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g60leigh build thread. it's gonna get messy

g60leigh Dec 12, 2013

  1. craigt1985

    craigt1985 Active Member

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    Talk about bad luck coming in 3's, hopefully you'll heal up, sort the car and find new job soon :)
     
    g60leigh likes this.
  2. g60leigh

    g60leigh Well-Known Member

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    Well out of hospital now
    Hospital selfie
    [​IMG]

    On the recovery road but damn it hurts.

    Getting new VVT and tensioner chain next week. Will fit it once my back allows it, unless someone wants to come help me out .

    Have had a new piece delivered while I was laid up. I commissioned this a while back and it's now all done. [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  3. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Hope your back on ya feet soon mate.

    Wheres the manifold from?
     
  4. g60leigh

    g60leigh Well-Known Member

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    Zak from ZK Fabrications made it up for me.
     
  5. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Any details for him mate? Large or smallport and how much?
     
  6. g60leigh

    g60leigh Well-Known Member

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    I have his details on Facebook mate. PM me and can add you/pass it on that way.
    Mine is small port so gone with small port. Could of used either though.
     
    Dani_B19 likes this.
  7. Adam P

    Adam P Active Member

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    Sorry to hear about the job mate, and your back! Hopefully the car will be fixed soon and you will be enjoying a remapped animal when done :)
     
  8. g60leigh

    g60leigh Well-Known Member

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    I've finally got the new cam chain tensioner, chain and gasket set.

    Had a delay due to getting wrong parts sent but all good now. Just wish my back would let me do it.

    Healing taking longer than I want and I now have to go back into hospital tomorrow as not healing quite right.

    Anyone local fancy giving me a hand doing it? Lol
     
  9. g60leigh

    g60leigh Well-Known Member

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    Been hampered a bit more with my spine. Now been told I can't do anything on the car or even drive for at least another month

    So any work I can do is limited to the bench.

    To keep me going I've fitted new injector seats to my large plenum intake. I have also ordered up a billet fuel rail and IE FPR housing. I don't believe for a second the claimed bhp increases from these but think it will look right on the new mani.
     
  10. Adam P

    Adam P Active Member

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    Ah man that sucks! take a positive from it and just collect all the parts ready to install once your back is better. It will all be worth the wait!
     
    g60leigh likes this.
  11. g60leigh

    g60leigh Well-Known Member

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    Well ********ed my self up doing the the new cam chain and tensioner today.

    Can't stand or walk anymore. And car still knocking like a bag of spanners.

    I'm not a happy bunny tonight.
     
  12. g60leigh

    g60leigh Well-Known Member

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    Had car taken into local garage who have it up on ramp.

    One of the cylinders has spun its shell.
    The rod cap was not fully tightened.
    Got to find out what additional damage has been done. See if its killed the crank and rod.
    If it has its game over and guess I will be parting it out

    Time to take a step away and reassess things.
    So farewell for now ladies and gents. ️
     
  13. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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  14. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Sorry to hear mate.
     
    g60leigh likes this.
  15. g60leigh

    g60leigh Well-Known Member

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    Time for another very minor update. Engine is pulled and getting new crank fitted. (Thanks Andrew@A.L.D for doing me a good deal)

    Going with OEM shells this time.

    While it's all out I'm fitting my home made uprated engine and gearbox mounts.
    [​IMG]

    I'm also adding the large plenum inlet mani.
    [​IMG]

    And today I've been and picked up these to throw into the mix.
    [​IMG]
    [​IMG]
    [​IMG]

    So as long as no more gremlins appear, the car should be coming back stronger than ever.
     
    Dani_B19 likes this.
  16. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    Not a problem.

    I got the bottom end for £130 and made my money back from selling the Pistons, crank and rods, I used the block in my S3
     
  17. jaykay8L

    jaykay8L Active Member

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    Hope things smooth out a bit on the back & the S3 front soon.

