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My minor modding thread

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

  1. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 28, 2009]
    was'nt so hard after all was it

    ;)
  2. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 28, 2009]
    No mate,all is good in the world... thanks for your invaluable expert eye and Tony's elite fabrication skillage... Home stretch now... WooHoo!!!!

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

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    [Sep 29, 2009]
    As a result of the following post from RyanA31.8T...

    http://www.audi-sport.net/vb/showthread.php?t=79325

    ...I called Jay this morning to discuss a system for my car... The deal Ryan has organised is a group buy... not sure how many of us it needs to qualify but I am up for this. £250 for a 2.5" SS cat back system is a great deal...

    As always I am up for getting it done, taking pics and doing a write up on my build thread as its all relevant. As Ryan is currently booked in perhaps he would add a thread and do his own write up too... Exhausts get discussed a lot on this forum so I reckon it would be a good idea to share some experiences from some of the companies that custom build systems rather than just buying an off the shelf solution like a Miltek.

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

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    [Oct 2, 2009]
    Had an interesting start to the day yesterday... The car I am driving about in while I work on my S3 ran out of fuel in the middle of nowhere (my fault entirely) so had to get the missus out of bed at 7:30am to bring me some fuel... she wasn't the happiest person in the world :)

    Anyhoo... went to the workshop straight from work yesterday afternoon (having put more petrol in the Golf of course) and made a start on the cold air feed and TIP fitting.

    Glen (Ess Three) managed to fit a 4" duct threaded past the battery and down into the bumper where the SMIC used to be... so after a quick PM I had a go at that too... gave up after an hour... no idea how he managed to get it in there but decided there was more to life and compromised but cutting it short past the battery so still getting the good stuff but with less lacerations of the arms and hands...

    Obvious differences between the OEM inlet to the airbox and the 4" ducting
    [​IMG]

    Modding the airbox to accept the ducting...
    [​IMG]

    Ducting fitted...
    [​IMG]

    [​IMG]

    [​IMG]


    With that done, I started to put the TIP together and plumb everything back up. Its a little tight in places and I would like to make some improvements to the outlet positions for the DV and one of the breathers (my fault entirely) but it all works and the top end of the engine bay is now complete and back together.

    Here is a pic of the TIP...
    [​IMG]


    Not a bad evenings work. Back on it from Saturday morning where the list of things left to do is getting smaller all the time.

    DP just needs the V-Band flanges properly welded on and a lambda boss too. I can then wrap it and fit it.

    The lower part of the exhaust and flexi to be welded up then fitted to the existing exhaust system.

    Oil drain needs further modding to clear the driveshaft and any additional heat shielding applied.

    Power steering pipe to be moved over a tad more.

    Driveshaft to be refitted, propshaft to be bolted back on.

    Everything to have a final going over to check its all tight and stuff...

    Fluids then start the car!!!

    Look for stuff leaking then last but not least of course, mapping!!!

    Will update the thread Saturday evening with progress..

    <tuffty/>
  5. ash_pearce
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    ash_pearce Member VCDS Map User

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    [Oct 2, 2009]
    Can't wait to see some videos mate! Fingers crossed all goes to plan!
  6. <tuffty/>
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    [Oct 4, 2009]
    Small update.... didn't get over to the workshop till late Saturday afternoon as the wife was having her hair done and I had the kids...

    Anyhoo... went through a check list of stuff to check, making sure things are tight and connected properly. Downpipe is done and now wrapped ready to go on tomorrow once the oil drain has been modded.

    [​IMG]

    Bill was kinda busy so gave him a hand with stuff today.

    Few things left to do, hopefully try and start the car late tomorrow with a mind to get her mapped in the week.

    Fingers crossed she will be running for Audi International on the 10th but not gonna rush getting the last bits sorted out..

