1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

My minor modding thread

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

  1. S3 HODGE
    Offline

    S3 HODGE Brown passenger seat.

    Joined:
    Apr 22, 2009
    Messages:
    1,202
    Likes Received:
    1
    Wow, Just looked at the link that Tuffty put up and that is one of the tidyest projects i think ive ever seen. Hats of to Badger 5! Awesome stuff!.....Only if i had enough money i would go all out on mine!
    #81
  2. bansheeboyo
    Offline

    bansheeboyo Member

    Joined:
    Dec 18, 2008
    Messages:
    201
    Likes Received:
    0
    holy **** the standard rods are laughable
    #82
  3. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    Didn't spend ages working on the car tonight, removed oil and water pipes plus EGT sensor, fitted the charge pipe brackets and charge pipe to Bills other engine ready for the various pipes to be fabricated.

    Managed to get the cat off but the DP is proving to be a bit of a pig... does anyone know of a better way to remove the OEM DP without cutting it in half?

    <tuffty/>
    #83
  4. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    #84
  5. S3 Paul
    Offline

    S3 Paul Well-Known Member Regional Rep

    Joined:
    Oct 27, 2006
    Messages:
    2,784
    Likes Received:
    75
    Ye. the down pipe is a pig. We dropped the prop shaft and lowered the subframe down. Just wait till you want to remove the 3 inch one with the car built up" thats fun .
    Ive been stuck in the garage most nights too. Mines nearly ready to go back in. Turnes out it was a valve stem oil seal that has come a drift on my old engine causing the blue smoke. So realisticaly ive gone a bit mad just for some stem seals ... but if im looking for power... a 110k engine wasnt a good place to start.

    Did you make a choice on a clutch?
    Also what oil will you be using?
    Ive got my running in oil and my first oil change stuff sorted but not decided yet what oil to use as from there...
    #85
  6. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    Not made a clutch choice as yet, too many other things on my mind atm without worrying about further expense :)

    Oil wise, I will be using Quantum semi synth 10W40 while Bill maps the car and the rings bed in from the honing then dumping it for Quantum 5W40 fully synth as thats what bill has in stock.

    I normally use Fuchs Titan SuperSyn 5W40 fully synth from GSF and change it every 5k

    <tuffty/>
    #86
  7. 1animal1
    Offline

    1animal1 The Clar!! it mouves!!!

    Joined:
    Dec 27, 2007
    Messages:
    9,981
    Likes Received:
    31
    looking good tuft.... really inspiring all this engine stripping, although i havent the luxury of a ramp so think my life may be a tad harder :(
    #87
  8. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    Just dropped into Bills tonight to arrange some stuff and the brackets for the calipers had arrived so while I was there I thought I may as well fit them up to see what they look like. The more observant of you will notice the disc is actually the wrong one for the drivers side (grooves are the wrong way around) but this was purely to test the bracket fitment.

    [​IMG]

    So Bill now has brackets and braided hoses suitable for these calipers. He is also going to do some for the cheaper 323mm LCR discs making this a very cheap alternative to Brembos using the calipers I bought from ebay.

    Back on it tomorrow though, plenty to do :)

    <tuffty/>
    #88
  9. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    Busy day, DP was very tight and tried various suggestions on how to remove this but ended up cutting the mount on the DP and undoing the propshaft to move it to one side... not as easy as it looked to be honest as I had to lever the engine/gearbox forward to disengage the prop fully from the transfer box.

    [​IMG]

    [​IMG]

    All the OEM stuff is now off ready for the new turbo/mani/DP/TIP

    [​IMG]

    Finished cleaning the sump and rocker cover too... AVS blows goats!!! don't do it kids!!!

    Before...
    [​IMG]

    ...after...
    [​IMG]

    ... and finally a pic of the brackets and pipes for the AP Racing ebay specials....
    [​IMG]

    ...to be continued... etc...

    <tuffty/>
    #89
  10. s3_kev
    Offline

    s3_kev Stage2'd!!!!!!

