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I stripped my Forge DV down as i wasnt sure if it was leaking... Advice needed please

Discussion in 'A3/S3 Forum (8L Chassis)' started by S3 Paul, Jan 19, 2013.

  1. S3 Paul
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    S3 Paul Active Member

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    Would vasoline work?
    I mean it is a good lube ;-)
    I'm going to lap my piston again tomorrow at work. In the same way I would do a valve to seat on a cylinder head. Would starting with a cordless drill slowly to rough the seat be too harsh? Then finish it by hand,
    I know forge do a service kit but once I've lapped the piston in would a new piston never fit? Or just not needed?
    Does anybody have a spare shim?
    Or do I need to swap to yellow spring too?
    Is the spring you need linked in any way to how/ who mapped the car?
    #41
  2. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Paul ive got a shim you can have.
    #42
  3. S3 Paul
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    S3 Paul Active Member

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    Top banana .
    are they all the same thickness?
    When could I get it?
    #43
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Bear in mind that the grease generally used is a silicon based one... this won't damage rubber seals... if you plan to change regularly then maybe it will be ok but petroleum based greases affect normal rubber o-rings which I believe the Forge ones are.. The kits are cheap enough to buy tbh...

    Use a green spring and a shim... the shim goes in first... reduces the volume of the piston (as Bill has mentioned before, air is stretchy as well as compressible) this will help the piston react faster... use a little grease or silicon to seal the shim where it sits in teh piston... use a green spring for the DV... mapping has nowt to do with DV's...

    <tuffty/>
    #44
  5. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Yup, think ive got 4 so wont miss them. If you can come through this weekend mate, then. Id say during week but im in manchester for the next 2 weeks mon to fri.
    #45
  6. A3 T
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    A3 T Lord Of The Rings

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    #46
  7. s3clarke
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    s3clarke Money grabbing s3!

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    It is pretty stiff to push the piston up with the blue spring, but then I've got nothing bar a standard one to compare it too. I put the standard one back on and took it down the road earlier, I recon it boosts better tbh. I got the valve 2nd hand and at the time didn't know you could service them and change springs etc. I'm gonna sell the forge I think.
    #47
  8. paultownsend
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    paultownsend Member

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    #48
  9. S3 Paul
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    S3 Paul Active Member

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    Well, as advised i dropped forge an email last night at about 10pm,
    this morning i received a reply saying... sorry to hear im having problems and that they will send me a service kit including a redesigned piston ( with a seal on) free of charge, They also said that if i run over 15psi of boost to stick with the yellow spring and see how that fairs.
    I am very impressed with the speed of the reply it was before 9 am! and the offer of free help .
    fingers crossed the forge DV may make it back on to the car in the near future.
    #49
  10. S3 Paul
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    S3 Paul Active Member

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    #50
  11. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Personally I still think a yellow spring could be a tad stiff... but can't fault Forge on their service... I would still try the green and a shim as a back to back and see how you get on... if they done what I think they have with an o-ring seal on the piston then it shouldn't really need a yellow spring to hold it shut... remember the pressure will be the same both sides of the piston under boost so it should force it open (when fitted the correct way round rather than having boost acting on the bottom of the piston itself)

    Good work... :)

    <tuffty/>
    #51
  12. vanilla_ice
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    vanilla_ice Member

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    Pics when it arrives please.
    #52
  13. rraghvani
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    rraghvani Whoever does not try, does not learn.

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    Yes it does – based on the sound that I hear when I lift off the accelerator, I get a whooshing sound type noise, when the air is being recirculated. At the time when I bought the DV, I thought it was a direct replacement, didn’t really know about the different spring rates and shims until afterwards. I’ve never had any issues, must be lucky!

    Over the last few years, of not using the correct size allen key, I round the bolts. Asked for replacements bolt parts from Forge, and they sent a replacement kit for free – brilliant service :thumbsup:
    #53
  14. S3 Paul
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    S3 Paul Active Member

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    well i received anothe email about 10 mins after sending my postal address saying the parts would be posted first class today. Realy good service!
    I will post pictures before i build it up. The only thing i need to sort now is something to seal the side port thread. ive removed it and cleaned off what looks like old locktite ,now the question is ... what can i use that i can get localy to reseal it.
    Halfords do a few high temp silicones but which to use as its not listed in the directions
    #54
  15. superkarl
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    superkarl MAN OF STEEL

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    Use a sump sealent or something.
    #55
  16. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    #56
  17. paultownsend
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    paultownsend Member