    <tuffty/>
  7. Broken Byzan
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    [Oct 4, 2009]
    Nice one Paul, i am sure Bill will do his best to get you to ADI,Will be a good advert for him :sign_plug:

    Oh and your spannering skills too obviously
  8. Paul @ Unit
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    Paul @ Unit Active Member

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    [Oct 4, 2009]
    fantastic, near the end now, bet you can see that bit of light at the end of the tunnel
  9. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    I hope im wrong...
    But i would expect the clutch to go pop as soon as the turbo comes on boost.
    Fingers are cross'd for you mate but the clutch i fitted a year ago (and flywheel) where well and truely cooked with only a tad over 300bhp.
  10. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Oct 5, 2009]
    Paul what heat wrap did you use on your DP?
  11. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 5, 2009]
    Just have to see... I am hoping that Bill will look to map it more progressively so it shouldn't all come in one big lump but it will be what it is and if a new clutch is needed then I'll sort that out...

    2" wide Thermo Tec from http://www.exhaustwrapshop.com/

    Weekend was a bit slow with not being able to get over Saturday that early and Bill had problems with his welding mask so the oil drain (which is holding up putting most of the rest of the car back together) has not been welded up fully. This needed to be modded again to clear the driveshaft.

    I did get hold of a CAT from an old exhaust system and have cut it about to fit up to 3" pipework. This will do until I can be bothered to source a sports CAT of some description. Its not as free flowing but its not like I am fitting it back on a K04 is it ;P

    With stuff still left to do and limited time during the week to get it done, I am unlikely to be at ADI Saturday. While I am sure Bill could get it done, he is busy sorting customer cars and I cannot expect him to swap his priorities about for me. I would rather it be done right than rushed and I still need to get the car MOT'd so I think its gonna be a tall order to get it all done for Saturday.... :(

    <tuffty/>
  12. badger5
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    [Oct 5, 2009]
    I am still seeing spots this morning... (boo hoo)
    effing weld mask doing my head in.. Grrrrr
  13. 1animal1
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    1animal1 The Clar!! it mouves!!! VCDS Map User

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    [Oct 5, 2009]
    good stuff tufts comin on well mate

    i payed a visit to JBS on sat to pic a mates car up....hes considering a GT28RS kit, i said he'd be better off with the GT30 if hes going to do it for the cost (hes a mechanic and will ALWAYS want more power).....trouble is hes driving a 2wd Leon Cupra so traction would be a problem....

    anyway, mentioned this @ JBS and the fact i knew sum1 fitting an underslung GT30 from America to an S3, the suggestion was that this wouldnt be possible and if it was, the turbo would be the wrong way (or sumat would be)..... i then mentioned that Bill was the 'man' which was met with a puff and a blow.... why is this conversion to unbelievable? JBS seemed shocked that i knew someone doing this until i pointed them in the direction of this thread, is it competition for something they can't do?

    thoughts please chaps :)
  14. badger5
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    [Oct 5, 2009]
    jealousy - lol

    huff and a puff so they may..

    so say... one day, they have a cast manifold which will accomodate BT's on underslung fitment in IHI and Garrett fitment. 2010 sometime

    The normal (USA) supplied turbo kit is as they say wrong way round, but this one I have had configured to be the right way round. yes its tight and some mods to transfer case webbing is req'd as posted, but it does fit mechanically. In 2wd cars it would bolt straight on, much easier than an S3

    made me smile when I read "huff and puff" lmao...
    hehe
    Last edited: Oct 5, 2009
  15. Broken Byzan
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    [Oct 5, 2009]
    Best get it completed to show it off at ADI then,lol
  16. badger5
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    [Oct 5, 2009]
    just need 48hours per day
  17. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 5, 2009]
    I'll see if I can take a crash course in TIG welding... and of course dose up on lemsip for my current man flu condition..

    <tuffty/>
  18. 1animal1
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    1animal1 The Clar!! it mouves!!! VCDS Map User

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    [Oct 5, 2009]
    well i was happy knowing it was being done Bill.... there was more said but this was closed down by the fact that i mentioned it was physically in the car now and ready to go within days.....

    back to my mates Leon, would he be able to source the same kit from America or would this have to come through you Bill with it being the 'correct' ;) way around?... (dont wana be cheeky :) ) ..... also id gather with a GT30 he'd need some sort of traction control device fitting....

    just a slight deviation but relevant sorry tufts ;)
  19. Broken Byzan
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    [Oct 5, 2009]
    You got ligts in the workshop aint ya :uhm:
    :p
  20. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Oct 5, 2009]
    Oh I can imagine there was a whole lot more said, not the first nor last time...
    They are good business for me.. and should keep it up :)


    If he knows what to ask for and buy he can source it himself... BUT, there will be no warranty offered on fitment and what is supplied will not be anything like the whole cabooch req'd to diy.

