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MUSH Developments` S3

Discussion in 'A3/S3 Forum (8L Chassis)' started by MUSH, Mar 15, 2011.

  1. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    get some airflow the oil cooler... it will need it.
    is this in addition to the water cooler as std?
  2. MUSH
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    MUSH MUSH Developments Ltd.

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    Airflow to the cooler will be good, its just that the plastic wheel arch liner could possibly be chopped and meshed over to aid airflow to go through as currently theres just the standard slits in the liner.


    The oem oil/water cooler is ditched at the minute, as the original was minging. But id happily reinstate it as the pipes are still there, just bunged up.
  3. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    Hmmm. Had similar type install come thru here, cooler sat same position, no ducting... and it ran hot.. unless airflow can get thru it its heatsinking not heat exchanging to air.. You should be able to duct some air from up front to it.

    You have oil temp measurement in car yea to keep an eye on proceedings?
    Big Bang Yam likes this.
  4. MUSH
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    MUSH MUSH Developments Ltd.

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    Ducting it is then, ill get some knocked up from the bumper apperture direct to the cooler.

    Temp monitoring will be from the liquid gauge.
  5. Eddy_s3
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    Eddy_s3 Member

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    Looking good mate. Will have to pop up and you can take me out in it so i can see how 400 horses feel like in an s3 haha.
  6. MUSH
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    MUSH MUSH Developments Ltd.

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    Course mate, cant bloody wait, this was meant to be a couple of months project before the house got in the way!!
  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Always the way :D

    2 years and counting!!

    <tuffty/>
  8. oubas2
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    oubas2 New Member

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    nice job keep up the good work :p
  9. MUSH
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    MUSH MUSH Developments Ltd.

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    Cheers bud, its coming along

    Got the pod back from my pals shop. One tin of christmas biscuits as payment and it was covered in the correct material. Light isnt good in the car so i had to get the garage torch on the go to take a photo...

    [​IMG]

    Ill get daylight pics soon, but im happy with how it looks!

    And lit up with the clocks...

    [​IMG]

    Got some 4 inch cold air feed pipe ordered to knock up a cold air duct for the oil cooler. Ill also chop out the wheel arch liner and mesh over. Might aswell as itll only take a few mins and the cooler cant exactly be too cold. My bumper removal procedure is honed to a fine art with an approximate timescale of about 22 seconds. lol
  10. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Looks spot on mush. Where you wired it into?
  11. MUSH
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    MUSH MUSH Developments Ltd.

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    Headlight switch directly underneath it bud, comes on with the sidelights. :thumbsup:
  12. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Sound. You dont remember which wires/colour? Need to wire mine in still haha.
  13. MUSH
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    MUSH MUSH Developments Ltd.

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    Not a clue Dan, the grounds are easy as there brown so i just used a multimeter, black probe on the brown then turned the switch on and prodeded the red probe til i found 12v when sidelights on. Checked by turning the switch on/off again then soldered them in. 5 min job mate
  14. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Ok fair dos.

    Bit of a daft question but hey lol. Does the gauge need 1 live feed and then 1 earth feed? Not got a clue about electrics, well car ones haha. I used a 9v square duracell battery to test the guage light worked, one feed on one connector and other feed on other connector haha.
  15. MUSH
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    MUSH MUSH Developments Ltd.

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    Yup mate, a ground and a 12v feed. ;)
  16. beachbuggy
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    beachbuggy Well-Known Member

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    Out of interest when you fitted the ecu I sold you did it just plug straight in? Am I right you had a auq ecu fitted and upgraded this to the BAM? How did that work did you change the loom as well to a bam loom or is it the original loom?
  17. MUSH
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    MUSH MUSH Developments Ltd.

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    Just plugged straight in mate. The AUQ and BAM engine looms are electrically identical, just a slightly different layout to cater for the different inlet manifolds. The compartment loom is only different in the sense that the BAM has the EGT plug (which i added anyways) and it doesnt have secondary air injection (which i previously deleted). So my looms were "BAM" spec anyways, hence the plug n play addition of a different ecu.

    ;)
  18. Eddy_s3
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    Eddy_s3 Member

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    When you looking to get it back on the road then? Hows the extention going?
    Should have mine sorted by the weekend i hope but if your free you could pop up and give me a hand with wiring and pipes and getting the engine back in tonight or tomorrow once you finish work if your free?
  19. MUSH
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    MUSH MUSH Developments Ltd.

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    Reet... Cars getting mot'd next month mate as im all spent up buying doors nd shizzle for the house. Extensions pretty much done building wise, now got the task of wiring/plumbing/boarding etc so still plenty to do. Had the week off it this week after i finished the roof and got it watertight.

    Ill bell you and come up ;)
  20. MUSH
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    MUSH MUSH Developments Ltd.

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    Well after giving Chris a hand yesterday with his S3 i thought i clean mine up. Just give it a basicwash but it looks the dogs dangleys. Just a few pics to show...

