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g60leigh build thread. it's gonna get messy

g60leigh Dec 12, 2013

  1. g60leigh

    g60leigh Well-Known Member

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    Got my modified switch back from Scott.
    Has to be installed without the new knob on first so that can fit the trim.

    [​IMG]

    And the final result with new knob installed.

    [​IMG]

    Only a little difference. But I like it.
     
    Dani_B19 and CMcKenzie like this.
  2. g60leigh

    g60leigh Well-Known Member

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    Today's delivery.
    More stockpile ready for rebuild.

    [​IMG]

    [​IMG]
     
  3. CMcKenzie

    CMcKenzie It's supposed to do that..

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    Liking the headlight dial :icon_thumright:
    Any chance of a link for the bolts for the covers?
    -Callum.
     
  4. g60leigh

    g60leigh Well-Known Member

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    No problem. Here you go - http://bit.ly/194DcVj
     
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  5. g60leigh

    g60leigh Well-Known Member

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    Opinions / advice time please.
    The hybrid turbo I am fitting has an actuator installed. Which I presume will be uprated in some way to match the turbo. I also have a forge actuator in my pile of parts waiting to be fitted.

    Should I stick with the one installed or stick on the forge one?
     
  6. superkarl

    superkarl MAN OF STEEL

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    The top hybrids are using a 12or 14psi actuator. So test them. Or speak to Dan and see if he will set one up for you.
    Saying that I think you can open the forge yourself and change springs.
     
  7. g60leigh

    g60leigh Well-Known Member

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    Forge one can be opened with a few Alan keys. I have messaged them to ask which spring matches my hybrid.
     
  8. superkarl

    superkarl MAN OF STEEL

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    Forge or CR? Like either of them will have a jar of glue.
    Look back to all the forums hybrid builds, they have 12psi+ actuators.
    holds power and torque longer in rev range.
    Stiffest you can get away with is what you want.

    I'm sure bill or Dan will chime in and tell a similar story
     
    g60leigh likes this.
  9. g60leigh

    g60leigh Well-Known Member

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    Max boost (according to their web advert) is 24-26 psi.
    Hopefully someone will keep me right.

    I've found forge to be helpful in the past but wether they can help with the tech info, I don't know.
     
  10. superkarl

    superkarl MAN OF STEEL

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    You need to do some fursther reading on that hybrid of yours. Vs what they advertise as marketing spiel
     
  11. g60leigh

    g60leigh Well-Known Member

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    Found a club gti thread on one. Did Bill and Welly do a build with one.
     
  12. superkarl

    superkarl MAN OF STEEL

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    Yeh and Dane, and Steve.
    They used to be the best you could get till people started fannying with them.
    Bill used to get one built to his own spec tho because of inconsistencies, so it became common for people to order a badger5 CR hybrid.

    The description is abit ambiguous but its a 2283/rs6 hybrid isn't it.
     
  13. g60leigh

    g60leigh Well-Known Member

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    The one I have is a turbo dynamics MD421:

    MD421 - Stage 4 Hybrid turbo comprises:

    High Flow K06 Billet Aluminium Lightweight Compressor Wheel
    Re-profiled compressor housing
    Turbo Dynamics designed uprated 360 degree thrust kit
    K04 Large trim turbine wheel with lightening modifications for quicker response
    Re-profiled turbine housing to suit new turbine wheel
    Turbocharger fully blueprinted to motorsport standards
    Max recommended boost: 24-26 PSI
    Estimated Power Output: 340-360 bhp with correct supporting modifications

    I'm more and more intrigued to see what this will do with the mods I have.

    I'm also getting my relentless down pipe ported with massive help from S3Dave.
     
  14. Gops

    Gops Badger 5 Edition VCDS Map User Gold Supporter Audi S3

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    Mines 16 psi actuator, max boost we went was 21-22 psi. More was just converting to heat! Good thing was the b5 mani didn't glow like the relentless!
     
  15. YSN

    YSN Member

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    So what does the Haldex controller do?
     
  16. superkarl

    superkarl MAN OF STEEL

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    Ahhh I thought it was a CR one.
    Didn't that guy Jimgrim have that hybrid? Guy with the Ming blue s3, think he's sold up now
     
  17. g60leigh

    g60leigh Well-Known Member

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    Best explanation stolen from web

    The sophisticated Haldex based all wheel drive system used in the VW R32 and Audi TT Quattro monitors throttle input, ABS wheel speed sensors, steering angle, etc to anticipate and distribute torque transfer from the engine to the driveline.

    Specially prepared Haldex control units are able to alter the time in which the system reacts to these dynamic changes and and how it reacts to them; creating more favourable or aggressive handling characteristics.

    This upgrade increases torque transmission at acceleration providing consistent performance with increased over-steer. The torque-transmission is influenced by how fast you press the accelerator down. The Haldex system can transmit torque before the engine delivers torque. At greater speeds the torque will decrease enabling less over-steer and safer driving properties.

