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My minor modding thread

Discussion in 'A3/S3 Forum (8L Chassis)' started by <tuffty/>, Jul 29, 2009.

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

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    Popped into see Bill today....

    [​IMG]

    330mm rotors with Badger 5 alloy bells... Bill is gonna get a set black anodised as well as a set of alloy caliper brackets.

    Bill also has some stainless steel braided pipes and some DS2500's to go with it all so I think that sorts the braking out a treat :)

    <tuffty/>
    #41
  2. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    #42
  3. A3Tom
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    A3Tom Smell my finger.

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    Damn you....are you trying to make my wallet ache???!!
    #43
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Sure... why not :)

    <tuffty/>
    #44
  5. A3Tom
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    A3Tom Smell my finger.

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    Interested in your brakes though..... Need to check the funds!
    #45
  6. 1animal1
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    1animal1 The Clar!! it mouves!!!

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    damn you tufty for being so inspirational :D
    #46
  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Happy to oblige :)

    <tuffty/>
    #47
  8. sean88boy
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    sean88boy black S3

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    hey looking good wish i could do the work my self!!:hi:
    what are those injectors and what size??
    #48
  9. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Siemens Deka 630cc... links to them are further up the thread (#36) :)

    <tuffty/>
    #49
  10. S3 Paul
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    S3 Paul Active Member

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    I think ive just had the same rods fitted as part of my new motor.
    what clutch will you be using with this?
    Im planning on an upgrade to my turbo once my bank account looks a little better !
    Do you know of any other S3/TT's running this manifold and turbo set up? is heat a major problem?
    I did look at having a tubalar manifold made but i like the idea of the stock look but is there a trade off with performance??
    #50
  11. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    No idea as yet... I am gonna wait until I get enough money to sort my gearbox out as I have a crunchy 3rd gear which is probably syncro related and will look into it when I am ready... however... any suggestions will be gratefully received :)

    I don't know of any others using this combo. Bill usually fits tubular top mount manifolds to the BT conversions he does but this log mani appealed as it was cheaper and kept everything looking OEM.

    Heat wise there shouldn't be much real difference to OEM but I am having the downpipe wrapped initially and getting both the mani and DP ceramic coated when funds allow.

    Obviously there will be a trade off but I am using a smaller than usual hotside to aid spool up which would choke a tubular mani to an extent at higher RPM. You would gain more power higher up the rev range with a combo of the right hotside and decent tubular mani. If I was chasing numbers and/or had deep pockets I prob would go tubular but if you do go tubular go top mount rather than underslung as its a pointless exercise IMO, benefits of a decent tubular mani are negated by underslung variants...


    <tuffty/>
    #51
  12. S3 Paul
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    S3 Paul Active Member

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    It would be a top mounted jobie.
    Ive just opted for the sachs power clutch for now with a new duel mass jobie.
    Alot of S3 and TT have a dodgy 3rd gear if the change if rushed.
    Only if driven like a loon does mine feel anything less than good.
    Is the manifold braced against the block? To carry the weight of the turbo??
    #52
  13. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    There isn't one on mine at the moment but can be fabricated if required

    <tuffty/>
    #53
  14. badger5
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    badger5 RIP S3dave Site Sponsor

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    no need to brace it

    can you predict which direction(s) things will expand to..? I know I cant

    just stop the downpipe wrenching onto the setup will be better..

    I dont brace turbos.. no problems yet
    #54
    AVLO likes this.
  15. Purple Princess
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    Purple Princess Moderator Staff Member Moderator

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    13 Days to go :) Im sooo excited for you to get this started woop woop
    #55
  16. bansheeboyo
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    bansheeboyo Member

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    hi paul do you know what size rim you have to rim for these to work?
    where do you buy the caliper brakets?
    for the 350 pounds what all do you get
    cheers scott
    ps cant wiat till you start:)
    also where is the best place to get a k04 hybridised:think:
    #56
  17. S3 Paul
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    S3 Paul Active Member

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    I Know its a bit cheeky... How much for a mani?
    And a down pipe to fit?
    Ive done the internals and fitting a sache power clutch... probs last about 5 mins though
    #57
  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    I have 18's but should fit under 17's... hope they do as my winter tyres are on my old 17's :)

    Badger 5 manufacture and supply brackets for Brembos. Bill and I offered up the disc and calipers last weekend and took some measurements over the ones Bill gets made for Brembos. I think he is getting some made in the next week or so...