    My price is very competetive on the sourced parts, its the none sourced fabricated parts which are exclusive to me, cos I make em. tubby and mani I buy in, and a few fixings and the odd hose. that is not a "kit", its all the other odds and ends which make it function.
    I wont be able to do anything other than supply & fit a complete kit as there are too many variables, and the "kit" aspect of it is what I pull together to make it happen.

    I am firming up on pricing of the US sourced parts now, so will post a link to whats what shortly. Main priorty for now is getting these customer cars finished.


    regards
    Last edited: Oct 5, 2009
  21. badger5
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    [Oct 5, 2009]
    lol - yip.. and candles... cos I burn them both ends dont ya know ;)
  22. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    I think its a case of diffrent strokes for diffrent foke.
    I know This is being built with a budget in mind.
    Massive steps are being made here. That said The JBS aproach is drop off your car... we do the work... you pick it up ( and pay a bloody big bill ) BUT they IMO do over build some parts where as bill has not done.
    They also dont modd the parts of the car that will be staying... such as the transfer box casing.
    I am in no way taking anything away from either place.
    As i said each to their own
  23. badger5
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    [Oct 5, 2009]
    overbuild some parts where I have'nt?
    care to enlighten me?

    I base ALL my builds on RACE experience from 1st hand abuse of my own equipment.
    road cars are not race cars, race cars is what I am in to, and apply the same build attention to detail to.... with the methodology of if it works in race conditions it will most certainly last on a road car.

    I dont quite follow what you mean re the over build statement?

    ??
  24. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    Oh here we go...
    Bill i will pm you my fone number if you wish to rant and rave . This was my way of saying... they wouldnt refit the pistons and rings that came from the engine. They wouldnt fit the used oil pump... all adding massively to the bill (even though they may well be servicable ), They would also say it would be 100% pointless using a stock clutch set up with this power on tap. The fact that you will work with the owners budget isnt a bad thing.
    With regard to the if it works on a track car it will last on a road car... im not a believer of this as no race car ive ever heard of does 100k plus between rebuilds/replacements.
  25. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Oct 5, 2009]
    You kinda have a habit of starting these things d00de...

    <tuffty/>
  26. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    I speak my mind.
    Always have,Always will
    All i said its two diffrent route to the happy place we will call a 400+bhp S3
  27. badger5
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    [Oct 5, 2009]
    fella, asking a simple question of you, which is not a rant.. (yet)

    The build is tufftys... 1st point of Clarification for you.
    I am assisting on the turbo side of things on the install, yep, and general there when a question needs an answer etc etc. The build spec is tufftys, and Budget, which is spelled out clearly from the outset is critical.... so minimal unneccessary new parts have been fitted. You may be confusing someone trying to "sell" all the other parts, with actually really needing to use them. Big Difference.
    Oil pump was working when it drove in.. no oil burn when it drove in.. why change if you dont have to, and dont have the bottomless budget to fund it.

    I build a spec of engine to suit customer requirement, but do not sell parts they dont need. The essential main parts (thus far) have been done. My advise was valves etc too, BUT budget wont allow for it, so state of tune will reflect not ringing its neck. Later on, when and if more is wanted, the path is clear on what to uprate next and what you will get for the ££ it will cost to do so. this is a road car, a daily driver, and one being built on a budget, mainly self built (respect to tuffty for that)

    anyone can throw keys at a tuner and pay a large bill for a finished product.. good for those that can, but they are few and far between.. thrown some my way I say - lol

    As for race car vs road car, if you had any notion of the stresses and heat generated during racing, and applied the additional engineering to retain reliability, to a road car, it WILL most certainly last longer. Plonk an ill prepared road car on track and it will guaranteed, DIE. Mileage is irrelevant fella.
  28. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    Im aware its tufftys thread and a major upgrade!
    Much respect to the man.
    Still not convinced that a race engines strengths are to make it last 100k plus. I too would be looking at valves , Im thinking of upgrading mine if i go after big power. i couldnt stretch that far just yet
  29. 1animal1
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    1animal1 The Clar!! it mouves!!! VCDS Map User

