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My minor modding thread

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

  1. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    Toms S3 is an early pre facelift with no ESP but has a digital clock we guessed it was narrowband but couldnt work out if it was me7 or 7.5.

    His car happily communicates using my Official Ross-tech hex can USB cable and VCDS and unisettings happily picked up the cable but just wouldnt read the ECU. We found a guide to using unisettings and follwed that eg have the ignition on etc but still no worky :(
  2. Westy
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    Westy Double Dark Side! Diesel & 8P

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    Go into options in VCDS and untick "boot in intelligent mode". I had to do this to get unisettings to work on mine.
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Narrow band is ME7, wideband is ME7.5

    ^^^ what he said :)

    <tuffty/>
  4. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    Dammit wish we had known this last night at 11pm sat in his car shouting at my netbook lol

    Still will keep that info handy as that could be useful in the fututre
  5. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Bill welded up my inlet for me this week... (thanks big man!!)...

    [​IMG]

    [​IMG]

    ...and the IAT sensor boss and the vacuum outlet plate (not yet drilled and tapped)...
    [​IMG]

    As mentioned in a previous post the throttle body adaptor...
    [​IMG]

    Did a bit of work to grind down the welds and tested it for leaks... (all good on that front)...
    [​IMG]

    Stuff to be used... chemical metal for filling pits/scratches and smoothing out the welds, etch primer and filler primer...
    [​IMG]

    Slap the chemical metal on (I used a little too much lol)...
    [​IMG]

    ...after (a lot of) sanding...
    [​IMG]

    Etch primed and marked up spots that needed a little more attention...
    [​IMG]

    Chemical metal applied to the runner welds to smooth them out...
    [​IMG]

    ...bit more primer and bingo....
    [​IMG]

    Hopefully I will get around to painting it tomorrow and will be sorting the charge pipes out for Bill to weld next weekend :D

    <tuffty/>
  6. StaceyS3
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    StaceyS3 Well-Known Member

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    Looks the dogs ******** mate very OEM ;)

    Am looking forward to before and after results
  7. Prawn
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    Prawn My other car is a MINI!!!!

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    My god, I knew it'd be good, but that's 10x better than I thought it'd turn out!

    epic work man, can't believe how smooth and OEM it's looking :)
  8. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    You've met Paul right? lol
  9. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    After a ropey start this morning driving the wifes car to the unit to do a mini service and change her fan belt (that decided to self destruct on me a mile from Bills!!!) I got the manifold painted in the same 5 wheel silver I have used for the cam cover and charge pipe...

    [​IMG]

    [​IMG]

    [​IMG]

    Managed to get a couple of runs in the lacquer but I'll flat them down when its had a good chance to dry and polish them out...

    Happy with the results... will do the revised charge pipe work next Friday when I am off and just waiting on some taps to do the vac outlets and then hopefully will be fitting it the following week as I have taken time off work...

    <tuffty/>
  10. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    Looks really good that mate :)
  11. Westy
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    Westy Double Dark Side! Diesel & 8P

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    Silver is so underrated. That looks really nice.
  12. Prawn
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    Prawn My other car is a MINI!!!!

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    I desperatey want one of these, but even £200 for the plenum is too much when there's so much work to be done to it :(

    Looks incredible PT, can't wait to see you reach that 400bhp target!
  13. badger5
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    badger5 RIP S3dave Site Sponsor

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    Looking good
  14. Munch
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    Munch Member

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    Looks awsome mate, job well done!! Has given me a few ideas for mine now :p
  15. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Thanks Bill... wouldn't be anywhere without your help.. :D

    Found somewhere safe to put the manifold so it doesn't get damaged (hopefully) before it goes on the car and took a shot of it with a throttle body on (also gives me something to hold other than painted bits while I move it about...)

    [​IMG]

    Roll on Friday... :D

    <tuffty/>
  16. mk1chopper
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    mk1chopper Missing the S3

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    Just finished catching up on this, looking good as always Tuffty hoping to see it at ADI as I didnt get a chance to chat with you at AITP.
  17. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Busy day doing stuff.... test fitted the inlet manifold so I could fabricate the pipework.... the std small port inlet looks a little underwhelming next to the new one ;P
    [​IMG]

    New inlet on....
    [​IMG]

    [​IMG]

    Fiddled about with the pipes and stuff using welding tape (tm)
    [​IMG]

    [​IMG]

    ...and the outlet for the DV...
    [​IMG]

    ...and of course bead rolled the ends :)
    [​IMG]

    ...I really could do with learning to TIG but for now its ready for the big man to sort out when he gets 5 mins..
    [​IMG]

    While the bumper was off I decided to stealth up the FMIC as I had been meaning to do it for a while but not got around to it...
    [​IMG]

    ....much better...
    [​IMG]

    ...and of course I had to take a pic of the engine bay assembled before putting it back as it was with the (rather pathetic looking) std inlet..
    [​IMG]

    I have the NPT taps now to do the vacuum fittings... tomorrows job..

    <tuffty/>
  18. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Well done, looks great mate
  19. superkarl
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    superkarl MAN OF STEEL

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    looks absolutely perfect under there :icon_thumright:
  20. Oke Phill
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    Oke Phill Member

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    Really nice. Strange question but what paint did you use on your intercooler?

