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. badger5
    Online

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,263
    Likes Received:
    668
    two of you in the room... Damn.... Scarey Mary :)

    lmao

    out OCD'd on cambelt.. made me smile
    AJC, Prawn and <tuffty/> like this.
  2. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,440
    Likes Received:
    1,281
    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:
  3. badger5
    Online

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,263
    Likes Received:
    668
    I presume viewed from #1 end it should read correct?

    good question..
  4. aragorn
    Offline

    aragorn "Stick a V8 in it!" Staff Member Moderator

    Joined:
    Jan 30, 2008
    Messages:
    15,495
    Likes Received:
    299
    The Audi service manual makes no mention of belt installation orientation.
  5. Vex182
    Offline

    Vex182 Guess what I drive...

    Joined:
    Apr 23, 2012
    Messages:
    913
    Likes Received:
    56
    That made me laugh! I have no idea which way mine is facing, but I do care about it staying tensioned and on! :)
  6. Scullies
    Offline

    Scullies Active Member

    Joined:
    Feb 9, 2012
    Messages:
    1,274
    Likes Received:
    309
    the cambelt is an easy fix, just paint it black
    no writing = no problem :)
    MIGGZ, StaceyS3 and <tuffty/> like this.
  7. Sam_
    Offline

    Sam_ Down under

    Joined:
    Mar 8, 2011
    Messages:
    2,806
    Likes Received:
    337
    It should be covered up anyway....
  8. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    It will be once I have decided if I am just painting the old cover or getting a new one :)

    <tuffty/>
  9. chaz20vt
    Offline

    chaz20vt Member

    Joined:
    Aug 25, 2012
    Messages:
    428
    Likes Received:
    21
    I like how much detail you go into with this
    Spot on...
  10. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    Little something turned up at the Badger Cave today :D

    [​IMG]

    [​IMG]

    [​IMG]

    ...project manifold is a go then :)

    <tuffty/>
    Gizmo20VT, Westy and Sam_ like this.
  11. Westy
    Offline

    Westy Double Dark Side! Diesel & 8P

    Joined:
    Dec 2, 2008
    Messages:
    17,295
    Likes Received:
    969
    Thought you were making a Pegani Zonda exhaust ;)
    fema|| and Gops like this.
  12. Andrew@A.L.D
    Online

    Andrew@A.L.D Cylinder Head Master

    Joined:
    Jun 19, 2009
    Messages:
    3,505
    Likes Received:
    354
    Where and how much please.
  13. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    Here :) ->collector info

    <tuffty/>
  14. superkarl
    Offline

    superkarl MAN OF STEEL

    Joined:
    Mar 28, 2010
    Messages:
    7,553
    Likes Received:
    1,074
    Where are you sourcing the tubing Tuffty? and what schedule?
  15. badger5
    Online

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,263
    Likes Received:
    668
    [​IMG]
    +
    [​IMG]
    Gops and Goubo1 like this.
  16. CazzaVR
    Offline

    CazzaVR Member

    Joined:
    Sep 7, 2013
    Messages:
    175
    Likes Received:
    9
    Oooh- looks very interesting! Very nice car mate- been working my way steadily through your thread- it's a real credit to you 8)
    Gizmo20VT and <tuffty/> like this.
  17. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    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/>
  18. Broken Byzan
    Online

    Broken Byzan Photographic Moderator Staff Member Moderator

    Joined:
    Apr 26, 2004
    Messages:
    12,568
    Likes Received:
    267
    actual YAY !!!
    StaceyS3 and <tuffty/> like this.
  19. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    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/>
    Kuvi-S3, Alex C, ScottD3 and 6 others like this.
  20. badger5
    Online

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,263
    Likes Received:
    668
    Superb
    <tuffty/> likes this.
  21. micky2 not 1
    Offline

    micky2 not 1 Member

    Joined:
    Sep 15, 2013
    Messages:
    58
    Likes Received:
    10
    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 ;]
    <tuffty/> likes this.
  22. jojo
    Offline

    jojo S3 Drift King! Staff Member Moderator

    Joined:
    Sep 4, 2003
    Messages:
    25,925
    Likes Received:
    1,558
    x2
    <tuffty/> likes this.
  23. Gops
    Offline

    Gops 6th gear @7000rpm

    Joined:
    Nov 6, 2009
    Messages:
    2,640
    Likes Received:
    285
    Looks absolutely brilliant! Was following this all day on FB!
    <tuffty/> likes this.
  24. Lewis583
    Online

    Lewis583 Active Member

    Joined:
    Mar 15, 2010
    Messages:
    874
    Likes Received:
    70
    That looks the nuts Paul. Easily on par with some of the professional manifolds available.
    <tuffty/> likes this.
  25. s3dave
    Offline

    s3dave TFSI Hybrid

    Joined:
    Nov 11, 2009
    Messages:
    10,120
    Likes Received:
    728
    Nice... you will be making TFSI Quatrro Downpipes soon...;)
    <tuffty/> likes this.
  26. superkarl
    Offline

    superkarl MAN OF STEEL

    Joined:
    Mar 28, 2010
    Messages:
    7,553
    Likes Received:
    1,074
    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
  27. Sam_
    Offline

    Sam_ Down under

    Joined:
    Mar 8, 2011
    Messages:
    2,806
    Likes Received:
    337
    Awesome work. Placement looks close to TSR but lower and more central between 3 and 4 whereas TSR is closer to 3.
  28. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,440
    Likes Received:
    1,281
    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?
  29. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    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/>
  30. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    Yeah pretty much... this is why it will be measure twice and cut once :)

    Will have a faff at the weekend

    <tuffty/>
  31. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,440
    Likes Received:
    1,281
    can't wait until it's all done mate, getting the mani out of the way seems like a massive step
  32. Scullies
    Offline

    Scullies Active Member

    Joined:
    Feb 9, 2012
    Messages:
    1,274
    Likes Received:
    309
    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?
  33. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    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/>
  34. s33nyboy12
    Offline

    s33nyboy12 Active Member

    Joined:
    May 14, 2012
    Messages:
    1,412
    Likes Received:
    168
    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
  35. badger5
    Online

    badger5 RIP S3dave Site Sponsor

    Joined:
    May 28, 2004
    Messages:
    7,263
    Likes Received:
    668
    feck that lol... biggest we can fit in there dude :)

    'because we can'
    Lewis583 and <tuffty/> like this.
  36. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    Well... thats the down pipe plans sorted LOL... :D

    <tuffty/>
    Vex182 likes this.
  37. <tuffty/>
    Offline

    <tuffty/> Badger 5 Edition Staff Member Moderator

    Joined:
    Sep 14, 2008
    Messages:
    15,731
    Likes Received:
    1,268
    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/>
    badger5 likes this.
  38. scotty_24
    Offline

    scotty_24 Member

    Joined:
    Feb 11, 2011
    Messages:
    211
    Likes Received:
    13
    Awesome work mate, this is some car!
  39. Sam_
    Offline

    Sam_ Down under

    Joined:
    Mar 8, 2011
    Messages:
    2,806
    Likes Received:
    337
    Forward planning for the 40 psi ;)
    StaceyS3 and Jason.s like this.
  40. Scullies
    Offline

    Scullies Active Member

    Joined:
    Feb 9, 2012
    Messages:
    1,274
    Likes Received:
    309
    Thats pretty low :)

Share This Page