1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Dane's Hybrid Conversion Thread

Discussion in 'A3/S3 Forum (8L Chassis)' started by Dane, Apr 11, 2011.

  1. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

    Joined:
    Nov 11, 2009
    Messages:
    4,049
    Likes Received:
    148
    Nice, this week is draggggggggggging!
     
  2. Google AdSense Guest Advertisement



    to hide this advert.
  3. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    not for me it is'nt :(
     
  4. Speedy Steve

    Speedy Steve Active Member

    Joined:
    Nov 14, 2008
    Messages:
    1,258
    Likes Received:
    15
    Manifold is looking good Bill dont forget mines next!
     
  5. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    #1 & #4 runners attached..
     
  6. slappy_dunbar

    slappy_dunbar Let's Do This

    Joined:
    Jan 2, 2010
    Messages:
    245
    Likes Received:
    20
    Tell me about it. 18months in and I still don't have one which doesn't blow through its gaskets. The outlet to turbo MUST conform to OE dimension, or else the gaskets rupture. 43mm tops.
     
  7. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    aye.. ;)

    "lucky" mine is dimensioned from oe specs - hehe

    its still a pia to make.. lol
     
  8. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    pix of prototype k04 mani..
    we will see how it fares..
    not an ecconomic thing to make........ so dont expect many/any more......

    enjoy.. (I know I have'nt)
    tacked and test fitted in the bay.. This is V2 already..!
    [​IMG]

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Collector
    [​IMG]
    [​IMG]

    Respect to those peeps who make tubular exhaust mani's - they are a huge amount of time to do.
    Yes this is a 1st off/probably one off, and the iterations to get pipes to clear the k04 turbo are a massive PIA... and time consumer.

    anyhows.. Its bigger bore than OE, consistent bore through the runners, and a combination of 1.25" and 1.5" sch10 - 316L pipe fittings. Runners in 1.25" sch10, collector & joiner to #3 & #4cyl in 1.5" sch10.

    Phew.. had enough of weldinh stuff for a while..
    plenty of metal splinters embedded in my hands and fingers.. doh!

    the plot thickens
     
  9. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

    Joined:
    Nov 11, 2009
    Messages:
    4,049
    Likes Received:
    148
    Woop, cheers for the update Bill, might pop across this evening to have a nosey if thats ok. As said before I can't wait to see how it turns out!
     
  10. s3dave

    s3dave TFSI Hybrid
    Supporter

    Joined:
    Nov 11, 2009
    Messages:
    10,120
    Likes Received:
    732
    Is it up for auction.......:sly:
     
  11. Welly

    Welly VX220 SC Driver :)

    Joined:
    Aug 5, 2009
    Messages:
    10,699
    Likes Received:
    120
    As does the volume of metal in your bloodstream....

    Looking good dude, very good in fact, hats off for the work gone into it.
     
  12. Speedy Steve

    Speedy Steve Active Member

    Joined:
    Nov 14, 2008
    Messages:
    1,258
    Likes Received:
    15
    Looks good Bill glad to see it loks easy enough to bolt onto the turbo unlike the xspower one
     
  13. Welly

    Welly VX220 SC Driver :)

    Joined:
    Aug 5, 2009
    Messages:
    10,699
    Likes Received:
    120
    Think that was one of the aims of the game in fairness, the XS one was a complete arse to fit.
     
  14. Westy

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,358
    Likes Received:
    1,007
    I think that's XS's motto isn't it!
     
  15. Speedy Steve

    Speedy Steve Active Member

    Joined:
    Nov 14, 2008
    Messages:
    1,258
    Likes Received:
    15
    Just a shame i dont know what to do about a manifold know
     
  16. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    some comparisons:
    K04 vs this prototype I've made

    Some Design aspects I wanted to preserve, having seen and handled a "few" other manifolds.
    1. It has to be bolt onto cyl head without use of "special" spanners. All fixings are easily reached with simple extension bar and socket.
    2. The turbo bolts must be accessible.. from the top.. This will use M10 Cap screws not stock bolts.. Stock bolts will fit but their heads and associated sockets are too big.. and they round pretty easy.
    3. Runners, need to be minimum port size and maintained throught their run to turbo
    4. Standard size OE exhaust gasket is utilised, not anything too large where gaskets are unavailable.

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  17. Westy

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,358
    Likes Received:
    1,007
    sexy stuff!
     
  18. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    JBS one when its available
     
  19. Speedy Steve

    Speedy Steve Active Member

    Joined:
    Nov 14, 2008
    Messages:
    1,258
    Likes Received:
    15
    I think it will have to be Bill if your not going to make a V3:sob:
     
  20. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    fitted with hybrid fitted (which needed to be clocked as it was'nt like std anyhow)
    PipeWerx dp shown.
    xs power one will need flange grinding (but dont they all!)


