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g60leigh build thread. it's gonna get messy

Discussion in 'A3/S3 Forum (8L Chassis)' started by g60leigh, Dec 12, 2013.

  1. coatesy
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    coatesy poking badgers with spoons

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    [May 3, 2014]
    Yes mate got it sorted set us back half a day like. All is good!
  2. g60leigh
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    g60leigh Well-Known Member

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    [May 3, 2014]
    Cool beans. Little bar stewards have no idea how much of a PITA taking a 50p bolt causes.
  3. coatesy
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    coatesy poking badgers with spoons

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    [May 3, 2014]
    Exactly, funny enough it was a 54p bolt, and the other I had one in my bag that was the same.
  4. g60leigh
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    g60leigh Well-Known Member

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    [May 18, 2014]
    It's getting close .......
  5. g60leigh
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    g60leigh Well-Known Member

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    [May 21, 2014]
    Been speaking to Coatesy and he says that tonight he should be adding oil and firing it up
    s3dave and ScottD3 like this.
  6. g60leigh
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    g60leigh Well-Known Member

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    [May 21, 2014]
    It lives....
    Just got to run in on actuator pressure now
  7. g60leigh
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    g60leigh Well-Known Member

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    [May 23, 2014]
    Quick one. Picking it up this afternoon. Taking vcds with me.
    What is worth logging on my run home?
  8. g60leigh
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    g60leigh Well-Known Member

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    [May 23, 2014]
    Got it home all safe and sound. Feeling very strong and wanting to pull. It's really hard to keep it under 3K rpm.

    Gonna change the oil tomorrow ready for the arduous 500 mile run in.

    Preparing a few other bits ready for the mapping.

    ImageUploadedByTapatalk1400873664.439052.jpg
    A mocal oil cooler I've picked up nice and cheap.

    ImageUploadedByTapatalk1400873729.441678.jpg
    My uprated fuel pump ready to go.
    Relay all wired and tested (thanks for the wiring help Mr Prawn)

    Now going to look at uprating the pipework to the intercooler. I currently have a Ver1 AH Fabrication intercooler.
    Looking at getting the larger ends welded on and the larger pipework throughout.

    Going to have another look through the sticky post but its a bit of info overload so if anyone knows what pipes I need I would seriously appreciate the heads up
    Prawn and Adam P like this.
  9. g60leigh
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    g60leigh Well-Known Member

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    [May 25, 2014]
    Busy morning. Done as much as I can with my glass back.
    Oil changed and nice quantum stuff out in.
    Metallic oil-
    ImageUploadedByTapatalk1401019925.998413.jpg
    ImageUploadedByTapatalk1401019938.015160.jpg

    Fitted my larger 19mm inlet oil catch can-
    ImageUploadedByTapatalk1401019970.468791.jpg
    Will get a coat of black paint now I am happy with the fit.

    And re fitted all my covers using the stainless countersunk fittings
    ImageUploadedByTapatalk1401020045.407068.jpg

    Also started to run wiring for the up rated fuel pump.
    I need to work out which of the lines in the engine bay is the fuel feed so I can add inline filter.

    I've been ordering more bits too.
    I've ordered all the new alloy bends and silicone bits to enlarge the intercooler pipework.
  10. g60leigh
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    g60leigh Well-Known Member

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    [May 29, 2014]
    [​IMG]

    Few more parts of the puzzle arrived today.
    Just waiting on the last hose and the hi grips and can rip the front off to mock it up and take the inter cooler somewhere to have the new ends welded on.

    Managed to fit the uprated fuel pump the other night. No pics and Prawn has well covered it and I didn't take my phone out to it. the only difference being I have also installed an inline fuel pressure gauge in the engine bay so I can keep an eye on things. Mainly just because I had one in my tool box.

    Making final arrangements to get it off to mapping now.

    Current to do list -
    Fit uprated cooler pipe work
    Fit oil cooler
    Rack up 500 running in miles
    MAPPING
    Prawn likes this.
  11. Adam P
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    Adam P Active Member

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    [May 29, 2014]
  12. g60leigh
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    g60leigh Well-Known Member

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    [May 30, 2014]
    My instructions for running in are/were-
    Bring car home and change oil out.
    Fill with quantum fully synth.
    Run for 500 miles off boost / under 3K revs. (N75 is unplugged)

    Got to be honest. This is confusing the hell out of me with so many differing opinions on process.

