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. StaceyS3
    Offline

    StaceyS3 Well-Known Member

    Joined:
    Dec 17, 2010
    Messages:
    2,113
    Likes Received:
    187
    Doing well mate will definately get there in the end 

    I'm following this closely am very curious what an underslung compact gt30 on an external gate can do ;-)
  2. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    Productive day....

    TPS delivered the rings first thing..
    [​IMG]

    Gapping rings isn't the most exciting job in the world but I actually found it quite enjoyable lol...
    [​IMG]

    ...when fitting new rings to an engine that hasn't had a rebore its a good idea to check the gaps top, middle and bottom of the bore as the gaps can vary... I found that on all mine they were larger at the top than the bottom (typical wear of course) so gapped accordingly... (the ring in the pic is a little lower than was measuring from... needs to be up a bit...)
    [​IMG]

    Fitted rings to the pistons clocking the rings at 120 degrees...
    [​IMG]

    ...oiled them up and fitted them into the bores...
    [​IMG]

    ...shiny new bottom end :D
    [​IMG]

    I cleaned up one of my old pistons to use as a 'plunger' for pushing the rings into place in the bore for the gapping process... good job that bit of the ring fell off else I may not have noticed how worn they were... old ring on the left, new ring on the right...
    [​IMG]

    Seems my engine was on borrowed time... got the verniers out to confirm...
    New ring...
    [​IMG]

    ...old ring...
    [​IMG]

    ...not good :(

    All better now though... the pistons that went in had next to no wear on the coated skirts and are of course 9.5:1 comp ratio... bores are in better condition than before and of course hopefully no more rattling now I have gudgeon pins that are 20mm where they need to be...

    Manifold is at machine shop being done so will have that for Saturday and can crack on with checking for final fitting and start working out the oil drain too...

    Happy with the progress and at least I know the engine is solid enough now... (until I stroke it of course LMAO!!)

    For those that are interested there is a useful series of videos on youtube that I used to get an idea of what I was letting myself in for...

    1.8t engine assembly HOW TO(part 1) - YouTube

    <tuffty/>
  3. badger5
    Offline

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,282
    Likes Received:
    673
    rings, rods, now talk of stroking.... lol

    ohh errr

    still talking about car bits?
  4. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    LOL... you have been working with me too long mate ;P

    <tuffty/>
  5. badger5
    Offline

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,282
    Likes Received:
    673
    lol - been a funny ole day today
  6. Broken Byzan
    Offline

    Broken Byzan Photographic Moderator Staff Member Moderator

    Joined:
    Apr 26, 2004
    Messages:
    12,579
    Likes Received:
    270
    :tapedshut:
  7. patTTpoa
    Offline

    patTTpoa Member

    Joined:
    Oct 27, 2011
    Messages:
    793
    Likes Received:
    6
    Nice work, & those vid's are spot on & I'm sure they will help many out.

    Pat
  8. StaceyS3
    Offline

    StaceyS3 Well-Known Member

    Joined:
    Dec 17, 2010
    Messages:
    2,113
    Likes Received:
    187
    Ahh them vids are very good watched them all right through before rebuilding my motor :)
  9. superkarl
    Online

    superkarl MAN OF STEEL

    Joined:
    Mar 28, 2010
    Messages:
    7,569
    Likes Received:
    1,082
    i've studied those videos too haha. i imagine alot of us have. just in case
  10. aragorn
    Offline

    aragorn "Stick a V8 in it!" Staff Member Moderator

    Joined:
    Jan 30, 2008
    Messages:
    15,529
    Likes Received:
    301
    That ring wears pretty weird! The parts i pulled out my 195k AEB didnt even look that bad!

    I wonder if thats been a side effect of the small end wear, or the power your running?

    The new pistons look in good nick. The black graphite area on the skirt often wears away even on lower mileage engines (my 100k pistons all had shiney silver patches in the middle of that graphite) and yours looks more or less intact. Your bores must be fairly decent too, as i found when i fitted new rings to my AJL and the TT BAM i rebuilt, none of them needed gapped, they were all already larger than the minimum specified by Audi.
  11. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    We think the bore wash I would have got from when my EGT probe was in the exhaust manifold and constantly thinking EGT's were too high probably contributed to their early demise...

    Despite the initial shock of yet more things going wrong I am feeling a lot happier that the bottom end is more sound than it has been which is just as well considering the potential increase in power I should get from the new turbo configuration...

    <tuffty/>
  12. Andy123
    Offline

    Andy123 Member

    Joined:
    Jan 3, 2009
    Messages:
    260
    Likes Received:
    2
    If Bill was happy with it-would you fancy an extra set of hands?
  13. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    Thanks for the offer mate... pretty much got it covered tbh and heard from Bill that the manifold is back... I won't be back at the workshop until Friday afternoon now and Saturdays plan is hopefully to fit the head/turbo back on if the oil drain etc goes ok...