    Also does this mean you have the charge pipe ready now?

    Phill
  21. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    I used Rustoleum Hard Hat satin black on the intercooler... charge pipe will be ready for you once the new one is welded and fitted mate... I am back on the std inlet currently until then... it will all be sorted in the next few days hopefully :D

    <tuffty/>
  22. Oke Phill
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    Oke Phill Member

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    Ah good stuff, i really like the black intercooler, nice and stealth.

    Ideal on the charge pipe when you are ready:thumbsup:
  23. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Very nice mate.

    Out of interest would you and bill reproduce these to sell on
    :)?
  24. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Too much labour involved mate... might as well just be one from Integrated Engineering...

    <tuffty/>
  25. Westy
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    Westy Double Dark Side! Diesel & 8P

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    Damn that engine bay is sexual :sex:

    Great work mate but I can't help but think that this car is almost too nice to drive. I think you should donate it to a museum ;)
  26. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    I have to agree with you on that as mine was a little different as i used Jenvey trumpets inside mine and that took a good few hours blending them in and making the other bits

    With all the hours into making them i would have to charge the same as the IE manifold if not more
  27. dre_S3
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    dre_S3 Member

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    Lovely work mate wish my engine bay looked like that top stuff :)
  28. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    I would like to start by saying.... Bill you are a f*cking legend!!!!!!!... he got back from holiday today and was straight on welding my charge pipe up...

    [​IMG]

    ...et voila!...
    [​IMG]

    ...so of course I painted it :D
    [​IMG]

    [​IMG]

    [​IMG]

    Got the vac points drilled, tapped and fitted too...
    [​IMG]

    [​IMG]

    Soooooo..... nowt much left to do now but dyno, fit it and dyno again :D

    <tuffty/>
  29. dre_S3
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    dre_S3 Member

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    Looks class mate

    dre
  30. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    So today was essentially dyno car with std inlet, fit large inlet, dyno car again...

    Car on dyno... ran the car up on the std inlet... I am running on just actuator pressure at the moment until I have the S4 MAF and 90mm TIP in place as I don't want to be buggering around chasing my tail on the mapping until all the changes I know I am going to make are done...
    [​IMG]

    First run had some boost creep for whatever reason and made 310hp @ 17/18psi peak... subsequent runs were 15psi consistently so maybe the Tial needed some heat in it to get it working right... second run netted just over 280hp... the EGT's were low 700's only spiking at 750 on lift off (no flow through the engine to cool)... that was at a steady 15psi..

    Then fitted the manifold.... cover off...
    [​IMG]

    Cover on...
    [​IMG]

    Results were impressive...
    [​IMG]

    [​IMG]

    17ish hp gain just by bolting on the fabricated inlet... was happy with that... :)

    Clearly the map needs tweaking but then this is the first time the car has been on the dyno with any of my maps on so overall very happy with the result considering its been tweaked from road logging etc..

    Fuelling is going into component protection (KFLBTS) as I have the EGT trigger set quite low... logging EGTs showed this can be upped a tad so will sort that later... it going rich cost me a bit of power top end too so if AFR had carried on rather than get rich then it could have made another 5-10hp based on what I normally see on the dyno

    Overall really happy with the result, happy with the map and looking forward to getting the S4 MAF and 90mm TIP sorted hopefully next week..

    <tuffty/>
    Last edited: Sep 30, 2012
  31. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    I gained 22 bhp from mine for some reason but if you make your own manifold it worth it i think
  32. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Total flow dude... larger plenum helps loads, large port runners don't restrict flow like the small port ones... you get more power for the same boost when you free up the flow like this...

    As Bill always says... its all about the flow.... just as relevant for forced induction as it is for NA ;P

    <tuffty/>
  33. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Its might be the trumpets i fitted to my manifold that helped?
  34. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Different specs different results mate... your tubby is larger than mine and your setup is different... can't really compare in that respect...

    I doubt the trumpets made that much of a difference tbh but the larger plenum and runners is the main thing here... if your mani fitted on mine made more hp than my one did I be surprised tbh...

    The excessive plenum is not the neatest/smoothest inside but a gain is a gain at the end of the day and its certainly gonna pay off when the boost gets turned up.. :D

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

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    <tuffty/>
    Last edited by a moderator: Aug 15, 2014
  36. s33nyboy12
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    s33nyboy12 Well-Known Member

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    Fricking sweeeeet! What stats you make???

    Sean
  37. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [post="1688026"]post 1750...[/post]

    <tuffty/>
    Last edited: Sep 30, 2012
  38. Oke Phill
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    Oke Phill Member

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    Amazing!! true true quality!
  39. s3gazz
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    s3gazz Active Member

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    Well done mate top notch
  40. superkarl
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    superkarl MAN OF STEEL

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    so on only 15psi, and circa 280-300hp car, there may be some gains to be had on a lil turbo like a ko4 or hybrid version.
    i know yours is flowing alot more air with a gt30 but, still low boost so maybe there is some power available for us.

    nice work.

    question, do you, or anyone know the capacity of the oem inlet plenum, and the plenum you now use?
    Last edited: Oct 1, 2012

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