    Not sure where you got that figure from??? My calipers cost me £325 from ebay (link further up the thread), I am not sure of the cost of the rotors, bells, brackets, bolts and brake hoses as yet. Best bet is to give Bill a bell for a quote.

    Me niether... making a start next Thursday evening...

    CR Turbos and Turbo Dynamics are 2 companies that spring to mind.... CR do a K04 hybrid for £495 + vat exchange IIRC...

    <tuffty/>
    #58
  19. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Bill builds down pipes on car as every BT he has done so far has been different. You would need to leave your car with him for a little while and you would need it at least wrapped but would recommend ceramic coating which will add to the expense but stop things melting.

    I will have this done eventually but it can take up to 2 weeks as the company that Bill uses is quite busy and I don't want to wait 2 weeks for my car :)

    Give Bill a call and he will sort you out a quote for a DP and a mani... (www.badger5.co.uk)

    <tuffty/>
    Last edited: Aug 29, 2009
    #59
  20. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    #60
  21. S3 Paul
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    S3 Paul Active Member

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    I did ask about uprating my engine mounts at jbs not so long back... But after being taken out in a fast octavia with them fitted,,, i decided to see how i get on with stock ones.
    The vibrations passed through the car were horrible.
    Making it more like a track car than a comfy fast road car.
    #61
  22. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Mat20vts A3 with a Badger 5 GT2871R has vibratechnics and when I went out in his car today to see how good his new DS3000's pads were I can honestly say there was no vibrations felt while driving at all... I had a lot worse when I fitted a powerflex dogbone bush...

    That said, the INA Track Density mounts are supposed to be hard....

    Erring on the side of THS as they are cheap (I know that doesn't make um better) but seem to have the same qualities as the INA Street Density stuff and the THS top hoses I have appear to be very good quality.

    Question still stands though if anyone has had experience of these mounts (or any others for that matter) then please let me know :)

    On a lighter note... I take my car into Bill's Thursday evening to make a start on fitting the rods. Plan is to remove as much as I can Thursday night ready to remove the head Saturday and get the rods in... Can't say I am looking forward to all the stuff I have to remove but its all for a good cause.... 400 of them to be precise :)

    Will start posting progress pics (hopefully) next weekend....

    <tuffty/>
    #62
  23. mat20vt
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    mat20vt Member

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    paul, the only way you can notice vibration in my car is the coins ratteling about in the tray. apart from that, its minamal. thats fast road mounts in mine.

    hope you get a move on with yours, i wana see how it spools up!
    #63
  24. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    #64
  25. A3Tom
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    A3Tom Smell my finger.

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    I'm loving all this gucci stuff you're getting :)

    Really looking forward to seeing it all come together.

    T
    #65
  26. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    #66
  27. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Finally started on the work... WooHoo!!!

    Here is a pic of the engine bay at the start... the aim is to return to looking like this as much as poss..

    [​IMG]

    After about 2 hours of casual spannering (and having to drill out a crappy screw holding the trim panel on in front of the inlet mani!!!) it looks like this...

    [​IMG]

    May not look like much but this is whats come off so far...

    [​IMG]

    All I can say is kudos to people who do this for a living... what a PITA!!! Sooooo much stuff needs to come off just to get to the damn head!!!

    Anyhoo, back at it Saturday and Sunday too I expect... I WILL have the rods in this weekend if it kills me :)

    <tuffty/>
    #67
  28. bansheeboyo
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    bansheeboyo Member

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    damn thats a clean machine:respekt:
    #68
  29. Dansmith
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    Dansmith Member

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    Am I just thinking like a single bloke? lol
    #69
  30. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    :lmfao:

    <tuffty/>
    #70
  31. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Latest batch of goodies arrived today... engine mounts and exhaust wrap.