    You are of course welcome to come down mate but wouldn't want to put you out of your way especially over Christmas..

    <tuffty/>
  14. badger5
    Offline

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,282
    Likes Received:
    673
    you would be welcome andy if you wanted to come down
  15. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    ^^^ what he said :)

    <tuffty/>
  16. Routledge
    Offline

    Routledge Wind Deflector Trend-setter

    Joined:
    Nov 7, 2011
    Messages:
    395
    Likes Received:
    10
    Wow this thread looks far too complicated for me to keep up, but seems like great progress is being made! :)
  17. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    Its not your average 'bolt bits on and go' type thread for sure but hoping the 'bloggy' approach to it will help people at least get an idea of the sort of work that goes into this level of modification and also be informational enough for anyone else considering going down this path...

    Its been a bumpy ride but loved every minute... even the times like black saturday lol...

    <tuffty/>
  18. Routledge
    Offline

    Routledge Wind Deflector Trend-setter

    Joined:
    Nov 7, 2011
    Messages:
    395
    Likes Received:
    10
    Yeah it certainly looks in-depth. If I ever get around to taking things further along those lines with mine I'll be sure to come back and read your content in full. It'll probably feel more relevant to me then.

    Glad to hear you're enjoying it - That really is the main thing! :)
  19. Lewis583
    Online

    Lewis583 Active Member

    Joined:
    Mar 15, 2010
    Messages:
    875
    Likes Received:
    70
    I wish i lived closer to Gloucester lol

    Fantastic build thread Tuffty :icon_thumright:
  20. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    Finished work for Christmas at 2.00pm today so took the chance to spend a couple of hours over the workshop to see if the machining work done on the manifold has done the job...

    The manifold... provisioning for wastegate...
    [​IMG]

    5mm machined from turbo mounting face and holes enlarged from M8 to M10
    [​IMG]

    ...obviously this has highlighted the crack I have which has been caused in fairness to the manifold by the stainless steel plug for the EGT probe hole I had put in...
    [​IMG]

    ...this carries on inside a bit to but Bill will weld these with his special rods so no drama... the TIAL wastegate will fit like this...
    [​IMG]

    So... all good so far... I already knew about the crack and we have a plan to deal with that so next job was to bolt it all too the head and offer it onto the engine to see if I now had the clearance I needed... first problem due to the 5mm of material removed from the flange was that the comp housing hit the nut/stud and wouldn't sit in the turbine housing square... booo!!!
    [​IMG]

    ..so a bit of fettling and repositioning of the manifold and that now clears... phew!!... next I dropped the head with the turbo fitted onto the engine... for the life of me it would not sit on the dowels on the back of the block!!!... clearly it was hitting something on the back of the block which wasn't obvious before... took the head off and plonked it on to a scrap block we have lying about for engine mock ups and bingo... the comp housing was hitting an unused bolt fixing on the back of the block!!...
    [​IMG]

    So out came the grinder and that 'issue' was no more... I used the old headgasket and a couple of the old head bolts to bolt down the head and bingo... everything now clears... still tight but a result non the less...
    [​IMG]

    Tried the TIAL to see what clearance we have there too...
    [​IMG]

    Fantastic... turbo fits... well happy with that... of course the next problem is the oil drain and the water pipe to the block... the old oil drain went under the bottom of the hotside but the T3 one is bigger so thats not gonna happen and the water pipe I currently have is no longer in the right position now the turbo has moved over a bit... I have to try and squeeze it between to block and the turbo somehow and I think some modding of the bevel box bracket may help here but thats tomorrows challenge :)
    [​IMG]

    Plenty left to do but at least I know the turbo now fits and the challenges left as relatively straight forward engineering and fabrication ones...

    Big thanks to Nigel for turning the manifold around so quick and of course a massive thanks to Bill for just about everything really :thumbsup:

    More tomorrow...

    <tuffty/>
    Last edited: Dec 23, 2011
  21. Andrew@A.L.D
    Offline

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,509
    Likes Received:
    355
    No chance of fitting a bigger turbo then? lol
  22. badger5
    Offline

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,282
    Likes Received:
    673
    *snug*
  23. BENJAMIN
    Offline

    BENJAMIN Member

    Joined:
    Mar 3, 2011
    Messages:
    486
    Likes Received:
    81
    Quite mad how little space there is, did you grease that turbo and use a shoehorn to get that in there? I fitted an underslung t3 fitment gt3071r to an 8p S3 and there is night and day differences in available space.

