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My minor modding thread

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

  1. Gizmo20VT
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    Gizmo20VT Member

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    Well done mate, taking notes on the build :D!
  2. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Just for you... (as is the tradition...)
    [​IMG]

    Depends what pipes you are on about... I used Simoniz wheel silver for the top pipe (the lacquer is soft though so will be using Rustoleum Hard Hat stuff next time) and Rustoleum Hard Hat satin black for the rest

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

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    You're clearly green to the concept Paul, as Westicles was infact wanting a picture of YOU sat in the empty engine bay :laugh:
  4. Westy
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    Westy Double Dark Side! Diesel & 8P

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    Such an amateur!

    Pic of you in the empty bay BT. Welly did it, I did it, Stacey did it, and I think Prawn may have also done it. We could even start a new thread with the pics ;)
  5. superkarl
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    superkarl MAN OF STEEL

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    Il do one today :D
  6. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Not a showman like you bloody lot lol... I was on my own earlier but Marks here now so if I get time I'll get him to take one...

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

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    It's the law. I'm gonna frame my pic and pop it on my garage wall.
  8. Vex182
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    Vex182 Guess what I drive...

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    I heard this too, you need a cheesy grin and hold your thumbs up too.
  9. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [​IMG]

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

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    And you look so impressed!

    Sadly, due to how big you make that ko3S you're holding look, the rest of the forum will now realise that you're only 4'3'' tall, and that the car is actually on the ground in this pic, not on a ramp

    :laugh:
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  11. Westy
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    Westy Double Dark Side! Diesel & 8P

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    Good work Paul.
  12. Vex182
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    Vex182 Guess what I drive...

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    Love the picture but love the size of the turbo even more!
  13. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    A little update on my side of Paul's cylinder head, Managed to get a bit of time on the head with starting on the exhaust ports

    [​IMG]
    [​IMG]

    I've only just started so not very exciting right now
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  14. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Its my best smile... :)

    Awesome dude... looking forward to the updates :D

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

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    Todays update....

    So split the box from the engine and stripped off parts I need to transfer to the new block...
    [​IMG]

    It was then I realised I hadn't covered all the bosses when I painted the block so I started cleaning off the paint... DOH!!... reason for this (in case you didn't know) is with heat the paint will soften slightly and 'give' a little... this can potentially loosen the bolt and of course stuff falls off... you can see how thick it was...
    [​IMG]

    After a scrape and rub over with a wire brush wheel on the dremal...
    [​IMG]

    ...and chased the threads too...
    [​IMG]

    ...done...
    [​IMG]

    New stat (OE)...
    [​IMG]

    Removed the clutch and flywheel from the old engine... pressure cover had no bluing or excessive wear...
    [​IMG]

    ...same with the DMF... no excessive play (although I do need to check the specs later to confirm) and again, same wear patterns as the cover...
    [​IMG]

    ...the plate however...
    [​IMG]

    In fairness the clutch still felt good, no judder or slipping but obviously it was close to the rivets...

    Std plate...
    [​IMG]

    [​IMG]

    Ah well... the cover and DMF will go again but will need to get a new plate but its lasted well considering.. 20k miles, quite a few launches and a bit of NLS plus 18 months of hill starts on my way home from my old job...

    To get over this I painted some more stuff... :)
    [​IMG]

    Need to clean up the old engine a bit ready for its new home and sort out my old turbo and other parts as thats potentially sold too providing its not going to ave an issue with the earlier style transfer box as this is different to my later one... and anyone that has read this thread will know the interesting times I had trying to get clearance

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

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    Not sure where the time went today...

    Cleaned up the old bottom end ready for its new home...

    [​IMG]

    [​IMG]

    [​IMG]

    Mocked up my old turbo kit for a perspective buyer... needed to check what issues there may be fitting to a car with the earlier style transfer box...

    Same lug that needs to be ground down...
    [​IMG]

    Top of the transfer box requires a similar mod to mine for comp housing clearance...
    [​IMG]

    ...and the main difference being the cast support bracket...
    [​IMG]

    ...vs my steel bracket...
    [​IMG]

    [​IMG]

    After sorting that... I painted some more stuff :)
    [​IMG]

    ...need to sort the box out really as its filthy... :(
    [​IMG]

    Tomorrow will be a little pamper day for the Golf as I have a couple of little jobs I need to do but after that the next job is to get the mock up block and gearbox back in the engine bay ready for working out where the turbo is going to go and for all the fabrication work that needs doing like the manifold and various coolant/oil lines...

    [​IMG]

    The head is bare so makes it very easy to take on and off the eleventy billion times that normally required when making stuff like this up... the block is bare too...

