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BAM S3 full rebuild for Hybrid or BT

Discussion in 'A3/S3 Forum (8L Chassis)' started by hoffmanvp3, Sep 18, 2013.

  1. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Dec 7, 2013]
    Well look what turned up while I was in Saudi:)
    BBT Hybrid KO4
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    Just waiting for a Relentless V3 exhaust manifold to come up for sale if any one knows one:)
  2. Jason.s
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    Jason.s Active Member

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    [Dec 10, 2013]
    Probably dirtier than the one that came off!
  3. IH786
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    IH786 Member

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    [Dec 10, 2013]
    I have a Relentless V2 (better than v3) for sale if you are interested - pm me :)
  4. s3gazz
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    s3gazz Active Member

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    [Dec 10, 2013]
    V3s don't **** tho also make great power with them too
  5. s3gazz
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    s3gazz Active Member

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    [Dec 10, 2013]
    Don't want to be taking that head off again
  6. Prawn
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    Prawn My other car is a MINI!!!!

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    [Dec 10, 2013]
    Surely the sensible choice for anyone fitting a ko4 of any type in the near future is to wait for Bills new manifold in the new year?

    It's only a few weeks away, and hopefully will be the answer we've all been looking for!
    chaz20vt likes this.
  7. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Dec 10, 2013]
    Prawn that's my plan as I didn't know Bill had one being developed while I was on the hunt for a V3
  8. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Dec 10, 2013]
    eh?
  9. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Dec 10, 2013]
    [​IMG]
    Westy likes this.
  10. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Dec 10, 2013]
    Bill you tease lol. That's the only thing I'm waiting on to fit my Hybrid:(
  11. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Dec 13, 2013]
    Well a little update.
    B5 V2.2 TIP install and replacing the old OCC system.
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    And all finished
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  12. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    Well its been a while since i updated this Thread so here is the run down.
    (Moderators my web browser keeps crashing so getting bored of copying all this over and over again so am posting in multiple pages, I'm not trying to get my post count up lol cheers)

    Ive put the RS4 alloys onto the Skud missile (Mk1 octavia 4x4 1.8t on Shark stage1 map) for those who dont know it and got me some Rota Grid Drifts 9.5X18" all round with 225 yokohama Parada Spec2 rubber and it stretches bang on for the Stance point of view.
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    Needed spacers tho running a 9.5 lol
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  13. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    Also fitted Bills High flow cast mani with large port mod and BBT stage4 hybrid KO4 also with large port mod.
    Here is the large ported stage4 Hybrid vs oem
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    Bills ported section KO4 vs oem KO4
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    And Bills large ported mani vs oem
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  14. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    Did have some problems with the EGT port not being machined correctly, basically the port was drilled too deep and didn't allow the crush washer on the egt probe to be held tight so a M5 copper washer takes up the slack and holds the probe secure.
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    You can fit the turbo and mani with the head on but seeing as i run the ARP stud kit for the main and head it`ll only cost me a gasket to pull the head as you can reuse the stud kit and its a ****e load easier to complete.
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    And a small tip...make sure the wells are dry for the head bolts as if there's fluid like oil or coolant in the well the bolts when torqued down will pressurize the fluid and crack the block, with a stud kit its not so much a problem as the stud is only screwed in hand tight.
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    Alingment marks for the 3" down pipe to clear the prop damper and dp flexi joint, this was a feeker as the Pipe Werx didn't have elongated bolt holes for the KO4 hot side to the dp flange the first time i fitted every thing back together and was rubbing:( but all solved with a bit of a CNC and jiggery pokerie lol
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    Nuns **** for clearance springs to mind, would appear the new mani has brought the dp over to the right a couple mm and was rubbing the first time i fitted every back together but this is as best as i can get without making a custom spacer gasket for the KO4 hotside to dp flange to push it back over to the left where it was before.
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    So the Blocks back together.......for now lol (bigger plans to come)
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    Last edited: Apr 20, 2014
  15. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    Now to replace that tiny front mount intercooler as its way way to small for the flow i`ll be producing lol.
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    Most people mount the fmic on the slam panel but looked shoody to me so I made a custome frame to carry the new Monster fmic
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    And then to pressure test for leaks.
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    My Custom boost system testers
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    And the frame made fitting the bumper back a piece of cake but did take a while with finding the best position.
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    snowy and Westy like this.
  16. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    Still to wire up the Water Meth Injection and weld on the injector bung onto the fmic exit elbow tho, half way through it now but off shore in Saudi doesn't help
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    Also vcds flagged up a DTC not supported or comms error with the Haldex coupling for the Quattro system and found this, a snapped Haldex earth strap due to corrosion.
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    And surprise surprise the Skud missile had the same error message and snapped earth strap, once sorted the DTC clears:)
    Easy to fix with a batt earth cable wrapped in electrical tape, this is the Skuds below, the rusty exhaust kinda gives it away and different back box but who`s being picky anyway lol.
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    Also heat wrapped the 3" down pipe and sports cat, even tho i soaked it in water over night it still itched the ****e outta me lol
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    snowy likes this.
  17. daz-20vt
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    daz-20vt Well-Known Member

