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. Andrew@A.L.D
    Offline

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,515
    Likes Received:
    361
    [Oct 1, 2012]
  2. badger5
    Offline

    badger5 www.badger5.co.uk Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,334
    Likes Received:
    695
    [Oct 1, 2012]
    or indeed this>> 2067cc 20v GTX3076r might have had something to do with it :D
  3. Andrew@A.L.D
    Offline

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,515
    Likes Received:
    361
    [Oct 1, 2012]
    I do forget that lol
  4. superkarl
    Offline

    superkarl MAN OF STEEL

    Joined:
    Mar 28, 2010
    Messages:
    7,615
    Likes Received:
    1,104
    [Oct 1, 2012]
    tuffty, is there any particular reason you used aeb runners for this? can agu runners be used? although i think they are slightly different shapes aren't they, aeb runners being curved rather than straight
  5. BuuBBa
    Offline

    BuuBBa Member

    Joined:
    Nov 20, 2011
    Messages:
    131
    Likes Received:
    3
    [Oct 1, 2012]
    Great to have You here Tuffty.. Man of the prototypes :thumbsup:

    Is there any other place to purchase the plenum than direct from xcessive manufacturing?
  6. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 1, 2012]
    AEB runners are square on to the back plate making the flow transition smoother... the AGU ones are at a more acute angle so for me the AEB runners seem the better choice... it emulates the SEM's approach and that manifold is one of the best on the market..

    AEB manis where easier to get hold of on eBay than AGU ones when I was looking anyway..

    <tuffty/>
  7. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 1, 2012]
    Not that I know of... mine was bought direct from xcessive...

    <tuffty/>
  8. StaceyS3
    Offline

    StaceyS3 Well-Known Member

    Joined:
    Dec 17, 2010
    Messages:
    2,131
    Likes Received:
    198
    [Oct 2, 2012]
    Think my local machine shop kept the drawings for mine, but wasn't anywhere as cheap as I was hoping IIRC

    [​IMG]
  9. superkarl
    Offline

    superkarl MAN OF STEEL

    Joined:
    Mar 28, 2010
    Messages:
    7,615
    Likes Received:
    1,104
    [Oct 2, 2012]
    how much is 'not as cheap as i thought'?
  10. StaceyS3
    Offline

    StaceyS3 Well-Known Member

    Joined:
    Dec 17, 2010
    Messages:
    2,131
    Likes Received:
    198
    [Oct 2, 2012]
    Can't remember but think was 150ish but in fairness I also had to pay for the time to do the drawing and they ran the mill over the end of the runners to get them 100% level and flat as all I had done was linished them :)
  11. superkarl
    Offline

    superkarl MAN OF STEEL

    Joined:
    Mar 28, 2010
    Messages:
    7,615
    Likes Received:
    1,104
    [Oct 2, 2012]
    you got shafted there stace
  12. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 2, 2012]
    Worked on the TIP today... took the current 76mm OD one off (yes, its smaller than Bills K04 TIP's!!) so I could use it as a kind of template for the new 90mm OD one...
    [​IMG]

    After some faffing about I cut up the 90mm bend hoping that what I had in my mind is how it might turn up... thankfully it did :)
    Using the power of welding tape and a bit of trimming of the hoses and pipes I ended up with...
    [​IMG]

    ..which fits nicely...
    [​IMG]

    So then had to think about how the filter would attach... still looking at filter options.. a 90mm necked version of what I have would be ideal but they don't do one :(
    [​IMG]

    [​IMG]

    All the was left was the DV inlet....
    [​IMG]

    Should be getting welded up at some point this week and I am waiting on some adaptor rings that will take the 85mm OD of the S4 MAF to 90mm...

    The end is in sight :D

    (although it never really is the end is it ;P)

    <tuffty/>
  13. Westy
    Offline

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,297
    Likes Received:
    972
    [Oct 2, 2012]
    It's sad and a relief as you know a build I'd drawing to its final stages. The relief is from knowing that most of the spending is over ;)
  14. Jason.s
    Offline

    Jason.s Active Member

    Joined:
    May 12, 2010
    Messages:
    2,879
    Likes Received:
    348
    [Oct 2, 2012]
    Cant seem to find one either. ITG are a bit closer with 86mm or 93mm. Rated to nearly 500bhp too.
  15. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 2, 2012]
    Don't panic... still more to do... got WMI to fit, ARB's and looking larger front discs with a possibility of changing the rears for something larger if I can work the balance right...

