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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 28, 2010]
    On the workshop floor just to the right of the fire exit :)

    <tuffty/>
  2. superkarl
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    superkarl MAN OF STEEL

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    [Sep 28, 2010]
    ahhh useful place then lol. id like to fit one but that oil catch tank thread confuses the hell out of me.
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 28, 2010]
    Its easy enough to do tbh but there can be a lot of pipes to remove and actually finding somewhere to fit the tank is the hardest of the lot lol... thats why its still on the floor :thumbsup:

    <tuffty/>
  4. superkarl
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    superkarl MAN OF STEEL

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    ahh i see. hard to find somewhere stealthy.
  5. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 28, 2010]
    ...hard to find anywhere period!... others have it mounted on the top of the bulkhead by the TIP... once I have finished fitting the TIP on mine I will see if it can be put there... tbh as long as I can see the level tube from the top even with a torch I am happy enough to drain it from underneath so may see if there is a bit of space lower down somewhere... not high on the priority list atm, called SFS again today and they now say the joiner I need will be with me Thursday at the latest... not bad considering I ordered it on the 14th...

    <tuffty/>
  6. Alex C
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    Alex C Well-Known Member

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    [Sep 28, 2010]
    so is Tuftys build thread/Haynes manual substitue coming to an end? :(
  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 28, 2010]
    Still got WMI to do, R32 ARB's and maybe some work on a 3" custom CAI... still a few bits on the horizon but other than changing the inlet mani to a SEM and a bottom end rebuild to 2ltr or something then engine wise its pretty much there..

    That badger bloke will be along shortly though with the word 'GT35' no doubt ;P

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

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    [Sep 29, 2010]
    Yay!... finished putting the TIP together, looks a bit different from the original one I made...
    [​IMG]

    ...and now...
    [​IMG]

    Done all the rest of the little jobs and turned her over with the injectors unplugged to get everything lubed up before firing her up for the first time...

    Pretty much fired first turn of the key, had a bit of a cough then settled to fast idle warm up, dropped out of warm up and I was waiting to see if the much discussed R32 throttle body erratic idle would appear and..... steady as a rock at 880 rpm...


    ...and as you can see here, the needle doesn't faulter... water temp at 90 etc...


    All good... can't tell you how happy I am... even a small seep from one of the water pipes didn't phase me... bit of work left to do like re welding the water pipe union.... we did pressure test the thing but heat and G12 always seems to find a way out!!!

    Night off tomorrow as I am shattered recovering from a busy few weeks and a couple of days of man flu...

    Thursday I will be bleeding the clutch and taking her for a test drive so that I can tell Speedy Steve how good/bad/indifferent the clutch is :)

    <tuffty/>
    Last edited by a moderator: Aug 15, 2014
  9. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 29, 2010]
    Thursday I will be bleeding the clutch and taking her for a test drive so that I can tell Speedy Steve how good/bad/indifferent the clutch is

    hehe thats what i like to hear! All looking good i would get some fuel as soon as you test it aswell thats if you can afford it after all the work youve done :)
  10. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 29, 2010]
    Its all good, I am gonna use my latest pay rise to buy half a tank :)

    <tuffty/>
  11. MUSH
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    MUSH MUSH Developments Ltd.

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    [Sep 29, 2010]
    love this thread, great work!

    Ill be interested to see where you install your catch can, it was easy enough on my mk2 20vt but as you say theres no room on the S3. Im only just starting to rip my engine bay to bits to fit a new engine and big turbo so this thread has helped me a lot. doubt ill be going as OEM as yours, but its good to see you can do it.

    Love all the little farication jobs on all the boost pipes/intercooler etc. adds a touch of class and good engineering!
  12. superkarl
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    superkarl MAN OF STEEL

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    [Sep 29, 2010]
    you mention your clutch, is it standard? are you concerned it will last ten minutes. but then i suppose its how you drive.
  13. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 29, 2010]
    oh dear....

    <tuffty/>
  14. Madeley
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    Madeley Member VCDS Map User

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    [Sep 29, 2010]
    Loving your work Tuffty, will we see the beast unleashed on the rolling road day?
  15. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 29, 2010]
    I doubt it tbh.... if there is time and enough interest at the end of the day then maybe but I suspect we would be all dyno'd out by then :)

    <tuffty/>
  16. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 30, 2010]
    Paul i dont know if you read my post the other day but have you welded the clutch pedal? may be worth doing if you havent done yet last thing you want is that going on you after all this work
  17. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 30, 2010]
    Oh and its thursday! whats it like to drive? haha
  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 30, 2010]
    I did mate and I haven't as yet... not high on the priority list... will look into it at a later date though... the clutch shouldn't be any stiffer than it was before as I am using an OEM pressure plate, just grabbier (new word)

    That would be Thursday evening... I do have an actual job during the day :)

    As it happens I can't get to the unit tonight as the wife is out but I am hopefully going to put in a couple of hours after work before she goes out and get the clutch bled and bumper on etc...