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    [Oct 5, 2009]
    cheers Bill, i did say to him before you posted that you would be best to knock everything together manifold and TIP wise...... will PM ya as i think he'd be curious as to what you could do regards his next upgrade cost wise..... whats the verdict on traction control for the gt28 or gt30....is it recommended for a daily driver, will the diff between these turbos be noticed or am i asking too big a question

    cheers

    Tim
  30. Paul @ Unit
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    Paul @ Unit Active Member

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    [Oct 5, 2009]
    thanx for ruinining an enjoyable read'
  31. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    WHo has ruined your read?
  32. 1animal1
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    1animal1 The Clar!! it mouves!!! VCDS Map User

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    [Oct 5, 2009]
    before this turns to arguments can admin plz delete the offending threads so we can sticky this please :) no offense to anyone ;)
  33. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    Why have thread that allows people to post on but then have them deleted.?
    Everybody has a veiw and should feel free to air it?
    Nothing i have said ( or any others as far as i can see ) should be cause for concern?
    Tuffty is building a big power car at low cost ( or so im thinking ) So that should be embraced but as with everything, There is more than one way to do things.


    Back to the topic in hand...
    I bet with the prop shaft back in situ. thats going to be clost to the down pipe. Are you retaining the standard heatshields fitted to the cars bulk head? I had alot of head aches trying to stop them ratteling against the 3 inch down pipe.
    Last edited: Oct 5, 2009
  34. 1animal1
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    1animal1 The Clar!! it mouves!!! VCDS Map User

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    [Oct 5, 2009]
    like i said, nowt against you Paul but the conversation is leaving what was the original post..... personally im enjoying watching this turbo upgrade coming together on a budget.... i for one am not interested in blowing anything huge on this car, and so this thread comes into its own....
  35. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    What is the budget??
    Sorry if thats a bit forward... but im curius what the ball park figure is to date???
    I havent spent a mad amount on my build but wondered what the extra cost of a cast big turbo manifold would be.
  36. s3_kev
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    s3_kev Stage2'd!!!!!!

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    [Oct 5, 2009]
    im having great fun reading this thread get home every day to come on here to see whats new, im almost as excited as tuffty.
    just wish id have had the chance to experiance a big turbo before maxing out my k04 which for me is enough for the road but without going in a big turbo i cant really say, but in a year or so i might be tempted for the upgrade we shall see but for me bill is the man here with the experiance and actually seems to make things a reality unlike some 'specialists', so when/if i go big turbo here is where my hard earnd is going :thumbsup:
  37. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    Ive got a "big turbo " sat in the boot of my mk2 golf which is/was heading for my s3 , Plenty of things need to be decided too before i think of taking it off the road again though. Im not so bothered for hiding my mods, More of the thinking... how would audi have made it look.
    I realy want to see how this set up looks/goes as much as anybodyelse.
  38. badger5
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    [Oct 5, 2009]
    its a case of do what you can when you can... bit by bit, OR be a very good saver and shop for parts but maybe not ever get their either

    tufftys getting it done, has rods, which should keep things inside.. lol, and the mapping will be tailored to suit... but he will at least have a gt30'd s3 to enjoy
  39. badger5
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    [Oct 5, 2009]
    - to put it this way, a Built "race" engine, which is blue printed, balanced, runs hi spec internals, forged pistons, rods, valves, springs etc etc etc, and tuned to standard level.... do you think in ANY way it would not last equally as long as a stocker?

    when things are pushed, like on track use, you find the weakness 'Sooner' than you would on the road.. employ an upgrade on both the race AND road version, there is a better component on both.. Race use finds a lot out. Those that dont and have'nt dont know.
  40. S3 Paul
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    S3 Paul Well-Known Member Regional Rep

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    [Oct 5, 2009]
    Can a gt3071 build boost slowly enough to stop the clutch eating itself?
    how would it compare to a gt3076?

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