    Just need to source a comp housing for the GT35 now... been looking at the GT3076 anti surge housing as this is a little smaller than the full fat GT35 one and can be machined to fit the GT35... gives the benefits of anti surge (not sure I'll need it be moving the surge line is always a good thing) and around 20mm extra room to play with... not much I hear you say but anything is a bonus considering the size of the damn thing...

    GT3076 housing.. (2" outlet)
    [​IMG]

    ...and a GT35 housing... (2.5" outlet)
    [​IMG]

    <tuffty/>
  17. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Amazing work as always mate. Guessing the old engines sold?
  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Yes mate soz...

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

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    Are you going top mount paul?
  20. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Currently yes... it will need to keep the turbo low but until I have the mock up engine in and a comp housing I don't know for sure... as I am not using an off the shelf mani I have the option to do what ever I need to get it how I want it :)

    Underslung still appeals... less stuff in the way of the DP and fluid lines...

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

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    really good work as always PT, are you off work all week or something?
  22. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Only until today... main focus was to get the engine out and sort a few things on the golf... can't do anything with the engine now until Andrew has done the head and it won't be going in until the manifold is done anyway... I need to source a comp housing to start the manifold build... can't go OTT yet as I need to sell the GT30 turbo kit first to finance the rest of the build

    As is the way, waiting on stuff :)

    No drama as I intend to clean stuff (shocking I know) and do a few other bits in the bay anyway...

    <tuffty/>
  23. badger5
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    badger5 RIP S3dave Site Sponsor

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    top mount ftw
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  24. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Spent a bit more time on the head, managed to finish off the main cutting on the exhaust ports and checked the seat with a seat cutter. Seats are all mint with a nice 45 deg and will cut another angle when i finish the ports off

    [​IMG]
    [​IMG]
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  25. badger5
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    badger5 RIP S3dave Site Sponsor

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    how do you check the installed heights after seat cutting andrew?
  26. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    Are these going to end up as 3 angle seats for greater flow capability?
  27. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    No real room on the inlets as the seats and are very slim to start with, The exhaust will have more angles

    I have a tool for that, in the picture about i just check them by hand with the cutter with no pressure.

    Finished the main cutting now, cleaned up the combustion chamber, Just have to finish of the ports with emery cloth

    [​IMG]
    [​IMG]
    [​IMG]
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  28. Prawn
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    Prawn My other car is a MINI!!!!

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    Lovely stuff!

    It may take a bit longer than originally planned before this sees the road again, but I think it's safe to say a fairly legendary car on 8L circles is about to step up another few levels in 1 large jump :)
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  29. Gops
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    Gops 6th gear @7000rpm

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    Those pics got me aroused...
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  30. badger5
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    badger5 RIP S3dave Site Sponsor

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    nice work andrew
  31. Gizmo20VT
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    Gizmo20VT Member

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    Same here :eyebrows:
  32. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Got the 'build' engine into the bay today for making the exhaust mani and any other fabrication that may be needed like coolant hoses etc...

    [​IMG]

    ...quite a bit of room once stuff is out the way lol...
    [​IMG]

    ...although not enough it would seem for a sidewinder manifold Bill has 'laying around' lol...
    [​IMG]

    Could see that I should have no bother relocating the PAS return line as its a royal PITA where it is currently (especially when bleeding the master cylinder!)
    [​IMG]

    My mate dropped off my wheels at lunch time after removing the tyres for me... refurb time ;P
    [​IMG]

    To be fair they are in a crap state so anything would help get them looking better lol...
    [​IMG]

    [​IMG]


    Started by removing all the rubber build up from the inside of the rim...
    [​IMG]

    ...then used a file to smooth out the worst of the damage...
    [​IMG]

    ...will take my wheel cleaning stuff tomorrow and give them a proper clean and degrease before using a bit of chemical metal to fix the bad bits and hopefully have at least one wheel painted tomorrow...

    Rest of the build is pretty much on hold now until I can get a comp housing and a few other bits so I can start getting the manifold built

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

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    This car is amazing the oem look and massive power it just goes from strength to strength,I can't wait to see this when I bring my a3 down to badger5 for mapping but that's been put on hold as the little one is due November so could be a while
  34. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    More head porn

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    I've just got to finish of the inlets now
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  35. Jason.s
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    Jason.s Active Member

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    Sidewinder manifold... DO IT
  36. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Looks awesome mate... :D

    Makes me feel better after the crap sunday I had painting the wheels LOL...

    <tuffty/>
  37. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    I think i'm going to have to get this done to mine, anything to help my little cotton real make power..
    Looks real good
  38. Gizmo20VT
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    Gizmo20VT Member

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    Andrew your headwork is amazing dude! :anbet:
  39. badger5
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    badger5 RIP S3dave Site Sponsor

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    lovely looking ports andrew
  40. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Thank you guys

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