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Lets get it on then, My 2.1 conversion

Discussion in 'A3/S3 Forum (8L Chassis)' started by Andrew@A.L.D, Dec 12, 2009.

  1. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 15, 2010]
    Looking good mate but is it me or are the cylinder jacket waterways looking blocked by the head gasket?

    [​IMG]

    <tuffty/>
    #41
  2. finesse
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    finesse Active Member VCDS Map User

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    [Mar 15, 2010]
    wow impressive!
    #42
  3. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    I still have the old head gasket from the 1.8 so i have a look at that

    Its the head gasket that the guys use on fourtitude
    #43
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 15, 2010]
    If you are still using the 06A block then use the 1.8 20v N/A gasket... Bill uses this one on his. He can give you the part number...

    <tuffty/>
    #44
  5. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    please does he have 83mm bore?
    #45
  6. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    I must correct myself the gasket you see there is a ALT not a ALH one

    ALT is a 2.0 20v Petrol engine

    The ALH is a 2.0 Diesel
    #46
  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 15, 2010]
    Yes mate... the Ibiza engine is a 1.9ltr, 83mm bore 06A block...

    <tuffty/>
    #47
  8. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Mar 15, 2010]
    06B 103 383 AF

    What I am using on my 83mm bores now

    NOTE: you will need to allow for this being a thinner gasket than regular 1.8t one.. it measures 0.3-0.4mm thinner when I checked mine
    change of CR and valve to piston clearance on TDC and lift @ TDC

    worth checking
    Last edited: Mar 15, 2010
    #48
  9. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    Do you think that head gasket i have above is ok?
    #49
  10. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 15, 2010]
    You got any better pics of the ALT gasket fitted? Top view or something? If the gasket is restricting the water ways in anyway I would so no. 83mm makes the cylinder walls thin and it is the last place you want to have restricted coolant flow... IMO

    <tuffty/>
    #50
  11. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    Just found the old gasket and yes you are right one of the water ways isn't there plus it's thinner than the S3 one and the S3 one is also fine with the bore ( edit its not fine with the bore ) going to order the one you said badger, thanks Tuffty for pointing that out as i wouldn't of seen it.

    2.0 ALT one is 1.11 mm thick

    1.8T APY one is 1.51mm thick
    Last edited: Mar 15, 2010
    #51
  12. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Mar 15, 2010]
    i cant view photobucket pictures at the moment I'm afraid on the network I'm looking from

    the water ways are smaller in the gasket in mine currently.. time will tell if this is good or bad.. stock gasket does not give full coverage either vs the actual block ports
    #52
  13. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    Another little update

    I've machined and balanced the pistons, now i don't have any clearance problems

    Fitted them and all is well and turns over by hand nicely

    Just got to pick up some valve steam oil seals, the head gasket Badger recommended and some other new bolts from Audi tomorrow

    [​IMG]
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    #53
  14. s3_kev
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    s3_kev Stage2'd!!!!!!

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    [Mar 15, 2010]
    impresive engine work there i dont mean on just stuffing some pistons into the block i mean the custom machining head work etc thats pretty special not many people could do that and to such a quality standard
    #54
  15. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    Thank you kev
    #55
  16. Plunky
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    Plunky Member

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    [Mar 15, 2010]
    Very very impressive, you have some skills there mate!
    Off subject, but is my n75f posted? :)
    #56
  17. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    It was today fist class so you should get it in a few days
    #57
  18. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 15, 2010]
    Been doing for years and had help from a mate that has a flowbench, if anyone wants this sort of head work i'll do it or £500
    #58
  19. HTC
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    HTC Active Member

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    [Mar 16, 2010]
    How much to just clean a head, fit new valve guides, valves and springs? No porting. I have the parts.
    #59
  20. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 16, 2010]
    I would have to look into that as when you fit new guides you need to have the seats recut to match

