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My Build Thread, Standard, Stage1, Stage2, K04 Conversion and Onwards.......

Discussion in 'A3/S3 Forum (8L Chassis)' started by Customboy, May 28, 2012.

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has this helped you?

  1. yes

    3 vote(s)
    100.0%
  2. no

    0 vote(s)
    0.0%
  3. maybe

    0 vote(s)
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  4. useless!

    0 vote(s)
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  1. Customboy
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    Customboy Member

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    [May 28, 2012]
    Ok everyone ihave finally decided to sit down and write this thread out, mainly because i see new members joining everyday and going down the same road as i have and also this may help them along the way so enjoy and if you have any questions feel free to ask me anything,

    My car is a Audi A3 1.8T AGU 1999 V Reg 150-BHP
    I bought the car just over two years ago its was bog standard and had only covered 75k and the previous owner was only the 2nd, the car had no faults or problems and drove great and nearly every optional extra fitted to the car, this was the bose sound system, electric sunroof and air conditioning, leather interior with electric lumbar support, heated wing mirrors and in the very great and rare kingfisher blue, with facelift handles, the owner wanted £3600 i bought the car for only £2600 after alot of haggling lol.

    this was the car a few days after i bought it, got a cheap set of rs4 wheels and they went straight on lol
    [​IMG]
    and then after cleaning
    [​IMG]

    after fitting the wheels i had to change the suspension set up as it was sitting way to high and rolling around, so next was a great bargain set of koni 40mm lowering springs for only £50 which is what is on the car now with the standard shocks but coilovers will come one day lol,

    once the springs had been fitted, i purchased a forge 007p dv
    [​IMG]

    once that had been done, i searched around for a stage one remap and finally decided to use Rtech after many great recommendations, after chatting to Ben on the phone he did me a fantastic deal for only £200 and came from Rtech to me in SE London the next morning, he ran a vagcom check and car was fine and then did the map and then we drove it and i loved it was the best money i ever spent, instant great response less lag and pulled so well i was over the moon and little did i know it the speed freak had been released in me that day lol, me and ben spoke about the car and he loved it as much as i did and recommended me to buy a pipercross panel filter and just get the airbox drilled and smoothed out, so next day i rang up pipercross and ordered a panel filter for only £32 and just by luck a fellow member sold me his smoothed and drilled box for only £20 so things started to roll

    pipercross panel filter
    [​IMG]

    after this had been done i wanted to stiffen up the handling of the car the springs and suspension where great but wanted more and got a OMP front strut brace for only £27 ebay bargain! and then got it fitted

    strut brace fitted and it made such a great difference
    [​IMG]

    then soon after wards another bargain popped up a forge carbon fibre engine cover for only £30 and i snapped it up and fitted it
    [​IMG]

    followed by my apexi boost gauge and holder for only £30 ebay bargain again

    my boost gauge
    [​IMG]

    followed by another ebay bargain a scorpian cat back exhaust system for only £90!! so on it went with some work and sounded great and help free the car up loads and still on their today!! then got a set of forge turbo pipes for £70 and got them fitted.

    so i left the car as it was for a while and just changed the brake discs and pads to black diamond ones grooved ones with the pads and at the same time gave the car a full major service so water pump cambelt oil etc and the car was better then ever,
    but i started to want more power haha done we all, and started asking about the next best upgrade and was a bit put off by the k04 conversion due to the amount of work involved and price, so spoke to nick at rtech and was recommended to go k03s turbo as one of my options and was a cheap thing to do, so off i went searching for a ko3s turbo, and found a great guy called paul selling a backdraft k03s turbo that had only covered 1k for £400 so after a few emails i snapped it up

    my k03s turbo currently on the car now
    [​IMG]

    then a few days later found the best bargain ever on ebay a forge fmic on auction and i won the bid for only £150 but without any pipes,

    the great bargain fmic
    [​IMG]

    then it was a case of getting the pipes and fitting the setup

    the pipes i ordered from ASH Motorsport for £113
    [​IMG]

    i cant thank my mate dan for fitting this kit and for all his help!!