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    Just purchased a new 710N valve from TPS. Forge 008 in the for sale section soon......:blush:
    #57
  18. S3 Paul
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    S3 Paul Active Member

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    thanks Paul,
    that was top of my little list ,
    a mate has said he uses two silicone based sealers to build Honda engines... Gets it from the dealers,
    He says I can use that , I think after a chat with him and looking the product up it sound spot on,
    i finished lapping the current piston in before I got the email from forge, so I will post pictures of that and the new one the are sending before I rebuild the DV
    #58
  19. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    You still want a shim dude?
    #59
  20. A3 T
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    A3 T Lord Of The Rings

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    Told ya ;)
    #60
  21. s3dave
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    s3dave TFSI Hybrid

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    New forge piston...

    [​IMG]

    [​IMG]

    Its got a lower seal on the seat, and the surface area inside is greatly reduced...
    #61
  22. badger5
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    badger5 RIP S3dave Site Sponsor

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    seems they're listening
    fair play...
    #62
  23. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Itll be interesting to see what piston design my forge supersize valve is, ill be stripping it down to fit a shim so ill post pics up to see if it is the old piston design of the improved version.
    #63
  24. A3 T
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    A3 T Lord Of The Rings

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    Looks good but i cant help thinking....


    what if that o-ring comes off ? :think:
    #64
  25. 16Klappe
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    16Klappe Princess Slayer

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    Then you're ****ed.
    #65
  26. StaceyS3
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    StaceyS3 Well-Known Member

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    Dani could post a pic of forges supersized dv piston when you get it?

    They've already replaced mine to an updated one already (FOC) but curious if they will be putting some kind of seal on there now?

    The original is the one on the right with the radius and the newer one was with the flat bottom :)

    [​IMG]

    [​IMG]
    #66
  27. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Thabks for that stacey, i now know what spec the piston will be and yeah course i will. How does the top come off? Screw top or allen screw? Also what spring you running?
    #67
  28. paultownsend
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    paultownsend Member

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    Fitted a new 710n from TPS today. A lot better than my 008.
    My lump has only a k03 but has a rock steady -22hg vacume. A green spring in the 008 would blow open up to 5 psi then the car would spin its wheels. With the yellow it held better at low boost, dump at light throttle, but would still chirp at certain loads. Shims mad it worse either way.

    710n holds perfect boost from vacume to its now 17psi boost. The new forge absolutely leaked. Great for £120 and purchased as a 'stage 1' must!

    Thanks for the advice bill et all
    #68
  29. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Also the new design looks alot better.
    #69
  30. StaceyS3
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    StaceyS3 Well-Known Member

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    Mines a screw top and running a yellow spring with a shim to reduce volume as I stupidly sold the 007 with the green spring as buyer requested it and I thought I'd never use it :(

    Anyone got a spare green spring (shameless plug) lol
    #70
  31. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Haha what you like. I may be able to help you out with that mate. Ill have to check when im back home friday but ill let you know m
    #71
  32. A3 T
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    A3 T Lord Of The Rings

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    Keep it short and say it how it is :lmfao:


    Maybe we should stick with the old one.
    #72
  33. S3 Paul
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    S3 Paul Active Member

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    Im prety sure the likely hood of the seal "falling off" has been looked into and tested?
    I wouldnt expect the would offer to send these pistons out to cure a problem if they had tested any and they had fallen off?
    #73
  34. 16Klappe
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    16Klappe Princess Slayer

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    Hopefully they've done more testing than they did on the originals. :)
    #74
  35. s3clarke
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    s3clarke Money grabbing s3!

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    well I contacted forge Monday evening and I haven't had a reply... ooh well the standard valve is back on and I think I prefer it.
    #75
  36. S3 Paul
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    S3 Paul Active Member

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    Never ever happy FACT
    #76
  37. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    So are we now saying that a green spring with a shim is better than the yellow spring in a 007p for stage 2 cars?

    Also is the redesigned piston that forge have released makes the DV operate better?
    #77
  38. s3dave
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    s3dave TFSI Hybrid

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    Well mine is back on the car and it feels/sounds a lot sharper...
    #78
  39. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    Cool will fire off an email to Forge and see if I can get a re designed piston for my 007p then.

    In regards to springs should I stick with the yellow?
    #79
  40. s3dave
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    s3dave TFSI Hybrid

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    Yes deffo as the volume as decreased
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