    Well i got the head gasket Badger recommended and its the same as the ALT one i have so will be sending the ALT one back as i got it from Euro car parts and the one i got today it from Audi so i would rather use a Audi one
    #60
  21. Gops
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    Gops 6th gear @7000rpm

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    [Mar 16, 2010]
    Wow amazing thread! Looking niceeeeeeeee!
    #61
  22. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 20, 2010]
    Just finished putting the head and bottom end together

    Just waiting for my flywheel now from TTV witch is taking the piss with the time

    [​IMG]
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    [​IMG]
    #62
  23. s3 Hoggy
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    s3 Hoggy Whats going on???

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    [Mar 20, 2010]
    looking good mate! bet you cant wait to get it back on the road,

    Matt
    #63
  24. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 20, 2010]
    Get it on the road, get it repainted, fit exhaust, coilovers, and remap it for the 2.1 then when i have some free money then go GT30
    #64
  25. s3 Hoggy
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    s3 Hoggy Whats going on???

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    [Mar 20, 2010]
    A week or so then :laugh:
    #65
  26. tankie2ndrtr
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    tankie2ndrtr Member

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    [Mar 20, 2010]
    Whats the grooves in the top of the piston crown for ?

    Gary
    #66
  27. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 20, 2010]
    I think you mean pockets

    Its for the valves when you fit performance cams
    #67
  28. tankie2ndrtr
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    tankie2ndrtr Member

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    [Mar 20, 2010]
    ahh 5 grooves "pockets" makes sense... so performance cams open the valves more then ?
    #68
  29. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Mar 20, 2010]

    Not necessarily, duration/overlap plays a part too...

    <tuffty/>
    #69
  30. tankie2ndrtr
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    tankie2ndrtr Member

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    [Mar 20, 2010]
    ah i getcha....

    Not one to be a pecamist Andrew... but wont the money your spending on this only be adding value to the individuality and exclusiveness to the car rather then adding value come an eventual resale ? Understandable if you plan to keep it for ever, i have looked at a 2.1 conversion in the past and once my mrs has done the sums it seemed a bit pointless, yeah ill have a cracking S3.. very rare hatchback weapon, but selling and using the mod money to go up a class... 03 S4's etc, seemed more sensible int he long run..

    I take my hat off to you though, gutsy and cant wait to see the finished product...

    Gary
    #70
  31. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 20, 2010]
    I see it as it was a cheap car when i got it and i had my last car for 10 years so it will most likely be the same with this
    #71
  32. SteveBAM
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    SteveBAM Black '03 S3

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    [Mar 20, 2010]
    top job mate, im sure this is going to be another big @ss thread..!!:icon_thumright:
    #72
  33. tankie2ndrtr
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    tankie2ndrtr Member

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    [Mar 20, 2010]
    Coolio, wish you the best of luck with it and have thousands of problem free miles to come :)

    Gary
    #73
  34. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 21, 2010]
    I hope so
    #74
  35. A3Tom
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    A3Tom Smell my finger.

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    [Mar 21, 2010]
    Looking good :)
    #75
  36. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 31, 2010]
    #76
  37. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Mar 31, 2010]
    What make of DP have you ended up getting?
    #77
  38. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 31, 2010]
    I got a cheap XS power one that i have modified for better fitment, As the head was on the bench on the head stands and turbo on it made the modification easy to do

    I've taken pictures of the modifications and sent them back to XS power and they are sending them to there suppliers to improve on the design and fitment

    I got the cheap down pipe as i don't plan to keep the K04 Turbo and will end up cutting this one up for when i go GT30
    #78
  39. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Mar 31, 2010]
    Very nice, hopefully people who buy xs power in the future will have a DP that fits and doesnt need hacking so much lol.
    #79
  40. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 31, 2010]
    As an engineer the modification wasn't that bad i would say

    I did say to them they need to review that turbo flange and move the CO sensor boss 5mm+ away from the manifold
    #80

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