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My minor modding thread

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

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

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    [Mar 31, 2013]
    Is that too high? it needs at least 5psi more i think
  2. Sam_
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    Sam_ Down under

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    [Apr 1, 2013]
    Nice one on fixing it in situ! I didn't realise you were running a pag parts manifold. Have you seen his underslung vband cast stainless tubular?

    There's a guy here running 43psi through a GTX3071R on a TFSI lump.
    basil brush likes this.
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 1, 2013]
    If I do a fundamental change of mani and turbo it will be to a tubular top mount... the most interesting results I have seen in all the BT conversions I have been involved with was the TSR tubular manifold and HTA GT3071 on a stroker... as much as I like my underslung setup the v-banded top mount makes life a bit easier maintenance wise

    The GTX2867r looks to be a nice looking turbo... certainly on a par with my current GT3071 towards the top end but with the potential to spool sooner on a 1.8...

    I like the idea of setup as I think from an almost perfect 1.8t BT conversion it looks to give the best of both the GT2871 and the GT3071 and remaining compact for ease of installation and v-banded for reliability etc....

    We shall see... need to price my kit up for sale and the new stuff to buy and see where it sits... if its financially viable (I am not made of money lol) then I'll go ahead...

    As I mentioned before, while I could just go fr a bigger turbo (GTX30 or something) I have never really been chasing power and just want to get a nice reliable 400hp and a drivable car rather than a dyno queen :)

    <tuffty/>
  4. Sam_
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    Sam_ Down under

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    [Apr 1, 2013]
    Yeah I'd like to go top mount eventually but the TSR manifold is mega money and it's either that or the CTS which seems to have it's downsides. What I like about the pag parts manifold is there's an off the shelf downpipe to suit. If I want a custom downpipe here to suit either, I'd need to be loaded.

    From what I've seen the GTX28 does look good. If I'd not bought the GTX30, I'd probably look at getting a T25 one to replace the GT2871 I have lined up.
  5. Lewis583
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    Lewis583 Active Member VCDS Map User

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    [Apr 1, 2013]
    You not thought about making your own top mount manifold any more Paul?

    Would certainly save you some money and you could run your current setup until its built.
  6. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 1, 2013]
    It was on the list... maybe still could be but tbh I have not really given it any more thought for now... I have a few other things to do and will spend a bit of time later this month sorting some stuff out and look at the prices of it all...

    The GTX2867r appeals and the TSR mani is low enough that the turbo isn't in your face like some top mount setups... the appeal of the underslung was purely the OE look but I have learnt loads over the past 3 years and in the back of my mind I know I would do things differently purely because I enjoy the building probably more than the driving lol...

    Anyhoo... some compressor maps showing the difference between the GTX28 and the GT30

    [​IMG]

    <tuffty/>
  7. superkarl
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    superkarl MAN OF STEEL

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    [Apr 1, 2013]
    Much better surge line. Spool like a beast.
    Theres a fella on vortex who im going to request some compressor and turbine maps from soonish.
    Plotted against revs to try anpredict how it will behave and wha sort of rev limit im going to have.
  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 2, 2013]
    Spent Monday playing with my PC in prep for a small upgrade, only car related thing I did was put the new tax disc in the Golf and had time to think about where to go next.... pricing up the GTX28 and all the other stuff I would need has realistically made my mind up... I am looking at around 1k min on top of selling on my gear and all the other unforseen costs that I haven't factored in as yet as I couldn't see much point in going to any more detail once I had worked out the basic hardware costs...

    Obviously at the time I was a little cheesed off with it all but the car drove lovely on the way home from Bills Sunday and after all the work we have put in getting the car this far it would be rude not to see it through...

    So... I have a list of stuff to sort out short term, VT mounts are ordered, I am going to poly other bits and replace some of the worn running gear components to freshen her up a bit, get the WMI installed and sort the DP out as its still knocking on the rack currently...