    Still need to weld the pinhole in the coolant pipe too, hoping Bill will have a spare 5 mins tonight to do that... if all goes to plan then I should be driving the car home Friday evening sometime...

    <tuffty/>
  19. Speedy Steve
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    Speedy Steve Active Member

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    haha im only messing mate i cant believe you've done so much this quickly as it is!
  20. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 30, 2010]
    The girl is home!!!!

    Bled the clutch after work and the pedal is light as a feather... that maybe more down to the fact my little Mk2 Golf has a cable clutch and is much stiffer than the S3's anyway...

    Checked for fault codes before I drove her out of the unit and got...
    17748/P1340/004928 - Camshaft Position Sensor (G40) / Engine Speed Sensor (G28): Incor. Correlation

    Bugger!!... would appear that despite me checking a billion times I have managed to slip a tooth fitting the belt... Its not the timing chain, I am damn sure of that... I checked it loads of times and span the cams round a few times to settle it all in... that was timed up fine... must have been when I was struggling with the belt over the back of the cam sprocket... ah well... will sort that out over the weekend, just have to lay off the boost...

    All I can say is she drives like a dream... the clutch is light and so far judder free, I haven't tested it 'properly' yet as I still need to sort the belt out and a couple of other things... looking good so far on drivability for the clutch, once I am happy the engine is running right then I will 'test' it a little more ;P

    One thing I have noticed is how much more responsive the boost gauge is and the DV.... while pottering at -0.5bar, a slight touch of the throttle and the needle just appears at 0.0 rather than moves there.... the couple of times boost has hit the 1bar region just letting off the throttle drops the needle into vacuum quicker than you can blink... before it would tail off... sure sign that the engine is breathing much better...

    Not going to get her on the dyno until I have sorted the belt, water leak and the hose (finally!!) turns up from SFS... yes... SFS STILL haven't delivered my hose despite assurances that it would be Thursday at the latest.... 16 days... to make a hose... brilliant!!

    <tuffty/>
  21. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 30, 2010]
    Sweet good job mate! Glad the clutch feels good may just have to book it in with Bill to get mine done
  22. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 30, 2010]
    Hold that thought until I have time to let it bed in and test it properly mate... all good so far but until I can unleash the full power of the engine I won't know how actual good it is/isn't etc...

    <tuffty/>
  23. scoobyra
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    scoobyra It's not f@cking ORANGE!!!!!

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    [Sep 30, 2010]
    I'm sooooo looking forward to seeing you car on the 9th Paul!
  24. Speedy Steve
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    Speedy Steve Active Member

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    [Sep 30, 2010]
    Well i am in serious need of a clutch so hurry up lol
  25. s3dave
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    s3dave TFSI Hybrid

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    [Oct 1, 2010]
    well done mate, love the feeling when the engine just wants to go.......you just know.....
  26. The Stig
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    The Stig Member

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    [Oct 1, 2010]
    i had the same fault, turned out to be just a dirty sensor. Good luck!
    Nice to read your build!
  27. JD09
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    JD09 I'm not modding, I'm improving VCDS Map User

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    [Oct 1, 2010]
    Blimey Paul, can barely keep up with reading the thread! Shows the speed at which you've sorted the car and got it together :thumb:

    Congrats on getting it run so well, looking forward to seeing it at some point over the coming months/year.

    Jamie
  28. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 1, 2010]
    Thanks for all the support peeps, very much appreciated especially as my girl nearly let me down today.... was driving home from work and suddenly lost power and the EPC light came on... throttle was unresponsive and I had all sorts of thoughts going through my mind.... managed to nurse her home and checked for faults...

    17743 - Engine Torque Monitor 2: Control Limit Exceeded

    Had a check under the bonnet but it was raining, the engine was idling perfectly and there was nothing obviously off or otherwise... bugger!....

    No real choice but to get her back down to the unit and have a look.... after driving her for a little while it felt more like a boost leak... there was no way it was a vac leak as I only have 3 vac pipes on the mani now and vacuum on the gauge was on the button... got her on the lift and had a look under the car as there was 'a noise' while driving and sure enough I noticed that the temporary joiner I was using (that is too big) had popped out of the jubilee clip underneath the charge pipe going into the TB...

    I did try and use a couple of clips just to hold it in but seeing as the water pipe needs a blob of weld and I need to sort the cambelt out I decided enough was enough and went home in the Golf...