    I'm concerned about running it lean if running hard as some people prefer.
    Especially as it's now a larger capacity with the 83mm pistons and running the hybrid turbo.

    Yeah hoses may look a little familiar mate. Not using the brackets as it happens though. Sticking with my current core.

    Figures wise. I have never really chased bhp figures always rated on the drive and feel. But ...
    According to bumf from turbo its good for 320 with map and exhaust. I am hoping to exceed that comfortably with all of the other mods and capacity increase.
  13. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 30, 2014]
    Don't go fully synth for the running in process... use mineral... change to fully synth at the 500 mile mark...

    Don't get hung up on keeping it under 3k either... you need to load the engine up to force the rings to wear in... thats the point of running in... its to bed the rings in to get a good seal in the cylinders... fully synth is designed to prevent wear... not much use if you are trying to promote it....

    Don't rev above 5k realistically but make sure you get on boost (N75 disconnected is fine, you will have actuator pressure)... boost will increase cylinder pressures and help force the rings to bed in...

    You ideally just need to roll boost in... I did my initial running in on the dyno (well, Bill did lol), dumped the oil (mineral) and used mineral until around the 500 mile mark then dumped again for fully synth... make sure you change the filter each time too

    <tuffty/>
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  14. Adam P
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    Adam P Active Member

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    [May 30, 2014]
    That's how i was initially going to run my engine in before speaking to tufty, who has advised me otherwise and to be honest after investing the money in the rebuild i wouldn't want to run it in incorrectly, i would be devastated! Here is the link for the running in oil tufty reccommended :

    TRIPLE QX 15w40 Mineral Engine Oil 5Ltr
    g60leigh likes this.
  15. g60leigh
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    g60leigh Well-Known Member

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    [May 30, 2014]
    Ok guys. Will pick some up from euro car parts today and swap back out.
    Will call at TPS too and pick up some more fully synth for the 500 mike change.
  16. Prawn
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    Prawn My other car is a MINI!!!!

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    [May 30, 2014]
    Who built the engine Leigh?
  17. g60leigh
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    g60leigh Well-Known Member

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    [May 30, 2014]
    Coatesy and his mate Roy built it up mate.
  18. Prawn
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    Prawn My other car is a MINI!!!!

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    [May 30, 2014]
    Ah, I see.

    The running in info is bad :(

    Tufftys advice is proper. Although personally, I'd also ignore the 5k limit :laugh:
  19. g60leigh
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    g60leigh Well-Known Member

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    [May 30, 2014]
    What would you do with Rev's mate? Redline all the way
  20. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 30, 2014]
    Don't confuse the poor bugger Nick lol...

    Ok... you don't have to keep it below 5k for the whole run in period... I assume its just to bed rings in to honed (not rebored) cylinders?...

    In fairness... mine was run up to 7k rpm (not redline as mine is 7.8k rpm) after the initial bedding in on the dyno but I didn't rev her out too often on the fresh mineral oil until I had a couple of hundred miles on the clock... that was my preference

    If you need or do take it over 5k occasionaly its not gonna hurt... the tell on mine was the catch can/PCV breathing... its got noticeably less as I hit 200 miles... this was due to the rings sealing better and getting less blow by in the cylinders...

    <tuffty/>
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  21. Prawn
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    Prawn My other car is a MINI!!!!

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    [May 30, 2014]
    Just listen to Tuffty Leigh, I'm only here to cause touble :racer:
    g60leigh and <tuffty/> like this.
  22. g60leigh
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    g60leigh Well-Known Member

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    [May 30, 2014]
    I've got some more mineral oil and new filter. Will change back over today/tomorrow.

    Job sussed.

    Now. Meth or no meth lol.

    Does anyone know anywhere doing the weld in bosses for the WMI nozzle to cooler pipework?
  23. coatesy
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    coatesy poking badgers with spoons

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    [May 30, 2014]
    not really, ran my engine in like that and its strong plus reliable. its just all myths tbh. each to there own i guess...
  24. g60leigh
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    g60leigh Well-Known Member

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    [Jun 6, 2014]
    Running in miles nearly completed.
    Car goes off for mapping on Monday.