    Long term I am going back to looking at fabricating a tubular manifold and also upgrading my current CHRA with a billet compressor wheel...

    <tuffty/>
  9. Sevv
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    Sevv Pushing the limits..

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    [Apr 2, 2013]
    hey Tuffty nice too see ur never ending progress mate youve gone so far with that 8L , neway i thought it be rude not to say hello as its been a while since my incident ... hope all is well mate

    and thanks for the help u always gave too :D
  10. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 7, 2013]
    Bit of an update... have been busy over the past week accumulating stuff...

    First up some number plate and sidelight LED's from our good friend Trups at EM Tuning... not fitted the sidelights yet as I have plans for the headlights later..
    [​IMG]

    Needed to remove the plate and the surround to allow the light fitting to be removed..
    [​IMG]

    ...needed to clean up the contacts with wet and dry as they were looking a little corroded...
    [​IMG]

    Swapped out the bulbs... Trups supplies ones that don't light up the road behind you :)
    [​IMG]

    ...nice white light...
    [​IMG]

    On to the next job, fitting some aero wipers I got well cheap on ebay.... these are the proper aero type, I have been running the std arms with aero 'upgrades' but these came along at a real good price and I needed new wipers...
    [​IMG]

    [​IMG]

    ...and bought a new blade for the Polo rear I already had...
    [​IMG]

    I have also bagged a pair of the TT fan jets for a bargain £8 (eBay again) which I will fit later...
    [​IMG]

    After the minor incident where I was close to parking the car up for a year I decided to change the engine mounts... I already have a set of THS uprated ones which have been working well but decided to make sure the engine stays where its put I went for a set of Vibratechnics mounts...
    [​IMG]

    [​IMG]

    Gearbox side first...
    [​IMG]

    ...two bolts have to be accessed through the trunking so the strut brace etc was undone so I could remove the top of the trunking to gain access to...
    [​IMG]

    ...and
    [​IMG]

    VT and THS (and OE)
    [​IMG]

    VT gearbox mount fitted
    [​IMG]

    Engine side is hidden by just about everything... so charcoal filter out and everything bungied out of the way (inc charge pipe)
    [​IMG]

    VT vs THS
    [​IMG]

    ..and VT fitted...
    [​IMG]

    Surprisingly the THS mounts are in rather good nick... nothing to suggest they are knackered at all... so they will be going on eBay LOL...

    One last job of the day... where I have had the head off more than a few times the bolts holding the damped crank pulley on were getting a little tired... these are quite a hard bolt too... 10,1 rated IIRC and I bought a set of replacements a while back but never got around to fitting them so today, I did.. just as well as one needed a little more effort to remove... these bolts require a 6mm allen key to remove... one rounded and needed a a bit of persuasion with a hammer and a splined bit...
    [​IMG]

    ...nice new OEM ones fitted...
    [​IMG]


    All in all fairly productive... I even manged to realign the exhaust as the middle clamp was loose and it was knocking in places and I even washed the car for the first time in weeks!!!...

    The mounts are still bedding in so there is a little more vibration than previously on idle but this is to be expected... I fully anticipate this to die down a bit over time... on cruise its unnoticeable...

    I have a week off at the beginning of next month... plans for then are:

    • Fit WMI (finally), I have all the bits now so no excuses...

    • Wire in a relay for the inline fuel pump

    • Look at modding the Miltek back box as its a little worse for wear after the NLS/launching and starting to make a hissing noise under full power... typically a sign its not flowing as well as it could so it will be dissected then made 3" internally with maybe some further fabrication on the tail pipes... don't know for sure until I am in there...

    • Refurb the headlights this time by removing them fully and doing it on the bench where I have a bit more control... I have bought some clear Lamin-x film which I am told (by Lamin-x) has UV protection built in...

    • Get the car on the dyno for tweaking and dialling in WMI...