    Joined:
    Feb 17, 2008
    Messages:
    1,999
    Likes Received:
    18
    did you end up leaving the subframe in place to get the dp off then?? as i never loosened the prop when doing mine with the subframe down,
    top job on doing the conversion would have loved to have done this on mine but my stage2 is doing me proud at the mo but time will tell, these forums always make you take that extra step as you have already learnt by the looks of it lol
    #90
  11. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    I tried to drop the subframe but the front 2 bolts were so tight I thought I was either gonna break the breaker bar or pull the car off the ramp!!! Think they were air gunned tight when I had the alignment done.

    Thanks mate, the encouragement and support from everyone has been great. I am not the first to have gone big turbo and won't be the last but seems to be a very select few that do go ahead with it on an Audi for some reason. Those SEAT boys on SCN though are all at it... quite an eye opener really.... but then I do have quattro to put the power down :eyebrows:

    <tuffty/>
    #91
  12. MintyS3
    Offline

    MintyS3 Works 60% the time, Everytime.

    Joined:
    Jul 2, 2008
    Messages:
    1,581
    Likes Received:
    4
    Allways said I wouldnt but that extra power is very welcome. Shame Im buying a house next year lol

    How much for the old turbo? lol
    #92
  13. S3 Paul
    Offline

    S3 Paul Well-Known Member Regional Rep

    Joined:
    Oct 27, 2006
    Messages:
    2,784
    Likes Received:
    75
    The brakes paul...
    You payed 325 ish for the calipers?
    How much did the brackets discs and hoses end up costing you?
    Im guessing around the same again?
    Just before i bought my S3 i bought a Brembo set up ( fitted but unused ) for £450 and sold them for £500.
    You can get them cheaper than most list prices if you shop around.

    Using the 2 peice disc set up... how much are these? How much are the replacement rotors??
    #93
  14. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    That was a good price, I wasn't looking to do my brakes at this point but stumbled across these calipers and at £325 for the pair seemed good value for money.

    I am not going to put prices up on the thread but you can get in touch with him directly and ask. Same goes for the hoses, brackets and bells...

    <tuffty/>
    #94
  15. badger5
    Offline

    badger5 www.badger5.co.uk Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,297
    Likes Received:
    678
    330x28 2-piece rotors which are 323x28 direct replacements for existing brembo users, and anyone who want to buy these bargain AP's off Ebay.

    £145/rotor
    £60/bell
    £13.95/rotor bolt set
    Brackets for the AP's £60/each
    tensile bolts for caliper to brkt £5/each (x4)
    DS2500's for the AP calipers - £99
    plus delivery & vat
    #95
    chris.sargent likes this.
  16. S3 Paul
    Offline

    S3 Paul Well-Known Member Regional Rep

    Joined:
    Oct 27, 2006
    Messages:
    2,784
    Likes Received:
    75
    Are those each for the rotors and bells? or per pair?
    Do the caliper bolts come as a x4 set for £5 or is it 4 x £5?
    #96
  17. Broken Byzan
    Offline

    Broken Byzan Photographic Moderator Staff Member Moderator

    Joined:
    Apr 26, 2004
    Messages:
    12,584
    Likes Received:
    270
    Thats each bell, each disc and each bolt

    £145 rotor x 2
    £60 bell x2
    £13.95/rotor bolt set x 2
    Brackets for the AP's £60/each x2
    tensile bolts for caliper to brkt £5/each (x4)

    £577.90 plus vat and delivery is how i read it.
    #97
  18. S3 Paul
    Offline

    S3 Paul Well-Known Member Regional Rep

    Joined:
    Oct 27, 2006
    Messages:
    2,784
    Likes Received:
    75
    £577.90 + the £325 for the calipers?
    So £900 for the full job?
    Not for me thanks.
    Takes any saving you make on the calipers way way way beyond Brembo kit or porsche kit money
    #98
  19. badger5
    Offline

    badger5 www.badger5.co.uk Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,297
    Likes Received:
    678
    Way beyond brembo/porsche kit money??? - this is a "2-piece" AP equivalent kit way less. you priced brembo 2-piece brake kits up lately?? I think you will be shocked (eg. Brembo GT Junior calipers are >£300 each +vat alone)

    find a 2-piece Brake setup using AP or Brembo calipers for better or same money

    To put this into prespective you get a 2-piece brake setup for the price of a one piece brake setup which is extremely good value. The Brembo 323x28 one piece brake kit I do is £940 inc vat in comparison.

