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My minor modding thread

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

  1. badger5

    badger5 www.badger5.co.uk
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    two of you in the room... Damn.... Scarey Mary :)

    lmao

    out OCD'd on cambelt.. made me smile
     
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  3. Prawn

    Prawn My other car is a MINI!!!!

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    to be technically correct and factory, which way should the writing be on the cambelt?

    Not that I'm going to change mine if it's wrong of course :laugh:
     
  4. badger5

    badger5 www.badger5.co.uk
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    I presume viewed from #1 end it should read correct?

    good question..
     
  5. aragorn

    aragorn "Stick a V8 in it!"
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    The Audi service manual makes no mention of belt installation orientation.
     
  6. Vex182

    Vex182 Guess what I drive...

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    That made me laugh! I have no idea which way mine is facing, but I do care about it staying tensioned and on! :)
     
  7. Scullies

    Scullies Well-Known Member

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    the cambelt is an easy fix, just paint it black
    no writing = no problem :)
     
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  8. Sam_

    Sam_ Down under

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    It should be covered up anyway....
     
  9. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
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    It will be once I have decided if I am just painting the old cover or getting a new one :)

    <tuffty/>
     
  10. chaz20vt

    chaz20vt Member

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    I like how much detail you go into with this
    Spot on...
     
  11. <tuffty/>

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

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    Little something turned up at the Badger Cave today :D

    [​IMG]

    [​IMG]

    [​IMG]

    ...project manifold is a go then :)

    <tuffty/>
     
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  12. Westy

    Westy Double Dark Side! Diesel & 8P

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    Thought you were making a Pegani Zonda exhaust ;)
     
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  13. Andrew@A.L.D

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

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  14. <tuffty/>

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

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    Here :) ->collector info

    <tuffty/>
     
  15. superkarl

    superkarl MAN OF STEEL

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    Where are you sourcing the tubing Tuffty? and what schedule?
     
  16. badger5

    badger5 www.badger5.co.uk
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    [​IMG]
    +
    [​IMG]
     
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  17. CazzaVR

    CazzaVR Member

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    Oooh- looks very interesting! Very nice car mate- been working my way steadily through your thread- it's a real credit to you 8)
     
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  18. <tuffty/>

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

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    Been a little while since my last update as I have been helping Bill catch up on stuff and had to send the collector back as they had made it in 1.25" ID tube rather than 1.5" ID tube... in the mean time I got the 70mm TB blasted ready for having beads welded on and of course painting :D
    [​IMG]

    [​IMG]

    I also painted the cam belt cover and modded it for the manual tensioner
    [​IMG]

    [​IMG]

    The new collector turned up Friday so game on...
    [​IMG]

    ...Nortech (the stars that they are) even did the final capping run on this one...
    [​IMG]

    ...and of course the obvious difference between 1.25" and 1.5"...
    [​IMG]

    ...it begins...
    [​IMG]

    So tomorrow I am gonna make a start and see where I end up... what is evident from my initial faffing is that its not as easy as you would imagine to work out where all this goes and to keep it all away from stuff that could melt...

    I have not discounted going underslung either... :)

    Hopefully some progress pics tomorrow...

    <tuffty/>
     
  19. Broken Byzan

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

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    actual YAY !!!
     
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  20. <tuffty/>

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

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    Long but productive day...

    rigged up a bracket to hold the collector in place as its next to impossible to hold that and tubing etc at the same time...
    [​IMG]

    Started with cyl 1 runner as this would have to tuck close to the block..
    [​IMG]

    [​IMG]

    Unfortunately some idiot had put a transfer box in the way and both the runner and the collector was too low to get anything else in so pulled it apart and started again... moved the collector a little higher and re-did runner 1
    [​IMG]

    runner 2 in weld tape (tm) stage...
    [​IMG]

    Runner 2 coming together...
    [​IMG]

    [​IMG]

    Now clears stuff and fits nice...
    [​IMG]

    Runners 3 and 4 were pretty straight forward comparatively...

    [​IMG]

    Had to make some adjustments to the bends to allow clearance (not loads of course but hopefully enough)
    [​IMG]

    [​IMG]

    Need to trim the transfer box bracket though...
    [​IMG]

    ...but it seems to fit ok and looks pretty good all things considered...
    [​IMG]

    [​IMG]

    ...so of course I had to try it on the new engine...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    ...and of course I made sure that all the studs were accessible... the most "awkward" ones being..
    [​IMG]

    ...and
    [​IMG]


    The manifold should be easy to fit in situe which of course is the next thing I have to do and once fitted to the mock up engine in the car I can work out where the wastegate will go

    All in all not too bad considering its my first attempt and I have never used a welder before... started just after 10am and finished up around 7pm... rather tired now to say the least lol..