    Onwards and upwards :thumbs up:
     
  18. g60leigh

    g60leigh Well-Known Member

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    Ok finally coming to the end after many delays and hold ups.
    As long as everything goes to plan I should be getting car back next week with the new crank installed and a few other bits for good measure too.

    Can anyone tell me if I need to do any running in of the new crank and its shells?

     
    Lavis89 likes this.
  19. g60leigh

    g60leigh Well-Known Member

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    Still not got the car back due to a run of delays that I'm not going to bore anyone with. But it will be stronger and right!

    While I've been waiting for it I've been playing with a couple of sideline projects.

    All still works in progress but here is a little taster.

    LED slimline fog lights--
    Ai don't think the stock fogs will fit with the new wellycooler I've come up with my solution to try.
    I picked these super bright Cob LED's from eBay. [​IMG]

    They came in packs of 5
    [​IMG]

    So got a pack for each side.
    Soldered on some tails
    [​IMG]
    And a quick test.
    [​IMG]

    Damn! They are bright. But go big or go home lol. Definite improvement over stock.

    Fitting the to split down stick lenses so made a backing board and attached them to it.
    [​IMG]
    [​IMG]

    Definitely slimmer. [​IMG]
    [​IMG]

    Should do the trick tho.

    I'm going to sikaflex them to the grills
    [​IMG][​IMG]
     
  20. g60leigh

    g60leigh Well-Known Member

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    Flat bottom steering wheel --

    Love the look of the FBSW and picked this up at a bargain price. But no air bag
    [​IMG]
    So grabbed an air bag cover
    [​IMG]

    Don't have a suitable air bag available got his from what I can see. The ones that say will work seem to still be 50/50 if the will work anyway so I'm fitting a resistor to the loom to prevent any errors showing on dash and ecu.

    This still leaves me with no horn.
    So my effort to resolve this goes like this.
    I've split the centre down.
    [​IMG]
    Added a car spacer between that magnesium block and the plastic disc.
    [​IMG][​IMG]
    Along with grinding down some of the central high spots.

    This allows a little flex within the centre disc piece.
    I'm going to fit a momentary push switch in the centre so that when pushing the disc it will depress the switch.
    The plan being it should work as a somewhat oem looking and working horn.
     
  21. g60leigh

    g60leigh Well-Known Member

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    I'm also starting work on a set of darkened headlights with updated projectors fitted. But no pics yet so that will follow.

    Couple of pics of my car as is at moment though -
    [​IMG][​IMG][​IMG]

    I'm also working on a dual stage WMI
    [​IMG]
    And a dual gauge steering cowli pod to hold my new AFR
    [​IMG][​IMG]
    [​IMG]
    [​IMG]
    [​IMG][​IMG][​IMG][​IMG][​IMG]
    [​IMG][​IMG]

    And thanks to a fellow ASN member I will also be playing with
    [​IMG]
     
  22. g60leigh

    g60leigh Well-Known Member

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    after a few false starts and deadlines missed I have now finally got my car back and it's alive.
    Although there is still a list do things to be done which I will slow they around to. Some plans have evolved and some scrapped altogether.

    Also got a nasty rattle coming from gearbox while idling. Goes when clutch is depressed?? Sounds to be coming from driveshaft area rather than flywheel though??

    Managed to get a few things ticked off so far.
    Integrated engineering fuel rail with sytec fuel pressure regulator fitted along with all braided fuel lines and AN fittings.
    Also fitted duel nozzle wmi set.
    [​IMG][​IMG]

    Fitted new alloys today - 18x9.5J Rota Grid Drift. But may come back off when bad weather hits us
    [​IMG][​IMG]

    Need to now move battery to the boot and sort intercooler pipe work so I can refit grills.
     
    StaceyS3, Jay A3, fanta and 1 other person like this.
  23. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Looking good mate.
     
