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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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    [Dec 31, 2013]


    Is that why I am now down 2 ramps currently with other peoples cars? lol

    hehe
  2. micky2 not 1
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    micky2 not 1 Member

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    [Dec 31, 2013]
    Hey Bill, you know my thoughts on it all....I want mine doing asap. Think tuftys going for tax exemption status on his. Push mine out if you need the space....I'll be back up on Friday.
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Dec 31, 2013]
    Bit more progress today... in between helping Bill with the Lupo I managed to get a few more things sorted...

    Cut the angled alloy pieces I needed for the charge pipe and trimmed the hose from the turbo to suit...

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Unfortunately ran out of argon for the TIG so couldn't weld them today but plan is to flush the welds before painting...

    Next I fitted the manifold/turbo into the car to make sure everything fits and to work out the wastegate... fitted coolant hoses and the elbow for the TIP...

    [​IMG]

    ...just need to connect these with a little bit of 100mm alloy lol...
    [​IMG]

    ...so, a little work to do lol...
    [​IMG]

    Next I played with the wastegate... I am a little limited due to the lower position of everything... so ended up with this...
    [​IMG]

    [​IMG]

    ...the extension was required to clear the gear change cables...
    [​IMG]

    So of course the next thing is to paint the Tial a decent colour lol....

    <tuffty/>
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  4. micky2 not 1
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    micky2 not 1 Member

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    [Dec 31, 2013]
    i like that colour...shame mines black
  5. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Dec 31, 2013]
    Easily fixed... I'll swap them ;P

    <tuffty/>
  6. Vex182
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    Vex182 Guess what I drive...

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    [Dec 31, 2013]
    I love the fabrication for it all, it's always Audi's version plus a little tweak! :)
  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 1, 2014]
    So... new year and same old crappy weather... went over for a couple of hours to sort a couple of things.. mainly a colour change for the Tial..

    [​IMG]

    [​IMG]

    [​IMG]

    <tuffty/>
  8. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Jan 1, 2014]
    Hob nobs and wine for lunch.....LMAO
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  9. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 1, 2014]
    In a rare change from the norm, I think I prefered it in Purple :laugh:

    Not that it doesn't look good in silver, and more in keeping, but I think some bling hidden away could have been like a treasure hunt for us at the shows!
    Lavis89, Dani_B19 and Gops like this.
  10. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 2, 2014]
    Today I have been doing a bit of finishing up on the B5 Lupo... mainly sorting the cam cover (that of course I painted lol) and the heatshielding...

    [​IMG]

    Did a few little things on mine today... the way the cover sits bothered me... it was never right since I fitted the new inlet and modding the charge pipe bracket made the cover sit lower and touch the charge pipe so I drilled out the spot welds holding the cover locating tab and tapped for M4...
    [​IMG]

    ..this lets me adjust its height...
    [​IMG]

    ...then flattened out the little brackets that the front clips of the cover fix too...
    [​IMG]

    ...redrilled the hole to retain positioning and trimmed off the rest... painted them black (of course)
    [​IMG]

    Cover now sits better (much more level) with clearance for the charge pipe...
    [​IMG]

    Last thing I did was to drill and tap the turbo's compressor housing for a boost take off that will be used by the N75... I did this rather than have a stub welded onto the charge pipe as its one less thing to weld (they are fiddly little things) and keeps the top of the engine free of pipes etc... obviously I painted the brass fitting :)
    [​IMG]

    Charge pipe and throttle body should be welded up tomorrow... throttle body is just getting a few beads welded on to stop the hose from popping off..