    the pics of the intercooler being setup
    [​IMG]
    [​IMG]

    intercooler fitted
    [​IMG]
    [​IMG]

    intercooler behind bumper not showing too much pipework
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    so once the intercooler was fitted it the car drove so much better and was tucked in great behind my front bumper without to much cutting or looking ugly, cant credit dan enough for his great work, and i couldnt wait for the k03s to be fitted and also had bought a neuspeed tip pipe for a great bargain of £120

    neuspeed tip next to standard one
    [​IMG]

    so once the turbo and tip was fitted, i drove it easy for a while till i could book it in at Rtech for stage 2 remap, but also decided to to get a new downpipe and decat and this is because i bought one on ebay for only £30

    the ebay bargain?
    [​IMG]

    it was fitted after cutting away my old pipe work and decatting the car, and only to find out the flexi joint was knackered and blowing like a tractor so then the seller on ebay disappeared and i was gutted so i worked hard and then bought a toyosport downpipe and decat and got it fitted and i loved it and the great price of only £90, then for some reason i wanted to change the airbox and got a simota induction kit for only £25 on ebay

    my simota induction kit
    [​IMG]

    i fitted it and wish i hadnt the car wasnt boosting right yes it sounded good but the engine just hated it so off it came and back to the good old airbox and panel filter and the boost issue was solved and sold the simota kit for a nice profit lol and used the money to buy a cold air feed pipe and fed it from the front bumper and straight to the airbox

    feed from front bumper
    [​IMG]

    feed to airbox
    [​IMG]
    [​IMG]

    also due to the fact my cheap wheels where starting to look worse and worse i sold them and fitted a set of 18 inch bbs LM replicas for a bargain £200 and also fitted clear indicators and facelift rear lights as the old ones look naff for another bargain of £50!

    car all polished with the rear lights fitted and new wheels




    [​IMG]
    [​IMG]


    Then got the car booked in with nick at rtech and off i went in the early hours to see him and couldnt wait for the extra power,

    car @ RTech having the stage 2 done
    The car was pushing 198bhp at the time of stage one
    [​IMG]

    on the rollers looking great
    [​IMG]
    [​IMG]

    my car on the rtech rollers getting mapped
    My Audi a3 @ Rtech! - YouTube
    My Audi a3 turbo @ Rtech! - YouTube
    the car was finished and done with the following results,

    the graph below is from the rolling road day at AMD essex on the 27th may with the COV crew
    [​IMG]

    223-BHP AND 253FTLB OF TORQUE, which i loved and adore to this day!!
    #1
    deeman88 likes this.
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  3. Customboy
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    Customboy Member

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    [May 28, 2012]
    the car drives great and fantastic and pulls so well, but as most people know power isnt anything without good brakes so got a set of S3 discs and calipers with braided line for only £60 and also number plate holders for my private plates for only £3 on ebay so on they went and also upgraded the brake fluid to 5.1 racing stuff

    my number plate holders
    [​IMG]

    my brake fluid
    [​IMG]

    i also changed the front light to a H.I.D set from a good mate and got him to change all the interior lights and number plates lights after meeting westy at ace cafe and seeing his lights cheers mate

    the standard lights
    [​IMG]

    the led light set fitted looks so great
    [​IMG]
    [​IMG]

    so the brakes where changed and so was the fluid and all i can say is wow made such a great difference and felt great to be able to push the car harder and get it stop on the penny !!

    now at the moment i have been working hard and getting the bits ready for the k04 conversion yes i know im mad!! i have hardly let the stage 2 warm up and went and bought a k04 turbo

    my great k04-023 turbo with all 4 lines and manifold for a bargain £400 only covered 44k
    [​IMG]
    [​IMG]
    [​IMG]

    also bought a 80mm jetex filter for a bargain £30 ebay to the rescue and a reducer for £12 ash motorsport and fitted it and sounds great and pulls just as well!

    jetex filter
    [​IMG]

    the reducer 80mm to 70mm
    [​IMG]

    fitted to the car within the airbox using the cold air feed in place
    [​IMG]

    video of jetex working love the sound!
    Jetex 80mm filter on Audi a3 1.8T - YouTube

    so i also bought the following for the conversion as well

    another bargain walbro 225 fuel pump and vr6 maf for only £60 new
    [​IMG]

    vr6 maf will just be using the housing as i have a new maf from audi fitted just after i had the stage 2 done at Rtech
    [​IMG]

    also thanks to dan (beachbuggy) for the 346cc red top injectors for a bargain £80
    [​IMG]


    also bought a used badger5 tip v1 for the conversion for a bargain £90! thanks to my friend erdal for the bargain
    [​IMG]

    last week picked up the vr6 single mass flywheel package for only £60
    [​IMG]

    and best of all and my favourite mod i bought a relentless manifold for £170 another good friend called dan did me a great deal still in the box unused

    the manifold
    [​IMG]

    so now im here at this point and will have to purchase a new fmic setup due to the fact my current setup wont work with the k04 conversion and if i did try it, could be very dangerous i cant thank nick (prawn) for his advice, and also will just need to purchase a relentless downpipe and decat pipe and then i can start the conversion and back up to Rtech for some more power!!!

    i hope everyone who reads this enjoys the read and understands what i have done and how i have done it,this has just been my way of doing things and in no way am i suggesting this is the only or right way to do it but hope it gives people ideas of how to do their setups or even improve on what i have done or are doing,

    i must say a massive personal thank you to nick (prawn), Nick at RTech , My good mechanic and friend Dan (VWDan) and all the members here who have given me such great advice and options in the route i have taken with my car and will keep updating this thread as i keep adding parts

    so please enjoy and feel free to ask me anything about my build or pm and add me on facebook

    enjoy

    customboy aka Bobby :)
    #2
    Sandra likes this.
  4. deeman88
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    deeman88 Watch this space...