    Always something to do but will be nice to get to a point I can drive her at her full potential... will be tweaking the map as I go along too...

    Not a fan of foam filters tbh and I ideally need to find something similarly sized to the current Jetex else it means using up space in the battery area I had earmarked for WMI... we shall see... priority is to the filter and it needs to be right but until the TIP is on properly I am not sure how it will go as yet...

    No problems only solutions :)

    <tuffty/>
  16. Broken Byzan
    Offline

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

    Joined:
    Apr 26, 2004
    Messages:
    12,604
    Likes Received:
    276
  17. s3dave
    Offline

    s3dave TFSI Hybrid

    Joined:
    Nov 11, 2009
    Messages:
    10,120
    Likes Received:
    729
    [Oct 2, 2012]
    You will be surprised how much space you have with the OEM airbox deleted....:whistle2:
  18. Westy
    Offline

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,297
    Likes Received:
    972
    [Oct 2, 2012]
    Lol, loads of room.
  19. Dani_B19
    Offline

    Dani_B19 Audi-sports own special child.

    Joined:
    Nov 9, 2008
    Messages:
    7,282
    Likes Received:
    90
    [Oct 2, 2012]
    Looking good as always PT, that intake is epic as well :).
  20. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 2, 2012]
  21. superkarl
    Offline

    superkarl MAN OF STEEL

    Joined:
    Mar 28, 2010
    Messages:
    7,615
    Likes Received:
    1,104
    [Oct 2, 2012]
    k&n will make pretty much anything. the size options are endless.
  22. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 2, 2012]
    Yeah... been scanning through their catalogue... my eyes are bleeding!

    <tuffty/>
  23. Vex182
    Offline

    Vex182 Guess what I drive...

    Joined:
    Apr 23, 2012
    Messages:
    933
    Likes Received:
    59
    [Oct 3, 2012]
    The difference is I guess you don't need an adapter to fit 76mm onto the turbo though like the K04 lol :p
  24. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 3, 2012]
  25. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 3, 2012]
    Yay!... TIP is now done... big thanks to George (again!) who came up trumps with the adaptor rings for the S4 MAF to take its OD to 90mm.. interference fit with a bit of sealant for good measure...
    [​IMG]

    [​IMG]

    Gas arrived too so Bill kindly welded up the alloy parts of the TIP and of course I painted it satin black... was toying with filter selections also... Bill has a few filters in stock so looked at using one of those...
    [​IMG]

    The Green is out purely as its 80mm neck ;P.... the K&N is a possibility as this filter can be used with a velocity stack which I can get in 89mm... the JR is long... it won't fit in the airbox... but its 100mm do can be made to fit my setup and as I like a challenge... I choose...
    [​IMG]

    Watch this space... it could be an epic fail lol...

    <tuffty/>
    Last edited: Oct 3, 2012
  26. Jason.s
    Offline

    Jason.s Active Member

    Joined:
    May 12, 2010
    Messages:
    2,879
    Likes Received:
    348
    [Oct 3, 2012]
    pft just have a f**k off filter where the battery was...Man up! lol. Make an airbox to encase it and spray it so it blends into the bay a bit better so it looks like it should be there not a lump of shiny metal you`ve bolted in.
  27. Andrew@A.L.D
    Offline

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,515
    Likes Received:
    361
    [Oct 3, 2012]
    [​IMG]
  28. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 3, 2012]
    that 'nearly' the plan... I reckon I can poke through the side of the OE airbox low down so it all passes into the battery area, remove the 4" cold air feed I have as it will be useless there anyway and there will be room for the jetex..

    <tuffty/>
  29. S3 JOHN
    Offline

    S3 JOHN Member

    Joined:
    Dec 13, 2011
    Messages:
    310
    Likes Received:
    3
    [Oct 3, 2012]
    Not too much tho , £120-130 is what i would charge with CAD time
  30. Dani_B19
    Offline

    Dani_B19 Audi-sports own special child.

    Joined:
    Nov 9, 2008
    Messages:
    7,282
    Likes Received:
    90
    [Oct 3, 2012]
    Not botherd about the idea of a velocity stack then PT? Would it not offer any gains on a setup like yours?
  31. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 3, 2012]
    Plausibly but it means waiting as they are from an american company and I kinda wanna get it sorted sooner rather than later plus I think the jetex looks cool...

    <tuffty/>
  32. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 4, 2012]
    Got around to fitting the TIP and S4 MAF today...

