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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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    [Sep 15, 2010]
    Can't really do much more until the turbo is back and that is currently unknown.... everything I nee to do now kinda revolves around that being on the car as I can't fit owt back in without it :(

    <tuffty/>
    Last edited: Sep 15, 2010
  2. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 15, 2010]
    Just grab Bills turbo and fit that! Last time i seam to remember it wasnt on his car!
  3. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Argh i see it now. Very nice.
  4. finesse
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    finesse Active Member VCDS Map User

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    nice work, surely you could have bought a nice B5 RS4 instead......
  5. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 15, 2010]
    Probably....

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

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    [Sep 15, 2010]
    Got a couple more things done today as I was out and about for a bit and spent a bit of time working out where stuff can go... bit of a pain not having the turbo as I can only do so much without the head etc being back in the car...

    Anyway, popped into Forge to pick up some bits so I could make the new TIP and finish the pipework to the throttle body..

    70mm 90 degree bend coming off the 60mm MAP sensor tube... you can also see the DV in the picture... I have been test fitting this in various places and now looks like it will go more or less where it is in the picture... kinda 'cold side relocation' style...
    [​IMG]

    ...as I no longer have a use for the 007p DV and the original positioning, I cut off the DV outlet from the charge pipe and made a plate that will be welded on to seal the hole...
    [​IMG]

    ...cut the 3" alloy tubing to make the TIP, here is a pic of the original one I made...
    [​IMG]

    ...all the inlets for attaching stuff like the PCV, N75 and charcoal filter are going leaving just an inlet for the DV (yet to be added)
    [​IMG]

    ...I also made a bracket to hold the power steering pipes in place as I have removed the SMIC's connecting pipe that they were originally attached too
    [​IMG]

    Still waiting on SFS to ship the joiner so I can get final position for the pipework and then thats the FMIC all plumbed in...

    I have a few little jobs to do but tbh most of what I have to do next really needs the head back on which I can't do until the water pipes are made which I can't do until the turbo arrives back although Bill thinks we may be able to do something to get it all started in the mean time...

    It was this time last year I started all this work... I thought I could do all that in 2 weeks too lol, ah well... not that bothered its off the road or taking longer but it does bother me that I am using space in the workshop that should be used for paying customers...

    Hopefully it won't be much longer :(

    <tuffty/>
  7. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 16, 2010]
    all welded up for ya last night..
    see if you can find the wmi boss, I did'nt see it.. so its not on the pipe yet
  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 16, 2010]
    Thanks mate, you are a star... will have a look around in the various 'safe places' dotted about the workshop :thumbsup:

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

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    [Sep 16, 2010]
    Had some good news today... CR checked my turbo over and the core is fine so all they they need to do is machine out a new housing to fit a 56 trim turbine (currently has a 48 trim turbine) which means I get the potential for a bit more power and should also help keep the EGT's a bit lower as they aren't backed up trying to get out past the smaller trim turbine...

    The turbo should be back next week on Tuesday so hopefully the car will be running again sometime over the weekend after that...

    Spent today painting stuff and cleaning my old head for Sandip....

    Still waiting for the SFS joiner so I dug out something that wasn't quite the right size and used that to help get the postions for the pipework... managed to get it all sorted and ready for welding and also found the WMI nozzle bosses so that can be welded on ready for when I have saved up for that :D

    Excuse the colour as it will be black but you can see where it all sits and the now final position for the supersize DV...
    [​IMG]

    ...and in the jig awaiting welding.... you can see the step from the 60mm tube to the 70mm tube... I cut a piece from the 70mm offcut and cut a section out so it would fit inside the 70mm bend... this will make it easier to bridge the gap for welding....
    [​IMG]

    Hopefully all be done tonight if Bill isn't too busy and I can paint it up and fit it in readiness for final assembly....

    <tuffty/>
  10. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Sep 16, 2010]
    Keep it coming paul. Also, bill clear your inbox :).
  11. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 16, 2010]
    done
  12. 1animal1
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    1animal1 The Clar!! it mouves!!! VCDS Map User

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    [Sep 16, 2010]
    Paul, your insane......bloody good work mate, everything looks stunning...you sat down and worked the man hours spent yet :)
  13. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 16, 2010]
    So I am told :)

    Ta, I try my best....

    Nope... nor the cost before you ask lol....

    <tuffty/>
  14. Welly
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    Welly VX220 SC Driver :)

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    [Sep 16, 2010]
    Word.
  15. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 16, 2010]
    Bill kindly welded the rest of the nearside FMIC pipework for me tonight.......