    Plain 323x28 disks are a budget option which are £119/pair +vat (£136.85 inc vat)
    Add the egay calipers - (£325)
    brackets- (£138)
    Pads - (£113.85)
    bolts - (£23)

    Totals - £736.70 inc vat - which is a very good price to build yourself an AP 4-pot brake kit.

    the 330x28 2-piece are the upper end upgrades for those who want them.

    regards
    bill
    Last edited: Sep 11, 2009
    #99
  20. S3 Paul
    Offline

    S3 Paul Well-Known Member Regional Rep

    Joined:
    Oct 27, 2006
    Messages:
    2,784
    Likes Received:
    75
    £138 quid for brakets?
    Bloody hell ! ive just made a set up for a mk3 vr6 golf using porsche 4 pots and brembo discs ( he suplied the calipers ) for £170 with him just needing the hoses to fit.
  21. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    ...lets put this to bed shall we? Awesome GTI do a GT Brembo kit for over £1200 inc vat using 323mm solid discs... (http://www.awesome-gti.co.uk/product.php?xProd=10949&xSec=381) euro prices being a PITA and making everything expensive...

    ...meanwhile and to bring my thread back on topic.....

    casual day cleaning the head and inlet mani, fitting the caliper brackets and braided hoses and playing with the fitment of the turbo and its pipework...

    Clean head and inlet mani
    [​IMG]

    Brakes more or less done bar bleeding and fitting the discs
    [​IMG]

    Studs and pipes fitted to the turbo to see if there are any probs and there was. Some of the fittings needed modding to fit and the supplied oil drain pipe wasn't for a transverse engine so gonna have to make something to fit properly...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Cleared a nice space for it all to fit :)
    [​IMG]

    Should have the head on this weekend and a start on the custom TIP. There is also some work to do to get the comp outlet connected to the cahrge pipe but Bill and I have a few ideas for that :icon_thumright:

    <tuffty/>
  22. ianysm
    Offline

    ianysm Active Member

    Joined:
    Oct 10, 2008
    Messages:
    1,003
    Likes Received:
    0
    Excellent report. Keep it coming! Looking forward to you finally driving it and the review!!

    I certainly wouldn't have the patience for it all (even waiting for you to complete is killing me!!!)

    Good luck
  23. S3 Paul
    Offline

    S3 Paul Well-Known Member Regional Rep

    Joined:
    Oct 27, 2006
    Messages:
    2,784
    Likes Received:
    75
    If every time i post something that goes against what you or bill says i get slated for taking the topic off thread... shall i just keep my information to myself?
    This is a web site where people come to look for help, to weigh up their options ... so we all give them options.

    In my opinion the brake one you have made could have been a wee bit cheaper considering the bargin of the calipers.

    Right.... as requested back on topic.

    I fired my car up last night ! all is well !!
    As part of your build are you fitting a new oil pump? I didnt notice which bearings you are using either... are they audi genuine ones or uprated items?

    Im still unsure as to what oil to use once ive run things in. The quantum syntha gold? Im guessing you mentioned is not available anymore so im told as its all gone to quantum platinum??

    When are you looking to fire things up??
  24. badger5
    Offline

    badger5 www.badger5.co.uk Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,297
    Likes Received:
    678
    yea, just for brackets, CNC milled as a limited qty batch..
    £60/brkt +vat, same price as brembo fitment ones, despite these being designed to fit this caliper/disk combo and the time spent

    you confuse DIY efforts with quality manufactured commercial ones we get made

    for those who dont/cant machine things or know where to start, it provides an option, which was trying to be helpfull from tufftybloke from the ebay link for some bargain 4pot AP's, in combination with disks/brkts/hoses/pads to get a great value but still high quality kit.