    I have also been given something else to test....
    [​IMG]

    Its a 70mm throttle body... just interested to see if it makes any difference at all...

    <tuffty/>
  11. g60leigh
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    g60leigh Well-Known Member

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    [Apr 7, 2013]
    I have posted a guide to fitting the TT washer jets if it is any use at all to you Tuffty.
  12. S3 Rav
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    S3 Rav Well-Known Member

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    [Apr 7, 2013]
    Pics of washed car?
  13. S3Zek
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    S3Zek Member

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    [Apr 8, 2013]
    tuffty dose the alloy part of the drivers mount pull out of the rubber easily? Mine dose and I'm concerned there **** so just want some clarification as ths's customer service is a load of f**kin **** as I contacted them twice now and ive heard f**k all over a week or two now, so word of advice to peeps is to get them through a dealer as direct they don't even seem to have a number to call, c**ts
  14. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 8, 2013]
    Guessing you are referring to the THS mounts? mine are fine mate, doesn't pull out at all... they are just over 3 years old and still seem pretty good tbh... I bought direct at the time as I had a discount code which knocked quite a bit off...

    Sorry to hear you have had the issues though... you could try them on their facebook page of course... they would have to respond then...
    THS Performance LTD | Facebook

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

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    [Apr 8, 2013]
    I can't mate... even washed she is still dirtier than I would like... (ask anyone that knows me lol)

    I need at least 3 days working on her before I would be prepared for pics ;P

    When done she looks a bit like this...
    [​IMG]

    <tuffty/>
    richard2k6 likes this.
  16. S3Zek
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    S3Zek Member

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    [Apr 8, 2013]
    Thanks for that mate, there bran new as well. I like the look of those vibes :) what's the rumble like in the cabin? It's never bothered me but I could stir a cup of tea on tick over if I sat it on the dash of my fiesta turbo lol
  17. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 8, 2013]
    tbh there is a little increase in cabin vibration on idle but its died down a bit as the mounts start to settle in and expect it to be even less over the coming weeks as they fully settle... its the same when doing the dogbone (I have a yellow bush)... that vibrated like hell initially now all is good... the VT's I have are the road ones...

    The THS ones are a little less harsh but I expected the VT's to be firmer (its the reason I went for them)... feels nicely connected too... just the small dogbone bush to do

    <tuffty/>
  18. superkarl
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    superkarl MAN OF STEEL

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    [Apr 8, 2013]
    dont you already have your inline pump wired in?

    been trying to get my head around wiring a pump in, im not very good with wiring etc. read a few threads where people have used a relay, i thought that was compulsory.
  19. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 8, 2013]
    Mine is piggy backed off the OE wiring... while its man enough and I haven't had issues its just best practice to go for a relay really...

    I did a little research prior to fitting mine and current draw isn't much different to OE as the intank isn't working anywhere near as hard as it would do on its own so there is a slight increase in overall current draw but for completeness I will fit a relay..

    <tuffty/>
  20. Gops
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    Gops 6th gear @7000rpm

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    [Apr 8, 2013]
    I love the attention to detail! And I remember saying to you tuffty, your car even when dirty, looks cleaner than mine, ALWAYS! Lol. I could eat food out of the engine bay
    MIGGZ likes this.
  21. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 8, 2013]
    Have some time off work so obviously this meant tinkering time with the car.... :D

    First job was to replace the small dogbone bush... instructions are supplied so won't bother with the detail so pics should do :)
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    There was an increase in vibration on idle but this has settled now... with VT road mounts, a yellow bush and now this bush there is of course going to be increased vibrations and engine noise... its the price of power or at least effective use of power... but when cruising there is nothing really noticeable and thats fine with me...