    So, in summary... SFS is responsible for my near breakdown as for some reason they seem incapable of making and posting a small piece of silicon rubber... which is apparently what they do for a living... I did call them today (yet again!) and they apologised (yet again!) and assured me they would be sending it out today (yet again!!!!)....

    Happy enough though... car was driving fine this morning on the way to work and looking at the water leak its no where near as bad as it was with the old hoses... easily fixed :)

    Will get the cam belt and water pipe sorted this weekend and await SFS's delivery with anticlimactic anticipation

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

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    [Oct 1, 2010]
    SFS are shocking !
    Ive been waiting nearly a year now for some purple vac hose they took payment for at a show and said a week at the most.
  30. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 1, 2010]
    Perhaps they are too ashamed to make it in that colour LOL... soz mate, been a long few weeks ;)

    I know they have had issues with black rubber supplies and that they have had to make one as they don't normally keep many in that size on the shelf (it is an odd size tbh) but its the constant 'we will ring you back with an update' and then don't!... I am far too soft with people like that tbh... if its not here Monday then I shall be ringing up again to check it actually shipped... will kick off if not... I need it for the show next weekend!!!

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

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    [Oct 1, 2010]
    Oi !
    You Leave my choice of colour alone !
    haha,
    Its not for the audi its for the skyline,
    Every show i went to i saw them, every time... it was being made on monday.
    Still waiting
  32. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 1, 2010]
    Call um... they actually answer the phone very quickly... which is more than can be said about their delivery times...

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

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    [Oct 2, 2010]
    A bit of a mixed bag today is has to be said....

    In between helping Bill on the dyno while he was mapping Welly's car, I pressed on with sorting the cam belt timing issue out on my car... was all going well, didn't even have to take off the stuff you normally do to change a belt as I used a method I saw in elsa using a threaded rod washer and a nut to compress the damper and move the tensioner roller away enough from the belt to get it off...
    [​IMG]

    All was going well and the timing marks (that were out after all!!) were all lined up... went to fit the engine mounts back and one of the M12 bolts felt very nasty so backed it out again and sure enough the thread in the alloy mount (the one bolted to the engine) looked a little worse for wear so ended up running a tap through it...
    [​IMG]

    ...now that was all good I put everything back together to check that the fault code had gone for good... started her up and there was a steady belt style whine... thought it may have been the alternator so checked for faults codes which had gone (yay!) and let the engine run another minute or so... the whine had got quieter but not gone... this bothered me quite a bit so I took the charge pipe off, removed the cam cover and...
    [​IMG]

    ...Bugger!!! the belt was toast.... I must have tweaked the middle metal belt cover with that stupid alloy mount as it has bent a tab over and it was this eating into the belt...
    [​IMG]

    Had enough by then... packed up and went home... will change the belt tomorrow making sure I have timed it up right this time...

    When I got home the SFS delivery was noticeably absent... hopefully that will turn up Monday but I WILL be calling them again to make sure its shipped!!!

    What a git of a day... Glad I decided to double check the cambelt though.. grands worth of head at the mercy of a fifteen quid belt... rubbarsh :(

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

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    [Oct 2, 2010]
    Dude, bummer big time on the belt - what an arsehole. Big thumbs down. :(
  35. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 2, 2010]
    Thanks mate, it's a shitter but hey ho... about on par with all the rest of the things that have gone wrong lol...

    Car isn't going anywhere at the moment anyway... not least until SFS eventually decide to actually send me my damn hose!!!

    I will use the blue one and take tools if need be to get me to ADI next weekend... not missing this one!!!

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

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    [Oct 2, 2010]
    Good lad, glad to hear it :thumbsup:. You may need a UNOS too.... :whistle2:
  37. 1animal1
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    1animal1 The Clar!! it mouves!!! VCDS Map User

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    [Oct 2, 2010]
    be good to see you again Paul..... just dont put the car in jeopardy to get it there mate
  38. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 3, 2010]
    Yes... I just might ;P

    When you dropping that round?

    Aye, car will be fine.... replaced the cambelt this afternoon and fired her up... no fault codes so all good... glad I did change it though and knocked through it in a couple of hours so not too bad a job...

    I am going to call another company tomorrow about getting a hose as a fall back in case SFS just really are that incompetent and I will be calling SFS as well to make sure they have indeed shipped it when they said they would...

    Doubt I will get time to get the mapping sorted before ADI although I may get a chance to get her on the dyno if Bill's not too busy but I know there is stuff booked in this week so as long as the engines running ok then all will be good...

    <tuffty/>
  39. superkarl
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    superkarl MAN OF STEEL

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    [Oct 3, 2010]
    id be looking for some kind of compensation for sfs's incompetance! your a paying customer relying on them and they cant deliver. freebies!
  40. s3dave
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    s3dave TFSI Hybrid

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    [Oct 3, 2010]

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