    You can see the MAP sensor boss in the straight part of the pipework and the WMI nozzle boss on the first bend on the left of the pic...
    [​IMG]

    ...need to paint it black and get it fitted although getting the DV outlet through the gap I have to work with is going to be fun :)

    <tuffty/>
  16. s3dave
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    s3dave TFSI Hybrid

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    [Sep 16, 2010]
    good work, is the wmi so far down so it circulates better or is it just where you plan plumbing the bottle?
  17. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 17, 2010]
    WMI nozzle should be as close to intercooler outlet as possible to allow maximum travel time for it to do its stuff on heat absorbtion and mixing etc
  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 17, 2010]
    Had a call from CR today and they are clean out of turbine wheels... it will take just over 2 weeks to take delivery of new stock but they do have new GT30 cores in with the right trim turbines... gonna cost a little more but I do end up with essentially a new turbo... just have to be more careful with this one lol...

    I also called SFS to chase my joiner and they have run out of black material to make them... they are getting a new batch in Tuesday so hoping to have the joiner by the end of next week...

    In the meantime, I started cleaning up some bits and spraying the remaining pipework now its done.... I did mange to put a dent in the top of the bend while playing with the final positioning before welding and I did knock most of it out... I sprayed it with a light coat and it became quite visible so I used some chemical metal filler to fill the dimples and now it all looks good... I opened up the hole for the DV outlet to the right size too.... that should get the air out :)

    A few pics..
    [​IMG]

    [​IMG]

    comparison of the normal 007p vs the supersize DV
    [​IMG]

    I spent a little time cleaning the PCV pipes I am going to keep. I will take pics etc when I have worked out what I am doing with it all...

    Turbo is still looking to be delivered Tuesday so we can get on with the coolant pipes and other than sorting the DV inlet for the TIP its just a case of bolting everything back together...

    <tuffty/>
    Last edited: Sep 17, 2010
  19. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Sep 17, 2010]
    Will this all be done by ADI paul?
  20. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 17, 2010]
    I would hope so... don't want to miss it this year...

    <tuffty/>
  21. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Sep 17, 2010]
    Good to hear.
  22. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 22, 2010]
    Turbo finally arrived from CR today.... boy was I excited (sad but actual true!)....

    Picked up the box from stores just before I left work for home this afternoon so I only had a chance to quickly look at the turbo before I set off... took a couple of pics..

    [​IMG]

    ...old housing and turbine...
    [​IMG]

    ...new housing and larger turbine :D
    [​IMG]



    It was then I noticed the box....
    [​IMG]

    ARSE!!!!

    Feck'n dumb ass Fed Ex mother feckers had dropped the box and damaged the V-Band housing....
    [​IMG]

    [​IMG]

    Feck'n retards!!! will be giving CR a call in the morning to discuss :(

    Took the opportunity to line up a K03, K04, my compact GT30 and Bill's not so compact GT35 for a bit of a comparison...

    ...hands by Welly (tm)...
    [​IMG]

    ...turbine comparisons... no K03 in this one as you can't really see it...
    [​IMG]

    ...and finally the difference between a T25 and T3 flanged hotside...
    [​IMG]

    Bit of an anticlimactic day all in all... fixable but shouldn't have happened and of course even more time taking up space and ramp time in the unit to which I am eternally grateful to Bill for but would rather not be taking up space better used for paying customers :(

    Anyhoo... at least I can get started on the coolant lines now even if I can't fit the bloody turbo to my new head yet and get it in the car... bugger!

    <tuffty/>
  23. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Sep 22, 2010]
    SSSSSSSSSSSSSUUUUUUUUUUUUUUUUUUUXXXXXXXXXXXXXXXXXXXXXXXX
    Last edited: Sep 22, 2010
  24. Welly
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    Welly VX220 SC Driver :)

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    [Sep 22, 2010]
    Granted, that does suck some serious balls. However, you already know my feelings on the FedEx front....

    [​IMG]
    liquids3 likes this.
  25. s3dave
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    s3dave TFSI Hybrid

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    [Sep 22, 2010]
    that isnt a potential crack/flaw by blade 6? maybe just the light.....
    did they shed any light why the other cracked? egts?
    Last edited: Sep 22, 2010
  26. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 22, 2010]
    Its all good... had a really good look over it and I trust CR to do a good job... shame about the couriers.... was packed well too, surrounded by a thick bed of polychips so must have been a fair distance to drop and cause that damage... Bill had similar with his race head... feckers dropped it twice... on the way to JNL Racing for porting and on the way back!!!

    <tuffty/>
  27. s3dave
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    s3dave TFSI Hybrid

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    [Sep 22, 2010]
    cool, i get it all the time with couriers, they just want to go home..... and stand on or drop anything that gets in their way....the part that has been bent removes, so it should be a quick fix, i would have got my copper hammer out...lol
  28. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 22, 2010]
    I'll see what CR can do before I take a blow torch and hammer to it lol... its a bloody PITA tbh and I still haven't received the silicon joiner from SFS... they are getting a call tomorrow too lol

    <tuffty/>
  29. Lee Goodall
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    Lee Goodall ..got my head together!