  24. g60leigh

    g60leigh Well-Known Member

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    Mapping tomorrow
     
    fanta likes this.
  25. g60leigh

    g60leigh Well-Known Member

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    Not a lot to report unfortunately.
    Got a baseline of 235bhp running on just actuator pressure.
    Had two issues while mapping. Exhaust is blowing around flexi area of downpipe which will need sorting but not that much of a problem.
    The main problem was one of the knock sensors throwing up a fault for signal too low which was pulling the timing back and killing power.

    Still managed to get it mapped but not able to get an accurate power run.
    Once new sensor is fitted I'm going to be doing some logs and sending them over to Rick. If the map needs any tweaking we are set for him to do it over Internet and go from there.

    So no hard and fast figures but map curve was nice and smooth and guesstimate peak bhp will be 320-330bhp. Bit down on the 350 I had kind of half hoped for but still feels like it will be a fun drive.
     
  26. g60leigh

    g60leigh Well-Known Member

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    Car is under the knife again having some more surgery.
    The spline on the selector shaft of the gearbox has eaten itself so the selector weight is spinning on the shaft. This meant it was getting difficult to engage gears and also knocking itself out of gear.
    That combined with the rattle that could be heard while in neutral has led me to go down the replacement option.
    I've picked up a TT box given it a good clean and a quick spray of paint.
    [​IMG]
    [​IMG]
    [​IMG]

    Hate fitting dirty parts.

    While it's getting done also fitting a new concentric slave cylinder. I'm confident that they will cure the noise.

    Also have the knock sensor here to fit and a new lambda sensor for my innovate AFR gauge. Hopefully this will cure the annoying E8 error I'm plagued with
    [​IMG]

    Get it running right again so can get a bit of logging done and map tweaks can be completed.
     
    Lavis89, StaceyS3 and fanta like this.
  27. g60leigh

    g60leigh Well-Known Member

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    Took an age of fault chasing and parts and sensor swaps trying to track down the horrible misfire.

    After swapping out
    Both knock sensors
    Oil level sensor
    Cam position sensor and trigger wheel
    Another new cam chain tensioner
    Gearbox speed sensor
    Crank sensor
    Replaced both the in tank and inline fuel pumps
    Went through all the wiring and connectors.

    Finally managed to get rid of error codes, miss fire and timing issues.

    Now doing some running to make sure none of the faults come back and will be pestering Rick to finally finalise my map.

    Managed to get a few other bits done too.

    [​IMG]
    New Bosch 044 ready to go in.

    [​IMG]
    New in tank pump with original level sensor

    [​IMG][​IMG][​IMG]
    Engine bay cleaned and dressed up.

    [​IMG]
    Got around to mounting the fire extinguisher

    Also have a trackslag pipe waiting to go in
    [​IMG]

    Had a bit of an issue with my speedo not working and fuel gauge having a mind of its own, which turned out to be a blown fuse for the reverse lights ???
    But while sorting that out I fitted this kit I git from a fellow forum member
    [​IMG]
    Genuine carbon fibre mask and chrome rings. [​IMG]
    Before
    [​IMG]
    After
    [​IMG]
    Fitted.




    Sent from my iPhone using Tapatalk
     
    scotty_24 likes this.
  28. scotty_24

    scotty_24 Active Member

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    I really like that
     
  29. g60leigh

    g60leigh Well-Known Member

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    Which bit bud?


    Sent from my iPhone using Tapatalk
     
  30. scotty_24

    scotty_24 Active Member

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    All of it ha ha but the carbon dials is a nice touch
     
  31. craigt1985

    craigt1985 Active Member

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    How have your LED fogs held up since you made them? Anything you would have changed or improved?
     
  32. g60leigh

    g60leigh Well-Known Member

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    In ashamed to say. I have t wired them in yet lol. But they are looking just as when installed so seem to be reasonably weather resistant


    Sent from my iPhone using Tapatalk
     
    craigt1985 and fanta like this.
  33. craigt1985

    craigt1985 Active Member

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    Haha, well they look good and if they aren't goldfish bowls by now then they much be well sealed! Was thinking of stealing the ideal to gain a bit more space when fitting my FMIC.
     

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