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
  24. badger5
    Offline

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,282
    Likes Received:
    673
    what mani, ben?

    other way round fitment helps.... but whats the intake pipe like for clearance past chassis/inner wing area?
  25. BENJAMIN
    Offline

    BENJAMIN Member

    Joined:
    Mar 3, 2011
    Messages:
    486
    Likes Received:
    81
    It's an ATP mani bill. Surprisingly I managed to keep full 76mm intake using 2 90degree bends, chassis legs not a problem but it comes in close proximity to the master cylinder.
  26. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    To be honest I reckon I could swap the turbo around like that and there would be similar room but then there are lots of other issues with that of course lol... They do fit turbos that way around in the states on mk4 platform cars (Golfs etc...)...

    Might be an option I guess if I decide to go for a bigger turbo but tbh I can't see that for some time yet lol..

    <tuffty/>
  27. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    Productive day today :D

    First task was to sort the oil drain... the old one tucked under the previous hotside but as the new hotside is bigger I had to come up with a better idea... trouble is there is little to no room due to the bevel box and the proximity of the driveshaft so I decided to modify the bevel box bracket to allow the oil drain to go parallel to the block...

    Took a notch out of the bracket to allow the oil drain to sit in...
    [​IMG]

    Plonked the head back on to make sure all was good...
    [​IMG]

    Pleased with that I went on to sort the water pipes... one of them just needed a little tweaking to make it fit properly but the one to the block was not going to fly so made a new one instead...
    [​IMG]

    Marked up where the external gate fittings needed to go while the head was back on (again!!! backs killing me lol...) and then Bill welded everything up (such a nice man...)
    [​IMG]

    Finished up with a few other little jobs... always the sorta jobs that everyone forgets about... painted the oil drain and the bevel box bracket, removed all the exhaust studs from my head as a couple had come loose... cleaned the threads and refitted with threadlock... happy with the position of the turbo housings and cartridge I also bolted everything up ready for final fitting...

    One last job before the head can go back on and thats to sort the turbo to charge pipe connection...
    [​IMG]

    I had to clock the comp housing round a little further down than it has been so it would clear the bevel box... I did try to re-clock it back to the original position but it hit the exhaust manifold stud and it hit the bevel box again so will leave it where it is for now and sort a solution for it another way...

    Day off tomorrow of course but may nip over for a couple of hours boxing day as my lot are off to the inlaws so will see what I can come up with to sort the charge pipe problem...

    Merry Christmas :D

    <tuffty/>
  28. Westy
    Offline

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,296
    Likes Received:
    969
    Good work as always Paul. I wish I'd had some spare time for the car today :(

    Merry Christmas.
  29. Lee172
    Offline

    Lee172 GT3071

    Joined:
    Jul 20, 2010
    Messages:
    431
    Likes Received:
    2
    Nice one tuffty, glad to see its going well.
  30. patTTpoa
    Offline

    patTTpoa Member

    Joined:
    Oct 27, 2011
    Messages:
    793
    Likes Received:
    6
    Coming along nicely tuffty, i bet you can't wait to get it running now!

    Have a good Xmas dude

    Pat
  31. Broken Byzan
    Offline

    Broken Byzan Photographic Moderator Staff Member Moderator

    Joined:
    Apr 26, 2004
    Messages:
    12,579
    Likes Received:
    270
    I bet he'd be down there tomorrow given half the chance,LOL
  32. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    He did pop in :)

    Anyhoo... spent a couple of hours at the unit this afternoon to see if I could sort out a solution for connecting the turbo to the charge pipe... I fitted the manifold and turbo to the build engine and was surprised to find that the hose fitted more or les right away... I had been playing with the clocking of the cartridge to get the oil drain into position so maybe I got away with clocking the comp housing too... had to fit it to the car to check... boo... would appear something had moved in between fitting the oil drain and tightening up the housings... pays to double check these things a few times even when you think you have got it right... check it again to be sure..

    Following a hour or so of lifting the head assembly in and out the car a few times, I had the clocking right this time and tightened everything up... then fitted the head one more time to be sure... :D

    I then reassembled it all back on the build engine and shock actual horror the comp housing was now a little further round and I was back at square one... knew it was wrong anyway so this confirmed it... booo...

    A bit of creative spacing of brackets and opening of holes later and I found a compromise that should work...
    [​IMG]

    While I was at it I also fitted the TIAL (after a de-bling session) and made a new water pipe for the other side of the turbo as I wasn't happy with the way I modded the old one to fit...

    ...old pipe...
    [​IMG]

    ...new pipe...
    [​IMG]

    ...and of course in keeping with the OEM+ look... what external wastegate???
    [​IMG]

    With the cover on of course there will be nothing to see...

    Couple of things left to do but essentially all thats now required is to fabricate the new downpipe and TIAL pipework and then connect everything back up...