    Its running well at the minute without the map. Feeling strong.

    Had a visit from @udi A3 Tom this afternoon. Swapped my clocks over with another set so now have all of my DIS displaying again. No annoying lines of blankness
    [​IMG]

    Which will be nice ready for my new sat nav coming. Decided to finally go RNS-E for a bit of a more modern feel. I'm hoping it will still display the directions on the DIS?

    Finally today I have done a bit of a DIY Bodge contraption.
    [​IMG]
    Would anyone like to hazard a guess as to what it is?
  25. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Jun 6, 2014]
    To collect oil?
  26. g60leigh
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    g60leigh Well-Known Member

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    [Jun 6, 2014]
    Yup. After last oil change I managed to dump near enough 4L of quantum on my drive.
    bigray likes this.
  27. g60leigh
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    g60leigh Well-Known Member

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    [Jun 10, 2014]
    Car coming back from mapping.



    BUT.......

    It's coming home on a trailer.
    As yet un diagnosed knock on the top end so Rick not happy to map it until it's sorted.

    F@?%€¥%g sick now.
  28. Adam P
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    Adam P Active Member

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    [Jun 10, 2014]
    Sorry to hear this mate! Im hopefully firing mine up for the first time on Wednesday if everything goes to plan, which it never does!
    Any ideas on what it could be? Whats your next action plan?
  29. g60leigh
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    g60leigh Well-Known Member

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    [Jun 10, 2014]
    Passing it back to engine builders is really my only option. Let then look at it and see what's up.
  30. Adam P
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    Adam P Active Member

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    [Jun 10, 2014]
    You will get there in the end, fair play to the mapper holding off, could have been even more costly.
    Good luck and keep us posted, surely you have some sort of receipt or invoice for the works?
  31. g60leigh
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    g60leigh Well-Known Member

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    [Jun 10, 2014]
    One of the forum lads did all the work. He going to check it over once I get it home.
    Adam P likes this.
  32. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Jun 10, 2014]
    Did you just drop a head in mate or had it rebuilt?
  33. g60leigh
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    g60leigh Well-Known Member

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    [Jun 10, 2014]
    Coatesy rebuilt it. Skim. Uprated stem seals and uprated exhaust valves
  34. g60leigh
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    g60leigh Well-Known Member

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    [Jun 15, 2014]
    Car has come home.
    [​IMG]

    [​IMG]

    Just have to find reason for the top end knocking.
    It's not all the time and seems to come on as revs rise slightly.

    http://youtu.be/Y2EJSkGvOmU

    Currently have rocker off but cannot see anything out of the ordinary.
    [​IMG]
  35. Adam P
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    Adam P Active Member

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    [Jun 16, 2014]
    We've all had a 'trailer' moment, its part of being an s3 owner i think lol any luck on finding the problem yet mate?

    [​IMG]
  36. g60leigh
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    g60leigh Well-Known Member

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    [Jun 19, 2014]
    No update yet Adam.
    Waiting for Coatesy to get a chance to come over and check it out.

    Your pic won't show by the way. Lol.

    I have made this while waiting tho. -

    [​IMG]
    Last edited: Jun 19, 2014
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  37. g60leigh
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    g60leigh Well-Known Member

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    [Jul 3, 2014]
    Still waiting to get my top end knock looked at
    I've had an endoscopic camera down through the spark plug holes. No sign of damage visible.

    I'm wondering if the new vvt tensioner that was fitted is faulty.
  38. g60leigh
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    g60leigh Well-Known Member

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    [Jul 16, 2014]
    Well it's been a while but still slowly working on this.

    Finished changing the VVT yesterday for a tested used one. Seems not tested too well though.

    The noise has gone from tickover to higher up the rev range now. Using the old screwdriver trick the noise is 99% definitely coming from VVT area.

    Going to have to bite the bullet and buy a new one. Also going to buy a new chain.

    Bad timing though as I lost my job last week.
  39. Scullies
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    Scullies Well-Known Member

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    [Jul 16, 2014]
    Sorry to hear about your job bud. Hope something comes up soon.
    g60leigh likes this.
  40. g60leigh
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    g60leigh Well-Known Member

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    [Jul 16, 2014]
    Thanks mate. Been stitched up due to time off I'm going to have to take for the spine surgery.

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