    The advantages of this HPP upgrade are it’s ability to predict the onset of torque. This upgrade takes into account the TPS signal more so than the OEM software and therefore can proactively begin applying power to the RWD clutch packs before wheel spin begins. As power is increased, more power lock occurs in the RWD unit until full lock is achieved. To summarize, the new HPP is more aggressive with how it transfers power and does so much more proactively than the OEM system. This is ideal for autocross, road racing, and street driving as well as enhancements to poor weather driving.
     
    YSN likes this.
  18. g60leigh

    g60leigh Well-Known Member

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    Is yours a TD too Gops?
     
  19. Gops

    Gops Badger 5 Edition VCDS Map User Gold Supporter Audi S3

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    BBT mate
     
  20. g60leigh

    g60leigh Well-Known Member

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    Does anyone happen to have a list of gaskets I'm best to change while changing the turbo, is also worthwhile getting new oil lines for the turbo or am I fine to reuse mine?
     
  21. vroomtshh

    vroomtshh Active Member VCDS Map User

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    Are you fitting a new manifold?
     
  22. g60leigh

    g60leigh Well-Known Member

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    I already have a V2 relentless manifold fitted along with V3 3" downpipe and sport cat and Milltek exhaust.
    The inlet is standard small port but with a phenolic gasket.
     
  23. vroomtshh

    vroomtshh Active Member VCDS Map User

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    [​IMG]

    You need items 2, 5, 6, 7, 8 & 9
     
    g60leigh likes this.
  24. g60leigh

    g60leigh Well-Known Member

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    Thank you. Trip to tps is in order. Pick up a couple of oil filters and some oil too for the rods running in.
     
  25. S3 Paul

    S3 Paul Well-Known Member Regional Rep

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    I have this turbo fitted on my car...
    I think what it will do is very much down to who map's it,
    I think 360 is well over what you will see though,
    I need a manifold and possibly WMI to see the best of mine though.
     
  26. g60leigh

    g60leigh Well-Known Member

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    Not expecting 360 (but it would be nice) already have the manifold and WMI so on the right path
     
  27. g60leigh

    g60leigh Well-Known Member

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    Vroomtshh can you send me a higher res pic please mate. I cannot make out the part no's
     
  28. g60leigh

    g60leigh Well-Known Member

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    Latest news is car is off the road with clutch problems. Less than a month after changing it all.
    Gear selection is fine with engine off. With engine on I cannot get reverse at all and the others are very difficult to engage. If I get it in first and sit with clutch fully depressed it creeps forward still.
    So obviously it's not fully disengaging.

    Hopefully it will be something like needing bleeding. But knowing my luck it will be something more expensive.

    My IE rods have landed in the UK just waiting for them to be delivered or the tax bill to arrive.
     
  29. superkarl

    superkarl MAN OF STEEL

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    Was the release bearing changed?
     
  30. g60leigh

    g60leigh Well-Known Member

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    Yeah that's part of the slave cylinder in these isn't it? That was done with a genuine LUK part.
     
  31. superkarl

    superkarl MAN OF STEEL

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    Yeh
    Maybe it just needs bleeding. Or you have a leak
     
  32. g60leigh

    g60leigh Well-Known Member

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    Really hope its something as simple as that. Is it just bled from the front of the master cylinder?
     
  33. g60leigh

    g60leigh Well-Known Member

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    Would an air leak cause this? Found a split in pipe near master cylinder.
     
  34. g60leigh

    g60leigh Well-Known Member

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    Bottom hose (90 degree bend) in pic was hissing air.
    [​IMG]

    Done a Sunday no parts available fix with black silicone.

    Is this a possible cause for the clutch problem? Anyone able to identify the part for me to get a replacement?

    Cheers.
     
  35. g60leigh

    g60leigh Well-Known Member

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    Few more pieces finally arrived

    [​IMG]
    Hopefully get clutch sorted at weekend and can then get started putting all of these in.

    Also got this as it was cheap and hopefully make it easier moving around my garage.
    [​IMG]
     
  36. g60leigh

    g60leigh Well-Known Member

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    Clutch fault turned out to be.
    The mechanic hadn't tightened the bolts on the pressure plate. This coming loose has meant that pressing pedal has bust seals in the slave cylinder.

    Anyway I have finally got it back today. Only had time for a very quick blast but big grins again.
    Plan on getting my haldex blue fitted end of the week or next weekend.
    Will then have a few weeks enjoying the car again and then...

    It will be off for its open heart surgery.
     
    Scullies likes this.
  37. Scullies

    Scullies Well-Known Member

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    My general rule, weld or loctite any important bolts :)
     
    g60leigh likes this.
  38. Westy

    Westy Well-Known Member

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    I'm sure my clutch kit came with a little sachet of something similar to loctite for the pressure plate bolts :think:
     
  39. g60leigh

    g60leigh Well-Known Member

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    Not sure if it did or didn't. I don't remember seeing one but it could of been in there.

    I actually think that he hadn't even tightened them though.

    All working now anyway. Onward and upward.
     
    Westy likes this.
  40. Adam P

    Adam P Active Member

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    Cheers for this will be ordering them to finish off my engine bay tidy up.

    Nice thread, will be keeping an eye on this one for sure!
    Hopefully, you received the bits i sent by now....
     

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