    [​IMG]


    [​IMG]

    Couldnt help myself so i took it in the estate again, theres only room for 3 gears but it drove perfectly. Not a great deal happens before 3krpm and it only builds then but at 3.5krpm it finds its legs and lets loose. Only boosting to 0.5bar at the minute which is perfect as its only on actuator pressure. Feels good though. Roll on a few weeks and itl be mot'd

    :)
  21. patTTpoa
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    patTTpoa Member

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    I like the wheels, what are they?

    Pat
  22. MUSH
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    MUSH MUSH Developments Ltd.

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    They are votex wheels and were an optional extra for mk1 TTs :) :)

    They came with the car with brand new michelin pilot sports all round so theyre going to stay on. I quite like them aswell.
  23. patTTpoa
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    patTTpoa Member

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    They are nice!
    Wouldn't mind a set myself

    Pat
  24. MUSH
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    MUSH MUSH Developments Ltd.

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    They might be dare i say "rare"....?

    I certainly havnt seen them before i had them
  25. patTTpoa
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    patTTpoa Member

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    I'm looking now, & I can't find them!
    So you could be right in saying they are rare!

    Pat
  26. Eddy_s3
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    Eddy_s3 Member

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    Was looking good when i was up at the weekend mate. The car looks immaculate. Love the engine bay, Very tidy :) Bet you cant wait to get it on the road. I have your N75 you lent me here, al drop it off at the weekend. Feel free to pup up mine on friday for it if your local. al be fitting my new intercooler :D
  27. Seansy
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    Seansy Member

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    Such an enthralling build process Mush. Kept me awake during work today!

    You a mechanic by trade or you very enthusiastic? How did you learn all this stuff? Fascinating!

    Seán
  28. MUSH
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    MUSH MUSH Developments Ltd.

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    No worries mate ill catch up with you soon. Let me know when youre fitting your cooler and ill give a hand! ;)


    Cheers Seán, it keeps me busy! Lol

    Im not a mechanic by trade but im quite handy and ive been taking things apart since i can remember. I used to help my dad restore his citroen 2CV and Dianes in the same garage and then ever since its been my garage, for my projects...

    Just how i roll... :)
    Last edited: Nov 20, 2011
  29. Seansy
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    Seansy Member

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    Gifted b@%*~#d!!

    Will be great to see this some day in the flesh. Next years show scene I will keep an eye out for it.

    Seán
  30. MUSH
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    MUSH MUSH Developments Ltd.

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    How rude....lol

    Cheers mate ill look forward to it

    Nick
  31. Eddy_s3
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    Eddy_s3 Member

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    Cool mate, it will probs be next weekend now. That's if Mr silicone hurry's up and sends me out new pipes
  32. MUSH
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    MUSH MUSH Developments Ltd.

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    Decided to get some ducting down to the oil cooler whilst i had some spare time tonight. This is obviously on the recommendation from others, mainly Bill to ensure theres a good flow of air through the cooler. Last thing i want is for the oil to overheat, thin too much and kill the rings or shells.

    Apologies for the poor pics, as is obvious is that i did this job at night, under the warm bright hue of a few site spec halogens... :laugh:

    Started off by sorting the lighting and tooling required, then getting the bumper ready for removal (AGAIN)...

    [​IMG]

    And this is how the cooler sits to begin with...

    [​IMG]

    I had to drop the oil cooler and at first i thought id remove the front of the arch liner in small pieces in the position of where the cooler sat...

    [​IMG]

    But then i decided to hack a bit more out, whilst leaving a few strips in purely for strength...

    [​IMG]

    Looks a bit rough here, but i smartened it up a bit before cutting some mesh, and rivetting it over the aperture. I used small rivets and placed 4mm washers on the back so the rivet clamps the mesh and the arch liner between the washer and the rivet head...

    [​IMG]

    Then it was ducting time. I did purchase some 4inch cold air feed ducting but it seemed a bit small to be honest so i acquired some 6 inch ducting instead. I mocked it up with cable ties to see how long it needed to be, and when i was happy i cut it to length and tied it in final position so the ducting directly feeds the cooler...

    [​IMG]

    And then it was all about getting the bumper back on. It was tight around the foglight but the ducting is strengthened by thin metal wire so it was easy enough to bend into shape to accomodate this...

    [​IMG]

    So when i was happy with how it sat and that the ducting was as open as it could be with a direct feed to the cooler, i stealthed it up a little...

    [​IMG]

    So now even with the grille back on, you can hardly tell. Ill probs give the ducting another slight dusting with matte black to get rid of the slight shiny surface on the inside...

    [​IMG]

    So now im pretty damn confident that all airflow entering the lower fog grille will be directed straight to the cooler. After this ill be testing when driving to ensure the oil stays at a decent temp.

    Ive got a day off on the 14th Dec for my daughters christmas panto so im booking the car in that morning for the MOT!! woop woop. Should come back ok so i cant wait!