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    [May 28, 2012]
    Rahhh. A wolf in sheep's clothing for real bro. I'm loving it
    #3
  5. deeman88
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    deeman88 Watch this space...

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    [May 28, 2012]
    Dibs on the fmic if you decide to change the setup. And you have quite some kit there. I'm grinning :)
    #4
  6. Customboy
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    Customboy Member

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    [May 28, 2012]
    sorry about the mix up with the pics

    my new relentless manifold
    [​IMG]

    thanks lee for letting me know !!
    #5
  7. Stuart Dobson
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    Stuart Dobson Member

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    [May 28, 2012]
    Wow you really have done a lot :D
    Really enjoyed reading the thread and Thanks for all your help.
    #6
  8. Customboy
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    Customboy Member

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    [May 28, 2012]
    well soon once i got the new intercooler sorted and car is ready for turbo fitting i will be selling

    k03s turbo
    forge fmic with all the pipe work
    neuspeed tip
    pipercross panel filter
    agu injectors
    and what other bits i wont need

    so a great set up for someone who wants stage 2
    #7
  9. Dan-Jnr
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    Dan-Jnr Active Member

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    [May 28, 2012]
    Nice progress like what you have done so far and all for bargain prices too.
    #8
  10. Customboy
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    Customboy Member

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    [May 28, 2012]
    thanks dan its always moving forwards!
    #9
  11. 16Klappe
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    16Klappe Princess Clap.

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    [May 28, 2012]
    Hang on, Bobby is Customboy and Customboy is Bobby?

    I used to be so mean to you, but now I know who you are I love you.

    Great car Ranvir, you've done her proud :)
    #10
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  12. deeman88
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    deeman88 Watch this space...

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    [May 28, 2012]
    Lool. I can't stop laughing.
    #11
  13. Customboy
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    Customboy Member

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    [May 28, 2012]
    Yeah I'm one of the same u bully haha !!
    #12
  14. Sandra
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    Sandra MODERATOR Staff Member Moderator

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    [May 29, 2012]
    Bobby, that is a great write up, tbh, i was disappointed when i got to the end, i wanted to read more. I love what you have achieved with all your hard work. Very well done. :) x
    #13
    Customboy likes this.
  15. Customboy
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    Customboy Member

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    [May 29, 2012]
    Thanks Sandra that means alot I will update it soon with other bits I got lined up, but I remember how I first joined and how great u guys where to me and helped me see the path I wanted with my car, so felt I wanted to give something back and help a new generation of Audi a3 owners and hope this does help x
    #14
  16. Sandra
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    Sandra MODERATOR Staff Member Moderator

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    [May 29, 2012]
    Glad your enjoying the site Bobby, and I will look forward to updates on here. Drive safe. :) x
    #15
    Customboy likes this.
  17. Paradox1
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    Paradox1 Active Member

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    [May 29, 2012]
    Im sure the first and last time I saw your car was at ace cafe, I think that was the same day you got mapped but didnt realise it was you until you were leaving. Now you going k04 and wasting no time with it. Look forward to seeing you do the conversion.

    Good luck with it

    You at ace cafe tonight?
    #16
  18. Customboy
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    Customboy Member

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    [May 29, 2012]
    I'm defo at ave cafe tonight but will leave about 10 as I got to start my new shift tonight !
    #17
  19. Customboy
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    Customboy Member

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    [May 30, 2012]
    Right guys just a quick update I got home and had this waiting for me

    [​IMG]

    My lovely catch can oh the joys of a ko4 lol
    #18
  20. Sandra
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    Sandra MODERATOR Staff Member Moderator

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    [May 30, 2012]
    Let the fun commence. Your not hanging about with your mods Bobby. :) x
    #19
  21. Customboy
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    Customboy Member

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    [May 30, 2012]
    Life is too short to hang around Sandra lol just a few more bits and I'm ready !
    #20
    Sandra likes this.
  22. flying oyster
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    flying oyster flying oyster

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    [May 30, 2012]
    nice build thread bobby looking forward to the next instalment already
    #21
  23. Customboy
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    Customboy Member

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    [May 30, 2012]
    Cheers Neil mate soon more bits to come !!!
    #22
  24. Darren4
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    Darren4 Member

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    [May 30, 2012]
    did you get that off eBay bobby :)
    #23
  25. Customboy
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    Customboy Member

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    [May 30, 2012]
    No mate off a forum member but it's the same as the eBay ones
    #24
  26. Paddya3turbo
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    Paddya3turbo Member

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    [May 31, 2012]
    Custom boy I'v just had my car in for an mot before I bang a decat on and I'v failed on a tyre and a number plate bulb lol ! Where did you get your bulb set ? Headlight , interior and number plate ? And how much ???
    #25
  27. Customboy
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    Customboy Member

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    [May 31, 2012]
    I have a mate who does the kits for me the interior lot costs about £40 the exterior lights it's me about £100 if I remember or less been a while mate
    #26
  28. Markeyboy
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    Markeyboy Fan of the R-Tech!