    Next job was to run the hose for the WMI... interior apart... again!...
    [​IMG]

    ...drilled a smaller hole next to the one that the opposite side of the pollen filter...
    [​IMG]

    ...getting busy in the cable trunking...
    [​IMG]

    Not fitted the pump yet as I need to run the wires and work out which side of the battery to fit it... that will come later as will fitting the nozzle which I have decided will go initially in the FMIC outlet... I am looking at using a dual nozzle system as have seen one of these work rather well... I may even look at staging delivery too...

    Next I polished the headlights again as they were showing signs of going a bit yellow again... this time however I have bought some Lamin-x to act as a UV shield... also had some LED sidelights from Trups to fit...
    [​IMG]

    ...after a couple of passes with the DA...
    [​IMG]

    Applying the Lamin-x..
    [​IMG]

    ...and done ready for trimming...
    [​IMG]

    Refitted..
    [​IMG]

    ...and next the passenger side :)
    [​IMG]

    LED sidelights...
    [​IMG]

    ...old 'blue' bulbs...
    [​IMG]

    Next job... new scuttle...
    [​IMG]

    ...TT fan washer jets... (part number 8N0 955 986 C)
    [​IMG]

    TT washers require a little work to fit... hole needs widening and lengthening...
    [​IMG]

    ...the hose fitting is a different angle to S3 ones...
    [​IMG]

    ...so a hot air gun, careful heating and a 3mm drill....
    [​IMG]

    ..extended the wiring on one of the jets...
    [​IMG]

    Fitted it on and wow... well impressed with the way they get fluid on the screen... great upgrade... will try and get a vid of them working tomorrow...

    Next job was to start the wiring for the WMI pump and the inline fuel pump as I am rewiring that to run from a relay... bought a 2-way fuse holder so I could sort easy access to the fuses in case the pump one went, that way I don't need to remove half the dash to sort it... removed the lower drivers side dash panel...
    [​IMG]

    Marked up and cut a hole for the fuse box and mounted this in the back of the little cubby...
    [​IMG]

    ...also fitted a switch so I could 'arm' the WMI as and when I needed too...
    [​IMG]

    ...and the finished article...
    [​IMG]

    Rest of the wiring to do next and hooking up of the pressure switch for the WMI...

    <tuffty/>
    Last edited: May 12, 2013
    ScottD3 and s3dave like this.
  22. s3dave
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    s3dave TFSI Hybrid Supporter

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    [May 8, 2013]
    Nice work, well worth the extra time for a switch on WMI .... Instant back to back differences on the Dyno..;)
  23. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 9, 2013]
    Quick vid of the fan washers...



    <tuffty/>
    Last edited by a moderator: Aug 15, 2014
    jojo, Alex C, ScottD3 and 1 other person like this.
  24. Jay A3
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    Jay A3 More power

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    [May 9, 2013]
    Love the fans! Might try this...
  25. s3gazz
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    s3gazz Well-Known Member

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    [May 9, 2013]
    Great work tuffty I'm in the middle of fitting my relay for the inline fuel pump which relay do I get pal 5 pin or 4 pin thanks
  26. Scullies
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    Scullies Well-Known Member

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    [May 9, 2013]
    Best to use a 4 pin, I used a 5 pin as its all I had at the time. 1 pin not used.
    I used this diagram

    Attached Files:

  27. jojo
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    jojo Looking for Boost! Staff Member Moderator

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    [May 9, 2013]
    How much is a new scuttle Paul?
  28. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 9, 2013]
    just under 45 quid

    <tuffty/>
  29. Prawn
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    Prawn My other car is a MINI!!!!

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    [May 9, 2013]
    you are a very controlled man PT.

    Many would have gone for the sustained pull and squirt to demonstrate the new fan jets, but not you oh wise one.