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    [Apr 20, 2014]
    Looking really good mate!! Very interested in this keep the updates coming!!!
    Whens it being mapped?
  18. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    Well that's the problem...Bills backed up till June and i work offshore a lot and don't get much in notice nor is it rotation by any means least so its basically who ever can fit me in next month, be it Shark, Niki, or just wait for Bill, but i`ll just get bored at looking at a S3 i cant really drive on actuator and probably pull the engine and re-bore / stroker it while i wait for bill lol.......who knows
  19. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 20, 2014]
    stroker ftw :)
  20. Sam_
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    Sam_ Down under

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    [Apr 20, 2014]
    Do you not have a 1 way (check) valve on your brake booster/servo hose?
  21. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    Nope, been meaning to get a new one but hasn't been a cause for concern
  22. Sam_
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    Sam_ Down under

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    [Apr 20, 2014]
    Interesting. I guess there must be one built into the servo...
  23. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    Don't tempt me Bill lol
    I do have a wedding to save up for, been politely reminded lol
  24. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Apr 20, 2014]
    The Mk1 TT hasn't got one iirc
  25. vroomtshh
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    vroomtshh Active Member VCDS Map User

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    [Apr 20, 2014]
    You've got one up behind the bulkhead heatshielding
  26. Miguel_S#
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    Miguel_S# Member

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    [Apr 21, 2014]
    Really nice work, congratulations.
    Probably you will have the engine with more power with a hybrid.
    Last edited: Apr 21, 2014
    hoffmanvp3 likes this.
  27. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Aug 21, 2014]
    Haven't updated my ASN in quite a while so here goes..

    Just before the Badger5 trip was thinking it'll be wise to uprate the brakes as the standard ones are ok if your grannies driving but not for what I have in mind lol
    So that being said a nice set of D3 360mm 6pot set up shall suffice:)
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    Didn't take long to bed in, running fast road pads as not planning on sending her into a track day gravel trap lol
    And coming from my Mk1 Octavia 4x4 1.8t20v which already has the S3 brake upgrade I almost put myself through the S3 wind shield when using the new brakes for the first time lmao.
    And when I go back to the Octy I barely stop due to the little brake travel required in the S3, so a little caution required me thinks.
  28. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Aug 21, 2014]
    In addition to installing the wmi kit i've installed a pressure gauge post solenoid valve to confirm what pressure the water meth pump is running at for tweaking during mapping as standard setting iirc is 200psi. it can go as low as 150psi or as high as 250psi.

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  29. kwistof
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    kwistof South East Events Moderator Regional Rep

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    [Aug 21, 2014]
    Lovin the 2 piece goodness, not even heard of that set up for the S3 tbh.
  30. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Aug 21, 2014]
    So the Badger5 trip begins, now most people would drive there car down for mapping but due to fitting the Hybrid KO4 without a map I was running off actuator pressure as I've disconnected the N75 valve as I didn't want to damage the motor but this almost makes the car very difficult to over take etc etc so hired a self drive transporter and used there clutch so to speak lol

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    Took the missus with me as I had booked us a nice little hotel in the Cotswolds as I was due to treat the missus from all the time I spent away off shore and working on the S3 car and other customers so quite literally 2 birds with 1 stone, as this'll give Bill plenty time to up rev his mani and map and do some making up to the missus:)

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    Very happy with the end results, but wasn't easy due to the rr being 30+C and having to wait for the motor to cool, even with water meth and 3 massive fans and Mark spraying water on the huge fmic. Very interesting point Bill pointed out was the brand of water meth I was using which is just VAG concentrate screen wash which claims to be up to 49% meth 49% water and rest cleaner and fragrance. Not idle due to the heat of the rr so Bill made up his own water meth mix which is virgin grade meth 99.85 or there about's and a little of the stuff I had supplied for colour and she accepted another 2 more degrees of timing and another couple bhp but also ait's and egt's respectively.
    Consequently I know make up my own mix from a local supplier of 99.85% meth and it really does make a difference running proper meth.
    By no means am I slagging the company that supplies lots of people across the UK with there own water meth mix as it does do a good job but there's always room for improvement but at the end of the day its a compromise.


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    And here is the proof of Bills v2 mani producing the goods...low egt's VS power on the highest map 347BHP

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    865-885'c typically peak and after 3 back to back runs, just crept into 900'c compare that with other set-ups and stage 1&2 std k04 cars which will be getting to the egt protection threshold if 920 frequently whilst making considerably less power, all credit to Bills mani:)

    So 347BHP and 296FtIbs which i very pleasing from all the hard graft, particularly that the BAM is still on standard bore @ 116K just with new rings.
    Bills rr is very conservative with power, in particular the torque which looks a little low (realistic -16% than actual) but on the road there's no shortage of it lol.

    So I leave with 5 map selectable software and really makes this a proper B road weapon
    Last edited: Aug 21, 2014

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