    Back at it tomorrow and hopefully be looking at making a start on the DP...

    <tuffty/>
  33. Prawn
    Offline

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,477
    Likes Received:
    1,299
    Is the build engine bills Ibiza engine? I've seen that blue rocker cover in another thread elsewhere tonight!
  34. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    It use to be on Bill's race car but DHL dropped it (and the head it was attached to at the time) so it got damaged and now sits on the build engine... it will crop up in a lot of builds as this is the platform we try bits on to look for clearances etc..

    The block is Welly's old APY block with a chunk out of one of the cylinder walls and the head was one of Bill's fully ported race heads that got nuked when the Denso plugs threw their toys out the pram..

    <tuffty/>
  35. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    Had a few little jobs to do this morning... made a bracket for the new water pipe on the turbo to stop it shaking loose, clearanced the areas around the bolt holes on the hotside as M10 cap screws and Nord Lock washers weren't sitting flat on a couple of the holes, re-compressed the cam belt tensioner damper then reassembled the manifold and turbo back onto the bare head and fitted it back in the car ready for the downpipe fabrication...

    Removed the driveshaft for better access and after chatting to the big man for the benefit of his sage knowledge I started measuring, re-measuring then cutting a few 1D stainless steel bends...

    After a little messing about and thanks to the joy that is 'welding tape (tm)' I have ended up with this (so far)
    [​IMG]

    ...which looks like this fitted up...
    [​IMG]

    ...and the heatshield now fits... result!!! no more melted (dried up and cracked to be precise..) inner cv boots...
    [​IMG]

    Doesn't look much for a couple of hours work I know but its the first downpipe I have cut up for myself (with Bill on hand for pointers...) so I was triple checking everything before cutting it as I didn't really fancy the idea of wasting too much tube by making silly mistakes...

    Had to leave early though due to family commitments else I am sure I would have finished it and made a start on the TIAL pipework too...

    Back at it tomorrow... hoping to start her up at the weekend... tall ask I guess but gotta have a goal :)

    <tuffty/>
  36. patTTpoa
    Offline

    patTTpoa Member

    Joined:
    Oct 27, 2011
    Messages:
    793
    Likes Received:
    6
    I hope you don't start it until Saturday morning!! Lol

    Looking good, but looking through yours & wellys hybrid tread I'm really unsure which way to go.

    But hay splendid work

    Pat
  37. badger5
    Offline

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,282
    Likes Received:
    673
    this week I am mostly welding stuff it seems.
    even badgerwagen got some welding done.. finished its external wg pipe and made a slip joint for it too.
    wrap it up and fit her on.. Also trying to get it running before 1st Jan.. (hmmm. tall order me thinks)
  38. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    We'd best pull our fingers out then bud... You weld stuff and I'll fit stuff :)

    Happy enough to put the time in on the Badgerwagon after all you have done for me mate..

    <tuffty/>
  39. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,792
    Likes Received:
    1,283
    Been one of those days where you seem to have done lots but don't have much to show for it...

    Started off with fitting a new earth lead to replace the haldex earth strap that corroded... I ended up buying one from Halfrauds as I had some money on a gift card from when I left my last job and needed to get some other stuff anyway... the one I bought was probably a little longer than it needed to be but I cable tied it out of the way to keep it safe and neat... you can just see the earth point on the diff and the earth point on the car body in this pic...
    [​IMG]

    Then cracked on with finishing the downpipe and TIAL pipework... Bill tacked what I had done so far together so it didn't move about and make the measurements go out of whack and managed to get the new downpipe to line up wit the rest of the system... result..
    [​IMG]

    ...and prior to welding...
    [​IMG]

    Once welded I will need to drill the holes for the lambda boss, EGT boss and wastegate pipe... speaking of which...
    [​IMG]

    [​IMG]

    The blue hose will be replaced with a flexi of course... :)

    So... essentially all thats left to do is weld it all up and wrap it in heat wrap then its a case of bolting everything back on, adding fluids and bobs yer muscle etc...

    Like I said... doesn't seem a lot but its all the measuring, double checking, removing, refitting etc that goes on that takes the time... even had to undo the dogbone and undo the propshaft to move it over as with the v-band on and how tight the space is its near impossible to fit without doing it... my last downpipe was the same tbh... then of course you have to put the prop back on and do it all up again else everything is out of alignment...

    Still... home straight now...

    <tuffty/>
  40. Dani_B19
    Offline

    Dani_B19 Audi-sports own special child.

    Joined:
    Nov 9, 2008
    Messages:
    7,275
    Likes Received:
    90
    Looking very good mate, keep up the excellent work.

    On a side note what heat wrap do you recomened using? Need to wrap my dp before it gets fitted.

Share This Page