    I just dont see why you post at all... its -ve continually.
    Its tuffties thread after all.. not yours
  25. badger5
    Offline

    badger5 www.badger5.co.uk Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,297
    Likes Received:
    678
    I have yet to see any actual "information" posted from you at all... have I missed it?
    lots of one liner criticism, minimal to no content I've seen yet. unlike tuffty/me

    those AP's are good. even better value, and when gone will be gone..

    For those 'genuinely' considering 4pots these will be a great option for them. Now that cant be a bad thing for forum guys can it? Now we have spent time on getting the fitment for S3/Golf/Leon via suitable machined CNC lightweight alloy brackets it gives options for those who want 2-piece 4pot setup or one piece for great value all in kit. NEW parts remember, not cobbled together used parts off porsches etc etc

    If its not for you fine... if you can make your own fine too. good for you, but to continually criticise without adding any value or information is tiresome and a poor reflection on you. Why criticise? What are you thinking you are trying to achieve by doing so? Looking Big and knowledgeable?? (cos your not coming across like that at all........ quite differently in fact to me)
    Last edited: Sep 12, 2009
  26. Broken Byzan
    Offline

    Broken Byzan Photographic Moderator Staff Member Moderator

    Joined:
    Apr 26, 2004
    Messages:
    12,584
    Likes Received:
    270
    The calipers were in fact a bargain, and Bill has given a blow by blow break down on the required parts needed to fit them to the car. Its not like he bought the calipers cheap, made a set up with discs etc and said there we are guys. £1100.

    There are std type large discs available, use them, make your own brackets and you have a big brake kit for cheap like the home made Golf setup you quoted above.

    I know i certainly would not like to take chances with brakes. thanks for your opinion, if you can base the opinions on some kind of fact then you wouldn't get flamed..
    Last edited: Sep 12, 2009
  27. Andrew@A.L.D
    Offline

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,509
    Likes Received:
    358
    Love it

    Whats exhaust manifold is that?
  28. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    Its a PAG Parts manifold, (google it) Bill imports them....

    The turbo and mani are part of a kit complete with oil and water pipes.

    <tuffty/>
  29. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    Good news :)

    I checked the pump over when I had it off... stripped and checked for wear, cleaned it throughly and bunged it back on... I cleaned the pick up for ages to make sure no debris was left in the strainer...

    The stuff Bill has is Platinum....

    Providing the TIP and DP fabrication goes OK, I would hope to start her up towards the end of the week....

    <tuffty/>
  30. 1animal1
    Offline

    1animal1 The Clar!! it mouves!!!

    Joined:
    Dec 27, 2007
    Messages:
    9,981
    Likes Received:
    31
    woah tufts excitin stuff :hubbahubba:
  31. S3 Paul
    Offline

    S3 Paul Well-Known Member Regional Rep

    Joined:
    Oct 27, 2006
    Messages:
    2,784
    Likes Received:
    75
    I was told ( and i think i read it on here too ) that oil pumps on a 1.8t was an item that can fail. I mean i hope yours is sound mate, But with the sump off i would have pop'd a new one in.

    As for me bodging things and just slagging bills work ... im realy going to leave that there.
    The one thing i will agree on is this is tufftys thread.
  32. Broken Byzan
    Offline

    Broken Byzan Photographic Moderator Staff Member Moderator

    Joined:
    Apr 26, 2004
    Messages:
    12,584
    Likes Received:
    270
    The main failiure is the pick up blocking up, and once you are in there to do that, most times garages stick a new pump in as the labour is already covered . I can assume Tuffty didn't skimp on this un neccesarily after spending so much on the rest.... At least i hope not. Only advantage you lot have with the A3/S3 layout is the sump will drop to swap the pump quite easily later