    [​IMG]

    Barg for the money...

    Back on it tomorrow, fluids out then remove a load of stuff to get to the cam belt and engine mount...

    <tuffty/>
    #71
  32. Dansmith
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    Dansmith Member

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    I'm sorry tuffty I couldn't resist! Car looks like its going to be sweet! I look forward to seeing the results!

    Dan
    #72
  33. bansheeboyo
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    bansheeboyo Member

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    well paul how did you get on fitting the rods?
    #73
  34. S3 HODGE
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    S3 HODGE Brown passenger seat.

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    Looks exiting, Post more pictures! :)

    I know Oli who owns and runs THS, Hes a top bloke and does good deals! Im sure your mounts will be top stuff because they get rated very well at APD (My local VAG Tuners/Revo dealer).
    #74
  35. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    What you wrapping paul, the exhaust manifold and DP? Also when you fitting the mounts, would like to know how the car will drive and feel when there on.
    #75
  36. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Was going to do a Saturday update this morning but didn't get time as the cat decided to get stuck up a tree so had to get him down before heading off to Bill's... so here is the weekends update instead...

    Saturday:
    All fluids drained... anything to do with removing the cambelt was as always going to be a complete PITA!!! Cambelt top cover required removal of the engine mount and dog bone plus loosening of the gearbox mount to jack the engine up and over enough to get the little plastic cover off!!! then it was the stupid chunky aluminium mounty thing to allow me to release the tensioner.

    Anyway, engine is apart, parts have been soaking overnight to clean them and the pile of bits I have had to remove grows larger...
    Pics from Saturday... they are a bit rubbish as I forgot the CF card for my digi cam and took them on the phone instead...

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    Sunday:
    Started by cleaning up the stuff left in the cleaning booth overnight. Sump needs a bit more work (Bloody AVS, oil baked on to the sump!!!)

    Cleaned up the piston, decoked and cleaned out ring slots. Rings looked fine so just did a fine hone of the bores to deglaze.

    Pistons and rods ready to be sorted
    [​IMG]

    OEM rods v Integrated Engineering rods
    [​IMG]

    Assembled
    [​IMG]

    Honed...
    [​IMG]

    Fitting last rod in
    [​IMG]

    Pistons/rods in with Tony's seal of approval :)
    [​IMG]

    I have removed the K04 but not had a good look at it yet.

    [​IMG]

    Few more oil/water pipes to remove and also the OEM downpipe.

    Started cleaning the head, other than it being grubby there is nothing more to do there but I have but the cam cover in the cleaner to get rid of the AVS grunge...

    Offered up the 330mm discs with the calipers today too... brackets will be sorted tomorrow, just a minor tweak to get the offset right then they can be supplied for those bargain AP calipers on ebay....

    Monday evening will consist of dry fitting the turbo/mani to Bills spare engine to mock up the 3" DP, oil and water lines and fitting the S3 charge pipe brkts etc to work out what we need to do to get it attached to the turbo.

    <tuffty/>
    #76
  37. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    Reminds me of last summer. Good luck with the build!:icon_thumright:
    #77
  38. MintyS3
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    MintyS3 Works 60% the time, Everytime.

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    All seems like effort to me lol :respekt:
    #78
  39. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Its a little more than anticipated granted... If this thread shows nothing more than how much effort goes into a build then I'll be happy.

    Mine should still be relatively easy compared to some. The Polo Bill has in his workshop at the moment has been in for a while now but the space limitations under the bonnet while trying not to turn it into a race car is bordering on ridiculous. The A3/S3 engine bay is capacious comparatively.

    Check out the Polo for an idea of 'real' effort :)

    http://www.seatcupra.net/forums/showthread.php?t=218680

    <tuffty/>
    #79
  40. Lee Goodall
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    Lee Goodall ..got my head together!

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    Good work mate. Looks like you're going to complete your build well before my turbo conversion is done.. I'm not even touching the internals lol.
    #80

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