    Might take some more pics on saturday when the car comes out the garage as ive been roped into helping me pal do his SMF conversion with new clutch on his mk4 1.8t. Joy of joys....:wacko:
  33. s17atw
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    s17atw Member

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    looking good mate.............
  34. MUSH
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    MUSH MUSH Developments Ltd.

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    Cheers bud, ill bell you tomorrow!! ;)
  35. MUSH
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    MUSH MUSH Developments Ltd.

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    IWent for the MOT today and it passed!!! woop woop.

    Driving it on the roads and getting it tested did highlight a few problems but theres nothing major to be fair.

    The brake light switch is a bit temperamental. It worked fine when i tested the lights but typically it was being a bit dodgy at the test centre. I got it working again but it showed up as a fault code so may be an issue. What it might be as it is working now is just the fact that its been standing unused for 18 months so it may just be a bit sticky. Ill keep an eye on it anyway.

    The drivers seat backrest adjusting button doesnt work. This isnt the worst situation as i adjusted the seat to my preference when i first got the car, so again, maybe an issue from it standing for a while. Ill keep trying it and will most probably have a dig around when i get some time.

    Biggest issue though is that a code for low signal from number 1 knock sensor keeps popping up. They were definately torqued up correctly so ill have a look into that probably on the weekend and look to replace before going any further. Both knock sensors were second hand anyways, i had to change them when upgrading the engine loom as the later sensors are different.

    But apart from that the car was great. It flew through the MOT which was a relief, but to be honest i couldnt see there being any major problems as its obvious that the cars been looked after. It came with all new genuine brakes/ball joints and had brand fire new michelin pilot tyres all round so i didnt really have any doubt about any of the mechanics. When stripping and assembling for the suspension upgrades everything looked fine aswell.

    So how does it drive? Quite well to be fair. Low down is quite gutless but thats obviously to be expected. The car isnt mapped for the correct timing/airflow/capacity etc so im quite happy with it. Theres no boost being made and the difference in capacity isnt dialled in yet so its bound to be a bit down. It does go very well though with no clunks/rattles and the engine is still quite smooth. I remember when i bolted up the k04 to my AUQ lump in my mk2, as that felt quite similar, in the sense that the setup wasnt correct for the ECU but it still went well. Its not as smooth as it should be but the adaptions are only starting to take shape so im not worried. The car still drives nicely low down and then when 3-3.5k comes along the boost creeps and the power starts to feed through. The turbo boost control is still only running on wastegate spring pressure so boost rises nicely and settles at about 0.6bar which considering there is the 0.7bar spring fitted, is pretty good. Best bit is that theres been no issues with the engine or turbo setup. Thats where all the money and effort is and thats going fine with no nasty noises or leaks.

    One thing thats a big difference is clutch control. Being a Helix single plate flywheel and cerametallic clutch its certainly bitey. You can retain control and do it quite smoothly, but it just involves a bit of thought and foresight. Not that this bothers me as, id rather a setup man enough to take the stick it will certainly receive in the future! My girlfriend wasnt to impressed but thats most probably more down to the fact that she cant get insured on it....:lmfao: Shes only been driving for just over a year now though so i politely reminded her that most newish drivers wouldnt get the opportunity to drive an S3 then either (never mind a highly modded example...;))

    So i capped today off with getting the car taxed so its now fully road legal. Got robbed for December but i dont mind as i couldnt wait to get some miles on it. I covered 20 miles today which isnt a great deal but ill get the 4 wheel alignment adjusted before carrying on as the front is both toe out a little bit and the rears, even though they look good by my "eye adjustment" will still need attention after the coilover and S3dave tie bars installation.

    So overall im pretty damn happy, and cant wait to crack on with the next chapter which will be...

    -Sort the knock sensor issue
    -Wheel alignment
    -Drop the oil and replace (Engine/box/Haldex)
    -Get some more miles on it.... :)
  36. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Feels good doesn't it :)

    'Well Jel' mate.. haven't driven mine for over a month and its killing me... roll on Saturday!!

    <tuffty?.
  37. MUSH
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    MUSH MUSH Developments Ltd.

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    Does indeed mate, its a new experience for me having only covered a few miles in this car. But thats all part of the fun!
  38. superkarl
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    superkarl MAN OF STEEL

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    so when is 'the' day, the day you get it mapped and drive home in a rocket ship with the biggest grin the world has ever seen??
  39. s17atw
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    s17atw Member

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    Champion, well done If you do end up needing a Knock sensor mate I think I have a few kicking around up here your welcome to...
  40. MUSH
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    MUSH MUSH Developments Ltd.

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    Well well, the "day" of reckoning certainly isnt booked yet. But aslong as the running in goes smoothly then theres only two more jobs needed before mapping and they are the inlet manifold project, and the fuel pump. Id ideally like to keep the S3 injectors in and then swap to the 630cc's before mapping.

    Fingers crossed it all goes well i think itll be march when i get it mapped as i start a new uni module early next year so will be busy with that aswell.

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