    S3 Paul, nice work on getting yours up and running
  33. S3 Paul
    Offline

    S3 Paul Well-Known Member Regional Rep

    Joined:
    Oct 27, 2006
    Messages:
    2,784
    Likes Received:
    75
    Chears .
    It was a scarey time !
    I know it was built right but it doesnt stop you not wanting to turn the key !
    I was going to do a build thread but... the mods inside are never that WOW as big turbos and stuff.
    I didnt mean tuffty might have cut a corner here with the pump. I just always knew i would fit a new one as an extra safe gaurd.
    Ive got one ... well not sure its a complaint about my set up... the sache power clutch feels wierd. the pedel has to be pushed all the way down. We have bled it up all number of times and its clear. no bubbles, Ive replaced the slave cylinder clutch and fly wheel and have been told by my mate who works for a good VAG modding company that sometimes this happens and it will "come up" over the next few days?? hope so!
  34. badger5
    Offline

    badger5 www.badger5.co.uk Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,297
    Likes Received:
    678
    the pump was a working pump when it came in, and pump 'failures' in the main are in fact pick up pipe blockage which AVS is a culprit. sluding on modern oils/cars is horrific to see. AVS enemy of the car owner. The one pump failure I have seen was a sprocket coming off the pump.

    Its been cleaned, visually checked, and deemed ok..

    Where do you draw the line on a budget build. His labour is free, its his own, so what is economic for DIY (strip & checking) is differently gauged when paying an hourly rate at a garage, where replacement would be cheaper.

    It was ok before, has been thoroughly cleaned off in every respect, especially the pickup pipe which did have some signs of debris, so all should be fine.

    A new one would be fine to fit also, but budget is a factor here.
    Last edited: Sep 13, 2009
  35. badger5
    Offline

    badger5 www.badger5.co.uk Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,297
    Likes Received:
    678
    "bodging things" being YOUR words not mine ;)

    leaving it there... nice... and thankyou - finally.
  36. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    Busy weekend....

    Brakes are now fitted and bled. I have tried them with both my OEM RSTT 18's and my 17" Avus's. Both sets of wheels need spacers to clear. I have 10mm spacers on the front atm which clear fine on both but wouldn't recommend anything less for the RSTT with an ET of 33... the Avus's would need a minimum of 5mm I reckon although you could measure the gap with a feeler gauge between the spokes and the caliper and I wasn't gonna risk damaging my calipers :). I have also painted out the yellow 'TVR' with matt black paint.... stealth++

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    The oil drain pipe issue has been solved...
    [​IMG]

    [​IMG]

    Charge pipe has been modified...
    [​IMG]

    [​IMG]

    Hit a few problems with the oil feed pipe, apart from it being a little too long, it doesn't have a reducer in it to limit oil flow to the turbo bearings. The Garrett GT30 I am using has a roller bearing whereas the K04 has a sleeve type bearing that uses high pressure oil to lubricate it. The roller bearing doesn't need this so a reducer is used to reduce pressure. This is currently being sorted... I also need a hole drilled and tapped in the exhaust mani to take the EGT probe that is usually fitted on the turbine housing of the K04.

    Once that is all sorted, I can bolt it to the head properly and offer it into the car for clearance checks before finally bolting in the head... WooHoo!!...

    In the meantime, here are a couple of pics of the turbo mocked up on Bills spare engine. This one done to make sure everything fitted as it should... good job we did this :)

    Big turbo?... what big turbo???...
    [​IMG]

    ...oh, THAT big turbo!!!!
    [​IMG]

    Think my OEM look is coming together ;P

    I feel a bit like Marks Evans... A Big Turbo Is Born!!!! LOL!!

    See you next time my big turbo chums....

    <tuffty/>
  37. Broken Byzan
    Offline

    Broken Byzan Photographic Moderator Staff Member Moderator

    Joined:
    Apr 26, 2004
    Messages:
    12,584
    Likes Received:
    270
    Wicked work there, i am liking the special tape you used.........J/K

    I can't wait for the next installment
  38. 1animal1
    Offline

    1animal1 The Clar!! it mouves!!!

    Joined:
    Dec 27, 2007
    Messages:
    9,981
    Likes Received:
    31
    tufts...costs costs costs please ...well an estimate ;)
  39. S3 HODGE
    Offline

    S3 HODGE Brown passenger seat.

    Joined:
    Apr 22, 2009
    Messages:
    1,202
    Likes Received:
    1
    Looks good! Will this be ready for the ADI on the 10th Oct?
  40. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,815
    Likes Received:
    1,290
    In a word, yes.... :)

    <tuffty/>

Share This Page