    Plan to grab a couple of days off work to finish it off and then it can be welded up... :D

    <tuffty/>
     
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  21. badger5

    badger5 www.badger5.co.uk
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    Superb
     
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  23. micky2 not 1

    micky2 not 1 Member

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    like it paul. Personally id want it a little higher purely to stop it cooking the TB. bt mines more track than road so you'll have lower temps. Great job....i got competition ;]
     
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  24. jojo

    jojo Looking for Boost!
    Staff Member Moderator quattro Audi S3

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    x2
     
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  25. Gops

    Gops 6th gear @7000rpm

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    Looks absolutely brilliant! Was following this all day on FB!
     
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  26. Lewis583

    Lewis583 Active Member
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    That looks the nuts Paul. Easily on par with some of the professional manifolds available.
     
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  27. s3dave

    s3dave TFSI Hybrid
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    Nice... you will be making TFSI Quatrro Downpipes soon...;)
     
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  28. superkarl

    superkarl MAN OF STEEL

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    How did you figure out where to mount the turbo? I mean whats the thought process behind the collector being in between 3 and 4? Youl obv have loads of room for the downpipe
     
  29. Sam_

    Sam_ Down under

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    Awesome work. Placement looks close to TSR but lower and more central between 3 and 4 whereas TSR is closer to 3.
     
  30. Prawn

    Prawn My other car is a MINI!!!!

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    Fantastic work PT!

    Drilling into that with a big holesaw to add the waste gate will be a scary moment!

    I assume the WG take off HAS to come from the very top of the collector so as to divert gasses from all 4 runners?
     
  31. <tuffty/>

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

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    Thanks guys... I was quite surprised how well its gone so far... didn't expect to be this far along... of course the tricky bit now is getting the weld sequence right so as not to 'paint yourself into a corner' so to speak...

    Karl... most of the mani's I have worked with or seen tend to place the turbo centrally between cyl 2 and 3 or just over cyl 3... they also stick the turbo high up which on smaller turbos works ok but they all still make the DP a challenge... most manis are made for the US market and they don't have servo's and other stuff in the way so I wanted the turbo in a more OE position so it gave me more room there...

    <tuffty/>
     
  32. <tuffty/>

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

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    Yeah pretty much... this is why it will be measure twice and cut once :)

    Will have a faff at the weekend

    <tuffty/>
     
  33. Prawn

    Prawn My other car is a MINI!!!!

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    can't wait until it's all done mate, getting the mani out of the way seems like a massive step
     
  34. Scullies

    Scullies Well-Known Member

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    Awesome work meneer :thumbsup:

    When the guys welded my mani together, they started with the runners, once they were all done, its was a calculation game to see which runner to weld at what time to the collector. But im sure you know all this by now after welding for a day :)


    LHD and RHD manis both have their issues. RHD has more space on the TIP side, where LHD has limited space on the TIP side. On mine, a 4" to 3.5" silicone reducer just fits past the valve cover and brake servo and my turbo sits higher up. Would never fit if I mounted mine at your level. I would have to go TIPless :(
    Then on the exhaust side, RHD is limited by brake servo and LHD could fit a 5" DP :)


    Also with the turbo being lower you have tighter angles to work with for the downpipe VS the turbo being a bit higher up you have a bit more room, not much but every ball hair counts :)

    S3 with longitudinal setup FTW

    Interested to see where you route the wastegate pipe? Similar to what Bill did on Stacey's?
     
  35. <tuffty/>

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

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    I am no stranger to the awkwardness of making a DP for a low turbo... my last setup was underslung remember ;P

    I might look at using 3.5" out the turbo but tbh 3" serves Bill's Ibiza ok so rather than try to fit large stuff in a small place I may just stick to 3" all the way... not chasing numbers with this so its down to whatever is practical...

    <tuffty/>
     
  36. s33nyboy12

    s33nyboy12 Well-Known Member

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    Very impressive mate!

    you must have the patience of a saint.........I'd be dying to drive it , clucking to get it finished lol

    Sean
     
  37. badger5

    badger5 www.badger5.co.uk
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    feck that lol... biggest we can fit in there dude :)

    'because we can'
     
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  38. <tuffty/>

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

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    Well... thats the down pipe plans sorted LOL... :D

    <tuffty/>
     
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  39. <tuffty/>

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

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    My patience is a side effect of my OCD... I do want to get it done and it kills me not being able to drive her but it needs to be done right and it would kill me more if I rushed anything for the sake of it and it wasn't right :)

    <tuffty/>
     
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  40. scotty_24

    scotty_24 Active Member

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    Awesome work mate, this is some car!
     
  41. Sam_

    Sam_ Down under

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    Forward planning for the 40 psi ;)
     
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  42. Scullies

    Scullies Well-Known Member

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    Thats pretty low :)
     

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