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Dane's Hybrid Conversion Thread

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

  1. Dane
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    Dane Faster than a V12 Q7

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  2. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 12, 2011]
    not for me it is'nt :(
  3. Speedy Steve
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    Speedy Steve Active Member

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    [May 12, 2011]
    Manifold is looking good Bill dont forget mines next!
  4. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 12, 2011]
    #1 & #4 runners attached..
  5. slappy_dunbar
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    slappy_dunbar Let's Do This

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    [May 12, 2011]
    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.
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 13, 2011]
    aye.. ;)

    "lucky" mine is dimensioned from oe specs - hehe

    its still a pia to make.. lol
  7. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    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]
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    [​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
  8. Dane
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    Dane Faster than a V12 Q7

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    [May 16, 2011]
    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!
  9. s3dave
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    s3dave TFSI Hybrid

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    [May 16, 2011]
    Is it up for auction.......:sly:
  10. Welly
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    Welly VX220 SC Driver :)

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    [May 16, 2011]
    As does the volume of metal in your bloodstream....

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

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    [May 16, 2011]
    Looks good Bill glad to see it loks easy enough to bolt onto the turbo unlike the xspower one
  12. Welly
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    Welly VX220 SC Driver :)

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    [May 16, 2011]
    Think that was one of the aims of the game in fairness, the XS one was a complete arse to fit.
  13. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 16, 2011]
    I think that's XS's motto isn't it!
  14. Speedy Steve
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    Speedy Steve Active Member

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    [May 16, 2011]
    Just a shame i dont know what to do about a manifold know
  15. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    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]
  16. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 16, 2011]
    sexy stuff!
  17. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    JBS one when its available
  18. Speedy Steve
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    Speedy Steve Active Member

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    [May 16, 2011]
    I think it will have to be Bill if your not going to make a V3:sob:
  19. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    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]
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    [​IMG]
    [​IMG]
  20. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 16, 2011]
    There's nothing quite like a good flange grinding :whistle2:
  21. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    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 - ;)
  22. s3dave
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    s3dave TFSI Hybrid

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    [May 16, 2011]
    Is that Danes then bill? when you forget about the cursing and cut hands i would be more than interested....:beerchug:
  23. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    Danes one yes.. Wellys oldun refurbished and made into v1.2 hybrid with its clipped turbine wheel.
  24. s3dave
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    s3dave TFSI Hybrid

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    [May 16, 2011]
    No i meant is that Danes manifold?
  25. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 16, 2011]
    I knew what you meant Dave and I know what's going through your head ;)
  26. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    yes.
  27. s3dave
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    s3dave TFSI Hybrid

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    [May 16, 2011]
    :whistle2:

    lol it will be interesting to see his logs with that baby ....
  28. Lee172
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    Lee172 GT3071

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    [May 16, 2011]
    Looking good.. x 2 on the logs!
  29. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    What are you expecting to see from logs. The reference is wellys results.
  30. s3dave
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    s3dave TFSI Hybrid

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  31. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 16, 2011]
    Danes has egt so we will see that..
    remembering remapped normal K04's already hit 920'c egt protection from their 250bhp levels ;)
  32. Dane
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    Dane Faster than a V12 Q7

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    [May 22, 2011]
    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!
  33. Dane
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    Dane Faster than a V12 Q7

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    [May 22, 2011]
    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]
  34. cecilthesausage
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    cecilthesausage ...It's Never Finished...

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    [May 22, 2011]
    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...
  35. Sandip
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    Sandip Well-Known Member

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    [May 22, 2011]
    Looking well :)

    Looks as though Pipewerx has changed their 3"downpipe slightly....
  36. Dane
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    Dane Faster than a V12 Q7

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    [May 22, 2011]
    Haha! Safe to say I barely have any finger prints left from rubbing my hands together
  37. cecilthesausage
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    cecilthesausage ...It's Never Finished...

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    [May 22, 2011]
    We need to get S1LFH to organise a group buy on the mani..... Lol
  38. Dane
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    Dane Faster than a V12 Q7

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    [May 22, 2011]
    I don't think there's anything Bill would rather do less at this point Lol
  39. cecilthesausage
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    cecilthesausage ...It's Never Finished...

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    [May 22, 2011]
    What another mani or do another GB with S1LFH or both lol
  40. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 22, 2011]
    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/>

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