    Charge pipe will be flushed/smoothed before painting :)

    <tuffty/>
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  11. Lavis89
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    Lavis89 Active Member

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    [Jan 3, 2014]
    i love how oem this looks whilst being a absolute monster of a build.
  12. Gops
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    Gops 6th gear @7000rpm

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    [Jan 3, 2014]
    I love the attention to detail! I want that inlet mani!! I wish you was there when my car was so you could paint my cam cover!
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  13. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 3, 2014]
    Must be pretty scary taking a drill to a brand new GT35 :laugh:

    Looking good PT, I honestly didn't expect you to be carrying on with the OEM appearence when going GT35 and top mount, most impressive!
    Alex C likes this.
  14. Scullies
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    Scullies Well-Known Member

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    [Jan 3, 2014]
    This look awesome, great work

    When you going to smooth out the comp housing and paint it :)
  15. Sam_
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    Sam_ Down under

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    [Jan 3, 2014]
    When he becomes a ricer ;)
    <tuffty/> and badger5 like this.
  16. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 5, 2014]
    So... it is the end of my christmas holiday... back to work tomorrow to deal with creating data exports for the crazy french :(

    Anyhoo... at a point where there are loads of small jobs to do... Bill welded beads onto the 70mm throttle body which of course I then painted... before I could fit it though I had to re-drill the adaptor plate for the 70mm TB... I had already had the bore taken out to 70mm so I marked up the holes, drilled and tapped

    [​IMG]

    [​IMG]

    [​IMG]

    I have now also removed the penetration from the welded beads and finished the inside of the TB a little to clean it up... Bill had also welded up the charge pipe so set to work flushing, filling and painting that..
    [​IMG]

    [​IMG]

    Looked at the oil/coolant lines too... oil feed test fitted... will make some brackets etc to hold that securely..
    [​IMG]

    Started on a coolant line but tbh I am not happy with it so I have ordered some more stainless and going to have another go...
    [​IMG]

    I really need to add a flexi in but seeing as I had a small incident involving fire and stuff with a burst 'flexi' on my last setup I have some better ideas on that but as Bill did point out I would be better off getting the oil drain done first as this dictates the clocking of the CHRA... once done then the coolant lines can be sorted...

    Got a few other small things sorted and made a list of stuff to order next week... charge pipe was dry but yet again the bloody paint reacted despite me trying to be careful this time (other stuff turned out fine) so fitted it to the engine anyway knowing it will need sorting later...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    So thats it for now... need to order a load of kit in the week including stuff to make the oil drain, some seals and stuff, clutch plate and exhaust boxes to make the back box... heatshielding should arrive in the week... going to use a combo of the OE one as its not bad on K04 cars and sure it up with other tactically placed shielding as required... plan is to turn key early February

    My feet are actual killing me with all the standing up lol... not used to it at all :D

    <tuffty/>
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  17. Kuvi-S3
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    Kuvi-S3 Active Member

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    [Jan 6, 2014]
    Pure awesomeness!!!

    The most detailed build I have ever come across. Well done tuffty
    <tuffty/> likes this.
  18. fanta
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    fanta Member

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    [Jan 8, 2014]
    In my impressed moment of inspiration I made the fatal mistake of expecting the Mrs to be impressed, we then had an 30 minute argument about the 'money wasted on that fracking car!' (My car not yours!) looking back I now realise my error in judgement :)
  19. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 8, 2014]
    Fatal mistake mate... tell the missus nothing lol...

    <tuffty/>
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  20. Jay A3
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    Jay A3 More power

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    [Jan 8, 2014]
    Best piece of advice on ASN!
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  21. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 18, 2014]
    Small update... a few parts turned up this week...

    [​IMG]

    ...made a start on the back box...
    [​IMG]

    ...and roughly mocked up some tail pipe options in photoshop... these use tactically cut 3" stainless bends..
    [​IMG]

    [​IMG]

    Slash cut and cutting to follow the bumper profile may be a bit more of a challenge...

    hope to get a bit more done tomorrow... ideally the oil drain mocked up ready for welding and coolant lines... need to get this lot done so the welding of the manifold can be finished and I can get it off for ceramic coating...

    Still waiting on a few other parts but hoping to have the engine in for the end of the month so I can get the DP and exhaust etc finished ready for first start!!...

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

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    [Jan 18, 2014]
    I think I might come and check this out tomorrow, give you a few tips and pointers where you're struggling :laugh:
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  23. Gops
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    Gops 6th gear @7000rpm

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    [Jan 19, 2014]
    I'll try and come down tomorrow Paul, so you can measure my miltek
  24. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 19, 2014]
    Little more done today...

