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My minor modding thread

<tuffty/> Jul 29, 2009

  1. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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  2. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    or indeed this>> 2067cc 20v GTX3076r might have had something to do with it :D
     
  3. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    I do forget that lol
     
  4. superkarl

    superkarl MAN OF STEEL

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    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

    BuuBBa Member

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    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/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    Not that I know of... mine was bought direct from xcessive...

    <tuffty/>
     
  8. StaceyS3

    StaceyS3 Well-Known Member

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    Think my local machine shop kept the drawings for mine, but wasn't anywhere as cheap as I was hoping IIRC

    [​IMG]
     
  9. superkarl

    superkarl MAN OF STEEL

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    how much is 'not as cheap as i thought'?
     
  10. StaceyS3

    StaceyS3 Well-Known Member

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    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

    superkarl MAN OF STEEL

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    you got shafted there stace
     
  12. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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

    Westy Well-Known Member

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    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

    Jason.s Active Member

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    Cant seem to find one either. ITG are a bit closer with 86mm or 93mm. Rated to nearly 500bhp too.
     
  15. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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  17. s3dave

    s3dave TFSI Hybrid Supporter

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    You will be surprised how much space you have with the OEM airbox deleted....:whistle2:
     
  18. Westy

    Westy Well-Known Member

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    Lol, loads of room.
     
  19. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Looking good as always PT, that intake is epic as well :).
     
  20. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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  21. superkarl

    superkarl MAN OF STEEL

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    k&n will make pretty much anything. the size options are endless.
     
  22. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    Yeah... been scanning through their catalogue... my eyes are bleeding!

    <tuffty/>
     
  23. Vex182

    Vex182 Guess what I drive...

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    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/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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  25. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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

    Jason.s Active Member

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    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

    Andrew@A.L.D May add NOS to 600+bhp S3.

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  28. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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

    S3 JOHN Member

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    Not too much tho , £120-130 is what i would charge with CAD time
     
  30. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Not botherd about the idea of a velocity stack then PT? Would it not offer any gains on a setup like yours?
     
  31. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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

    vrbob Thats no Moon, Thats a space station!

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    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/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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

    ScottD3 I want your faulty electronics Supporter Team V6 quattro Audi A8 Team Akoya saloon TDi Audi S8

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    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

    Welly VX220 SC Driver :)

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    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

    Reesy Well-Known Member VCDS Map User

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    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/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    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

    s3 Hoggy Whats going on???

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    Paul the amount of effort you and Bill have put into this is staggering!

    unbelievable build!
     
  40. Scullies

    Scullies Well-Known Member

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    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
     

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