    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  21. Westy

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,358
    Likes Received:
    1,007
    There's nothing quite like a good flange grinding :whistle2:
     
  22. Google AdSense Guest Advertisement



    to hide this advert.
  23. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    making another will be expensive - unless it can be copied in a low cost country the hours req'd to make this vs what people are prepared to pay...... is the question...

    pay enough and another can be made - ;)
     
  24. s3dave

    s3dave TFSI Hybrid
    Supporter

    Joined:
    Nov 11, 2009
    Messages:
    10,120
    Likes Received:
    732
    Is that Danes then bill? when you forget about the cursing and cut hands i would be more than interested....:beerchug:
     
  25. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    Danes one yes.. Wellys oldun refurbished and made into v1.2 hybrid with its clipped turbine wheel.
     
  26. s3dave

    s3dave TFSI Hybrid
    Supporter

    Joined:
    Nov 11, 2009
    Messages:
    10,120
    Likes Received:
    732
    No i meant is that Danes manifold?
     
  27. Westy

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,358
    Likes Received:
    1,007
    I knew what you meant Dave and I know what's going through your head ;)
     
  28. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    yes.
     
  29. s3dave

    s3dave TFSI Hybrid
    Supporter

    Joined:
    Nov 11, 2009
    Messages:
    10,120
    Likes Received:
    732
    :whistle2:

    lol it will be interesting to see his logs with that baby ....
     
  30. Lee172

    Lee172 GT3071

    Joined:
    Jul 20, 2010
    Messages:
    431
    Likes Received:
    2
    Looking good.. x 2 on the logs!
     
  31. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    What are you expecting to see from logs. The reference is wellys results.
     
  32. s3dave

    s3dave TFSI Hybrid
    Supporter

    Joined:
    Nov 11, 2009
    Messages:
    10,120
    Likes Received:
    732
    The EGTS.....
     
  33. badger5

    badger5 www.badger5.co.uk
    Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    8,076
    Likes Received:
    1,073
    Danes has egt so we will see that..
    remembering remapped normal K04's already hit 920'c egt protection from their 250bhp levels ;)
     
  34. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

    Joined:
    Nov 11, 2009
    Messages:
    4,049
    Likes Received:
    148
    So update time,

    The manifolds on and the turbos on! (not as straight forward as it sounds)

    The milltek is in position, the injectors are in, the wiring has been repaired to the abs sensor, the n249 has been deleted and Bill is currently putting everything back together then it's mapping and water meth time!
     
  35. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

    Joined:
    Nov 11, 2009
    Messages:
    4,049
    Likes Received:
    148
    Not a lot to take pictures of,

    But this is the milltek, some pretty big tail pipes, bigger than I remember - pretty cool though

    [​IMG]

    [​IMG]
     
  36. cecilthesausage

    cecilthesausage ...It's Never Finished...

    Joined:
    Jul 20, 2010
    Messages:
    933
    Likes Received:
    112
    Lookin good Dane... Lookin good bet you can't wait can ya... Just like your first Christmas... Lol... Waiting for Bill to come down the chimney with his big sack lol...
     
  37. Sandip

    Sandip Well-Known Member

    Joined:
    Nov 7, 2006
    Messages:
    2,424
    Likes Received:
    76
    Looking well :)

    Looks as though Pipewerx has changed their 3"downpipe slightly....
     
  38. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

    Joined:
    Nov 11, 2009
    Messages:
    4,049
    Likes Received:
    148
    Haha! Safe to say I barely have any finger prints left from rubbing my hands together
     
  39. cecilthesausage

    cecilthesausage ...It's Never Finished...

    Joined:
    Jul 20, 2010
    Messages:
    933
    Likes Received:
    112
    We need to get S1LFH to organise a group buy on the mani..... Lol
     
  40. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

    Joined:
    Nov 11, 2009
    Messages:
    4,049
    Likes Received:
    148
    I don't think there's anything Bill would rather do less at this point Lol
     
  41. cecilthesausage

    cecilthesausage ...It's Never Finished...

    Joined:
    Jul 20, 2010
    Messages:
    933
    Likes Received:
    112
    What another mani or do another GB with S1LFH or both lol
     
  42. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

    Joined:
    Sep 14, 2008
    Messages:
    17,804
    Likes Received:
    2,217
    Yep... it was not the most entertaining afternoon but I can now see how to get a K04 off with the head in place... I look like I have been self harming by the state of my forearms lol...

    Amen to that brother!!!

    <tuffty/>
     

Share This Page