    Coolant lines...
    [​IMG]

    [​IMG]

    Oil feed...
    [​IMG]

    Oil drain...
    [​IMG]

    There are of course a couple of gaps to fill lol... these will be filled with PTFE lined flexi's...

    Now that the lines are essentially done the mani can go off for the final welding and then off to be ceramic coated..

    Getting there :D

    <tuffty/>
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  25. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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  26. superkarl
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    superkarl MAN OF STEEL

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    [Jan 19, 2014]
    Noice!
    <tuffty/> likes this.
  27. sean_s3
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    sean_s3 Member

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    [Jan 19, 2014]
    That looks very tidy , great work.
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  28. Scullies
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    Scullies Well-Known Member

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  29. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 20, 2014]
    Love it PT, coolant lines look fantastic, I like how all the bends are to the perfect angle and it all sits so neatly :)
    <tuffty/> likes this.
  30. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 24, 2014]
    Day off to day to go a do some more... the build is at the loads of silly little jobs stage...

    First job, tailpipe... had a go using two 90deg 1.5D bends...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    ...put the back box in place to get a better idea of where things were likely to end up...
    [​IMG]

    Next I knocked up one of the hangers...
    [​IMG]

    [​IMG]

    [​IMG]

    Bit more to do but parts of the box needs final welding now before I can do the rest and the DP needs fabricating before I can see what else needs doing to mate the back box to the centre section
    [​IMG]

    Last job of the day... using a section from one of the tailpipe offcuts I made a bracket for the coolant lines...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Just need to make a little clamping bar to hold them in place and job done...

    Getting there :D

    <tuffty/>
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  31. Lewis583
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    Lewis583 Active Member VCDS Map User

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    [Jan 24, 2014]
    I love all the little details you are adding Paul like the coolant lines bracket. Top work as usual fella.
    <tuffty/> likes this.
  32. superkarl
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    superkarl MAN OF STEEL

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    [Jan 24, 2014]
    Love it.
    How many times did you measure those tail pipes lol?
    <tuffty/> likes this.
  33. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 24, 2014]
    Not that many tbh... I measured the gap between the pipes on a miltek to an S3 Bill has in at the moment and used a flat surface and a set square to make a mark to cut... used the chop saw to start the cut (its a little brutal) and finished off with a hacksaw...

    Then ground it a little finishing off on the linisher to get the mating surfaces flat and bingo...

    Took a little effort to get it to where I was happy but its worked out ok...

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

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    [Jan 24, 2014]
    I think I can pop down Saturday Paul.. You still wanna measure the slash cut?
  35. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 24, 2014]
    If you are passing then all good but no need to make a special journey mate although obviously always good to see you... I can get a slash angle from the miltek on the car thats in but yours has the 'special' tailpipes so dunno if there is a difference..

    I think I am just going to stick to the slash cut rather than the slash and bumper angle as it looks a real c*ck to do and I don't want to end up scrapping these and have to start over...

    <tuffty/>
  36. Sam_
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    Sam_ Down under

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    [Jan 25, 2014]
    Just make sure it doesn't stick out too far. That's the only thing I don't like about the Milltek "Special". An inch off it and it'd be way less Nova.
  37. Gops
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    Gops 6th gear @7000rpm

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    [Jan 25, 2014]
    Will try n pop up if I can :) I'm not sure what difference there is if there is any... But always around to offer help where I can!
    <tuffty/> likes this.
  38. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 25, 2014]
    soooo... I slash cut the pipes... look a bit better I think..

    [​IMG]

    ...outside tailpipe slightly set back to follow curve of bumper
    [​IMG]

    ....done...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    <tuffty/>
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  39. Vex182
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    Vex182 Guess what I drive...

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    [Jan 25, 2014]
    I agree with the pipes like that, they look very clean and subtle.
  40. s3 Hoggy
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    s3 Hoggy Whats going on???

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    [Jan 25, 2014]
    Yep looks great now

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