scullies
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    Scullies Active Member

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    Good news, the manifold clears the transfer box with about 1" of clearance :w00t:

    [​IMG]

    [​IMG]
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  9. Scullies
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    Scullies Active Member

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    Manifold is welded up, still waiting for the precision 46mm wastegate to arrived so I can sort the wastegate angle out...

    [​IMG]

    They say a big turbo needs a big DP😁 , EGT bung is due for delivery tomorrow, thanks for the fast shipping Bill 👍. One is going in the collector and one in the DP. DP will be OEM EGT sensor and collector will be a aftermarket k-type unit, just for interests sakes.

    [​IMG]

    Oil return line should be sorted tomorrow, then can start sorting out the DP to meet the exhaust and fit the catcams. Hopefully by then the WG will have arrived.
    Last edited: Jul 12, 2014
  10. voorhees
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    voorhees Moderator Staff Member Moderator

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    Looking good
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  11. badger5
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    badger5 RIP S3dave Site Sponsor

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    phat downpipe :)
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  12. Scullies
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    Scullies Active Member

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    as they would say in South Africa....fokken moerse groot dik downpipe :laugh:
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  13. MIGGZ
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    MIGGZ nanananananananan BATMAN

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    hahahahahhahahahhhahaha i laughed hard at that
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  14. Scullies
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    Scullies Active Member

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    so today proved to be a challenge,

    Installed the cat cams while I wait for the WG to arrive. Removed the stock cams and noticed the same sort of issue Tuffty had with his exhaust lifters. Weird looking markings on the face of the lifters. These were the brand new ones that came with the AEB head.

    [​IMG]

    [​IMG]

    So they have been replaced with the used ones from my AMK head.

    and then...... I decided to check the inlet lifters. I took them all out and found 2 of them had come apart. So I swapped those out for some used one as well. I have no idea how they are coming apart in the engine. It almost like there is too much oil pressure in them and they are popping apart.I cant see how that would happen as there is always pressure on them, between the camshaft and the valve/spring...


    and then.......

    one of the cam cap bolts snapped, it was the last bolt I was making hand tight and it decided to retire. I dont have a easy out screw remover set, so had to make a plan with various tools around the workshop, these are the kind of tools I like to call "multi tools" as they have other functions with a bit of imagination.

    One thing I have noticed, my AEB head has grey coloured cam cap bolts and so does the AGU head. Now my AMK head has black coloured cam cap bolts and so does the BAM and APX heads I have seen. I wonder if they upgraded and don't break so easily.

    I have sent the manifold to get the exhaust flange machined, as it has warped about 1mm from welding.
  15. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    I had a similar experience with my exhaust followers mate...

    [​IMG]

    [​IMG]

    [​IMG]

    <tuffty/>
  16. MIGGZ
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    MIGGZ nanananananananan BATMAN

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    happy pop out yo mama day dude!!!!!! hope you have many many many more boosted miles

    :yahoo::rock::thrashi::beerchug::jester:
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  17. Scullies
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    Scullies Active Member

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    Wastegate finally arrived, 4 days late!!! So thats delayed getting BB back on the road.

    [​IMG]


    At least I got a birthday present ...........

    [​IMG]

    Its all fitted now and started the car, all its ok....for now.
    Still need to make the flexi section from the DP to the exhaust system.
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  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Pics or it didn't happen :)

    <tuffty/>
  19. rupe
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    rupe A3 TQS

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  20. Scullies
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    Scullies Active Member

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    Please refer to post #337 :laugh:
  21. Scullies
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    Scullies Active Member

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  22. rupe
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    rupe A3 TQS

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    ahh ok fair enough, just thought it was worth mentioning :icon_thumright:
  23. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    On the bloody bench is no good!!... need to see it in the bay dude... :D

    <tuffty/>
  24. Chlippo
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    Chlippo Member

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    Do you happen to find spare parts for your s3 in Dubai? I am currently in abu dhabi
  25. Scullies
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    Scullies Active Member

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    Nothing to see here :)

    No parts are available for the S3, but a lot of engine and chassis parts are the same as TT 225
  26. Scullies
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    Scullies Active Member

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    Got my aluminiun vbands in, hope to get the charge pipe welded up in the next few days.

    [​IMG]
  27. badger5
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    badger5 RIP S3dave Site Sponsor

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    mine arrived today too
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  28. Scullies
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    Scullies Active Member

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    so the vband welding was a success. I removed the rubber gasket and clamped the 2 halves of the vband together. Busted out the sanding disc and took the lip and a bit of meat off the compressor outlet. I wanted to slide the vband over the comp outlet .
    Then went and got the vband welded.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    Still have a bit more to do. The 2 silicone couplers will be remove and the charge pipe welded, the DV still needs to find a permanent
    The welds will be smoothed out and painted black.
    The BOV is just temporary, its there so I can drive the car while I sorted out the vband setup.


    [​IMG]
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  29. Scullies
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    Scullies Active Member

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    happiness comes in a can these days :arco:

    [​IMG]

    Charge pipe getting there, slowly... :(

    [​IMG]

    [​IMG]
  30. badger5
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    badger5 RIP S3dave Site Sponsor

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    will the dv cope with the amount of flow it has to bypass?
    listen for chirpy noises when rolling off boost
  31. Scullies
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    Scullies Active Member

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    Yeah, no issues with the boost dump. Its a nice quiet phssssh noise, no squirrels or birds under my bonnet :)
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  32. S3Fanatic
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    S3Fanatic New Member

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    Nice project dude.. Just been reading the entire thread.. If that was my car with all those problems i would sell it.. I also got a strokerkit on my car.. Only problems yet is that my exhaust manifol cracked... Im not sure i if you had the car on the dyno? My stroker engine deliveres 608.9 hp and 666.8 nm... ON MY FWD LOL! Engine is out and im looking for a Yellow S3 like yours to get the quattro so the wheelspin stops on the freeway :D

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