    A simple on / off, that's your lot. Point made

    :laugh:
  30. jojo
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    jojo Looking for Boost! Staff Member Moderator

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    [May 10, 2013]
    Brand new? That's quite cheap!
  31. dre_S3
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    dre_S3 Member

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    [May 10, 2013]
    Good work mate, lights look so much better to they did look in a sad state when I saw your car on the weekend :)
  32. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 12, 2013]
    After the success with the headlights I had a go at the foglights too... I have read up on some techniques for this as they are glass but I don't have a coarse enough cutting compound to give it a go at the moment so decided just to do a few passes with the coarsest compound I had and while still showing signs of pitting they were a lot clearer so applied a little lamin-x over them too...

    Before...
    [​IMG]

    ...after...
    [​IMG]

    Found a spare few hours to get the wiring started too.... wired up the inline fuel pump to a relay and wired up the WMI control wiring ready to fit the pump and tank...

    Useful wiring posts.... yellow is ignition live but this cuts on turning the engine over so no use for the fuel pump... reds are permanent lives...
    [​IMG]

    For the pump I decided to use the fused side of the intank fuel pump as a trigger for the relay...
    [​IMG]

    Wired the relays in, used the yellow ignition live post for the WMI as this doesn't matter if it looses power during engine start and used the permenant post next to it as this had the thickest red cable going to it... this supplies the +12v for both the inline fuel pump and the WMI pump...
    [​IMG]

    Loomed up to go to the fuse box I had previously fitted and wired up the switch so I could switch WMI on and off as needed...
    [​IMG]

    Earthed the inline fuel pump securely too as the original earth looked like it had got a little warm... soldered all the connections too be sure...
    [​IMG]

    Even though the WMI pump is not yet fitted I did test the setup prior to refitting the dash panel... pressure switch is set for 18psi...
    [​IMG]

    Thats about it for now... back to actual work tomorrow but now that most of the ground work is done then the rest of the WMI install won't take long to finish... just need to work out what I am doing with the boot now :)

    <tuffty/>
  33. A3-Lee
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    A3-Lee Active Member

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    [May 12, 2013]
    Cars amazing mate can you post the tt washer jet part numbers please
  34. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 12, 2013]
    8N0 955 986 C

    <tuffty/>
  35. s3gazz
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    s3gazz Well-Known Member

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    [May 12, 2013]
    God tuffty that looks hard when I don't do wires and that ha em
  36. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 13, 2013]
    Its not too bad when you put your mind to it... just looks worse than it is... if you are in any doubt though leave it to someone that is more confident as tbh getting this wrong can lead to potential engine damage

    <tuffty/>
  37. Sidey
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    Sidey Active Member

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    [May 13, 2013]
    Fantastic work as always Paul..
  38. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 26, 2013]
    Managed to grab a couple of hours today to get a little more done....

    Marked up the FMIC outlet for the WMI nozzle boss...
    [​IMG]

    Bill worked his magic and a boss appeared... I then drilled and tapped it to take the nozzle...
    [​IMG]

    My WMI kit is made from a combo of AEM and Devils Own parts as I already had a pump and Bill had some other spare bits lying about so I took the one way valve out of the AEM nozzle holder as I was using a DO check valve and fitted it with the smallest nozzle... idea being that I would rather have a proper atomised mist of meth to help cool stuff down and aid consistency... if it looks like I need more volume of meth then I will look to fit a second fine nozzle further up the pipe work... twin nozzle setups seem to work quite well if done right...
    [​IMG]

    Bill also worked his magic on a small alloy tank I bought which while small should be fine for my needs... blocked up the 'supplied' hole as I wanted the tank to sit low and Bill welded a boss on the end so I could fit an outlet
    [​IMG]

    Made up some brackets to support the tank and this is the final layout....
    [​IMG]

    Just need to actually fit the brackets, tank and pump and its job done :)

    <tuffty/>
  39. Prawn
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    Prawn My other car is a MINI!!!!

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    [May 26, 2013]
    Baby Meth tank!

    Looking smart as ever mate. Be good to see this finally running on meth like the rest of us :)
  40. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [May 26, 2013]
    Mines not on meth yet as i'm still trying to find a good W/M kit

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