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    [Sep 23, 2010]
    That's unlucky mate. I hope you can sort it out without too much trouble.
  30. 1animal1
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    1animal1 The Clar!! it mouves!!! VCDS Map User

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    [Sep 23, 2010]
    PAul thats **** dooood, hope ya get it done sooner rather than later
  31. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 23, 2010]
    Called CR and their hands are tied... I can make a claim through the courier but it would take a while and chances are they would play the 'inadequate packaging' card but they did offer to get the oxy on it and fettle it back... this would of course mean I would be unable to fit the turbo until it came back which as Welly has found out is likely to be a while as they are bonkers busy and under staffed... so we did it ourselves....

    [​IMG]

    Bit more flatting to get it true and job done... didn't take long and one less thing to worry about now...
    [​IMG]

    Been playing with ideas for the coolant pipes too so that is next on the list to do....

    Hoping to get a couple of days on the car over the weekend as I have Monday off... hopefully gonna break the back of the work and have her more or less together by close of play Monday... thats the plan anyhoo...

    <tuffty/>
  32. AJC
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    AJC 3rd Gear

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    [Sep 24, 2010]
    Good effort Paul. Despite numerous setbacks along the way you do have the end in sight. Can't wait to see the results.
  33. Welly
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    Welly VX220 SC Driver :)

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    [Sep 24, 2010]
    Good work dude :thumbsup:.

    I knew that would come good in the end.

    There are no problems.... only solutions.... lol
  34. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 26, 2010]
    Busy weekend sorting a few little yet important jobs... but... coolant hoses are made and fitted..
    [​IMG]

    [​IMG]

    ...and of course most importantly the head is now on the car!!! Woo actual Hoo!!
    [​IMG]

    ...fitted the new cam belt and refitted the engine mount before I left today...

    Mostly a case of bolting stuff back on, I have a few things to buy tomorrow but I have the day off to get most of the car back together... still waiting for SFS to deliver the reducer though although they tell me I should get it Monday... hummm.... we will see....

    Nearly there.... big thanks (yet again) to Bill for his help, as always much appreciated mate and you can have your ramp back very soon... promise :)

    Lets hope I don't get held up by a bit of silicon!!!

    <tuffty/>
  35. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Sep 26, 2010]
    Good work
    and thanks Bill on behalf of Paul, and the readers of the thread, without your assistance it mat not have existed at all..
  36. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 26, 2010]
    Cracking work guys! now hurry up and et it running so we can find out what the clutch is like!
  37. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 27, 2010]

    no problem.
  38. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 27, 2010]
    One thing i thought last night if you havent already paul is wouldnt it be worth welding the clutch pedal so it doesnt snap on you as there have been so many failures lately
  39. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 28, 2010]
    Been fighting man flu all day but more or less did a 12 hour stint on her today...

    Lots of fiddly stuff and mundane stuff to do but basically went from left to right across the engine bay putting stuff back, changed the oil filter and filled the engine with oil, filled the gearbox with oil as it was drained to remove the bevel box, plumbed in the coolant hoses, EGT probe, downpipe, exhaust, driveshaft, propshaft yadda yadda... all seems to take time to do but all must be done...

    One of the things I did this time around was to simplfy the PCV system... I had already removed a lot of the hoses etc under the inlet mani but sorted it out properly this time as I had the access...

    Replaced the lower PCV valve and t-piece with a bit of hose... I used silicon but rubber will do and silicon that is fluorosilicone lined would be better but it will do for now...
    [​IMG]

    ...only pipes coming out of the bottom of the inlet mani now is the large one for the DV and the two smaller ones for the FPR and boost gauge...
    [​IMG]

    ...I have had to use an incorrectly sized blue joiner while I wait (still!!) for the SFS one to turn up!!!... needed everything in place to sort the DV fitment and TIP fabrication out.

    DV in place...
    [​IMG]

    ...and pipework from the DV...
    [​IMG]


    ...too the TIP...
    [​IMG]

    ..this is now the only inlet going into the TIP, all thats entering the intake system now is air and fuel...

    A few little jobs left to do starting with painting and fitting the TIP properly... engine bay looks more or less back together...
    [​IMG]

    ...FMIC is looking neat and stealthy...
    [​IMG]

    ...and of course I couldn't resist checking to see that I still have an OEM look... (despite the blue joiner!!!)
    [​IMG]

    Nearly finished, been tiring and I am royally knackered right now.... up at 6:30 in the morning :(

    Hopefully get to start her up Tuesday night... and I must remember to bleed the clutch!

    Again big thanks to Bill for welding my DV inlet to the TIP and of course for his continued support of my modifying habit (which in fairness he did start... sort of... ok, it's always been there!!!)

    <tuffty/>
    Last edited: Sep 28, 2010
  40. superkarl
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    superkarl MAN OF STEEL

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    [Sep 28, 2010]
    im assuming you have an oil catch can? where is it?

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