    [​IMG]

    [​IMG]

    Had to do a pikey bodge to get a filter on but at least I know it will go...
    [​IMG]

    The ring I had made up for the filter side of the S4 MAF will need to be 100mm not 90mm like I had before... this will allow me to use a 100mm joiner (like I have done with the 90mm one) and fabricate a suitable 100mm joiner to go into the filter... I can then mod the airbox and fabricate the support brackets to keep it all nice and tidy...
    [​IMG]

    [​IMG]

    The S4 scaling was added to the map and flashed in... all I can say is she feels really different... just wants to rev and pull even at a lowly 15psi!...

    Hope to get her on the dyno over the next few days to check everything out... and maybe add boost ;P

    <tuffty/>
  33. vrbob
    Offline

    vrbob Thats no Moon, Thats a space station!

    Joined:
    Jun 19, 2007
    Messages:
    2,362
    Likes Received:
    158
    [Oct 4, 2012]
    Top work mate :)

    V impressed with the OEMness with the covers back on concidering the size of that pipe work and filter!

    i take it your battery is in the boot now and are you still running a cold feed to the mahoosive filter?
  34. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 4, 2012]
    Battery in boot install from here battery relocation to boot>>>

    ...I will look into getting some of the 4" stuff I have into the bumper somehow and just point it up to the general direction of the filter (had to remove it from the airbox as it was in the way of fitting the filter)

    <tuffty/>
  35. ScottD3
    Offline

    ScottD3 I want your faulty electronics

    Joined:
    Nov 24, 2010
    Messages:
    15,109
    Likes Received:
    1,013
    [Oct 5, 2012]
    Tuffty, I feel I need to congratulate you on your OEM engine bay obsession.
    It looks amazing.

    I like it and its nice change to see someone trying to keep it OEM.


    Keep it up :thumbsup:
  36. Welly
    Offline

    Welly VX220 SC Driver :)

    Joined:
    Aug 5, 2009
    Messages:
    10,699
    Likes Received:
    117
    [Oct 5, 2012]
    That's been the aim of the game all along!

    Fair play Tuffty, credit where it's due, even despite great adversity, you have stuck with your OEM goals, and will now succeed.

    This I respect.
  37. Reesy
    Offline

    Reesy Well-Known Member VCDS Map User

    Joined:
    Jan 20, 2010
    Messages:
    3,614
    Likes Received:
    133
    [Oct 5, 2012]
    If it doesn't, give up on the under bonnet OEMness, get a bigger Turbo, just keep it tidy and have lots of BHP.
  38. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,924
    Likes Received:
    1,336
    [Oct 5, 2012]
    Thanks for all the kind words guys... :D

    Grabbed a bit of time this afternoon to sort out the pikey bodge to secure the filter... George the super hero to the rescue yet again machining me up a 100mm OD adaptor ring for the MAF tube so I could use 100mm from the MAF to the filter...
    [​IMG]

    ...then fab'd up a suitable bend in 100mm alloy to join the filter to the MAF
    [​IMG]

    ...after painting it (of course :)) I set about modifying the airbox so the filter would fit...
    [​IMG]

    ...modded the cover a little...
    [​IMG]

    ...and of course with all the covers fitted...
    [​IMG]

    ...and to prove its actually there...
    [​IMG]

    Got a couple of support brackets to make and check some clearances to prevent rubbing etc but thats more or less it bar WMI fitting (test fitted a tank and thats goes in ok)... all I need now is more boosts!! :eyebrows:

    <tuffty/>
  39. s3 Hoggy
    Offline

    s3 Hoggy Whats going on???

    Joined:
    Apr 4, 2009
    Messages:
    1,657
    Likes Received:
    98
    [Oct 5, 2012]
    Paul the amount of effort you and Bill have put into this is staggering!

    unbelievable build!
  40. Scullies
    Offline

    Scullies Well-Known Member

    Joined:
    Feb 9, 2012
    Messages:
    1,282
    Likes Received:
    318
    [Oct 5, 2012]
    Hmmmm, yum yum....food for thought :)
    Why do you have to use the S4 maf housing, couldnt you use a 4" tube, cut and shape it to your needs and fit the MAF directly to the tube. It would reduce the need to silicone joiners :cool:

    I think you also need to add an index to your build, the 1st post should have a link to all the specific topics :happy: - OK OK, I know I'm being lazy but its takes so long to find things on your build. I have actually book marked a lot of your pages to use as references :D

Share This Page