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    [Jun 14, 2012]
    fantastic read mate,

    that new mani tooks lovley,


    when do you reckon youll be ready to go?
    #27
  29. dre_S3
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    dre_S3 Member

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    [Jun 14, 2012]
    Loving the build mate and what Markeyboy said when does the fun begin :)
    #28
  30. Customboy
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    Customboy Member

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    [Jun 14, 2012]
    Just two bits are left before I can start anything, firstly I just bought a miltek downpipe and decat used, and then will need to replace the whole intercooler setup and then just got to work hard to get fitting paid for a remap at rtech so I'm looking at least another month and I can't wait lol
    #29
  31. Customboy
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    Customboy Member

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    [Jun 21, 2012]
    Right everyone a quick update I know it's been a while but today bought a miltek downpipe and decat and now all I need is the welly cooler setup and the fun can begin !!

    heres my miltek downpipe and decat

    [​IMG]
    More
    On the way soon !!
    #30
  32. dre_S3
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    dre_S3 Member

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    [Jun 21, 2012]
    I thought milltek only done the twin sport cat off the standard downpipe for the 8l k04,
    nearly there then mate you at ace cafe next week
    #31
  33. tubby-ben
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    tubby-ben Member

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    [Jun 21, 2012]
    looking good bobby, hey when u fitting ur coilovers?
    #32
  34. Customboy
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    Customboy Member

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    [Jun 21, 2012]
    Dre see u at ace cafe lol !! And Ben when I can get a set sorted lol !! And finding someone to fit them lol
    #33
  35. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jun 21, 2012]
    hmmmmmmmmmmmmm is all I can say Bobby.....

    You're going to have a small issue with that downpipe.

    The LCR it came from has a flanged joint on the centre section, where your current exhaust has a slip joint.

    On my milltek cat back and XS DP, I simple had the centre section cut down and expanded to fit over the XS DP, but due to the bend in yours right by the flange, I think you're going to need to cut your system down and get a flange welded on instead.

    I could be wrong, but that's how it looks to me.
    #34
  36. Customboy
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    Customboy Member

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    [Jun 21, 2012]
    Yeah I noticed that as well mate but may just do as u said get it cut and welded or perhaps just replace the pipe work from the centre section with the right fitment
    #35
  37. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jun 21, 2012]
    To do that you'd need an Lcr car back bobby; which is 2.75". Your system is 2.5", so it's all or nothing!

    The XS decat pipe is straight, so easy to just do a slip joint onto it
    #36
  38. Customboy
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    Customboy Member

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    [Jun 30, 2012]
    Right sorry it's been a while but a new update firstly on my way to me now thanks to oly on here are a set of JOM coilovers was going to get the FK street ones but I could say no to the great price!!

    In the post my s3 arb has arrived still nicely wrapped
    [​IMG]

    Then soon after a set of adjustable drop links I may not need them but I want to low on my car so just in case
    [​IMG]

    Then today just got in then found this

    My new heat shield bargain £20!!!
    [​IMG]

    And even better just had a custom flange made so I can use my miltek downpipe and decat hurrah !!

    Its not to pretty but does the job and was only £20, plus once it's fitted will go back to garage to do a complete clear up and remove all flanges and make new ones and weld a new pipe for it to add to my current exhaust setup

    [​IMG]


    Plus went a bit crazy and bought a new intercooler lol it's the welly cooler set up pic is below should be with me Monday
    pic of it it's a 600x300x76mm
    [​IMG]

    So I'm getting there and soon fitting can start I can thank nick (prawn) enough and arrin !
    #37
  39. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jun 30, 2012]
    ARGH. Bobby, why did you waste £35 on those drop links?

    They're of no use to you what so ever.
    #38
  40. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jun 30, 2012]
    I've drawn it for you:

    [​IMG]

    The S3 arb goes under the drive shaft, not over, so adjustable drop links are about as much use as a chocolate tea pot.
    #39
    k1ano likes this.
  41. superkarl
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    superkarl MAN OF STEEL

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    [Jun 30, 2012]
    best diagram i've ever seen
    #40

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