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My minor modding thread

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

  1. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Feb 14, 2014]
    Youll like the 16mm rarb mate, I fitted one years ago and planted the car more.
    <tuffty/> likes this.
  2. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 15, 2014]
    [​IMG]

    [​IMG]

    Just sayin' :)

    <tuffty/>
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  3. CazzaVR
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    CazzaVR Member

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    [Feb 15, 2014]
    Nice!
  4. Prawn
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    Prawn My other car is a MINI!!!!

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    [Feb 15, 2014]
    Flywheel looks nice :laugh: where did that come from? :racer:

    It's almost time PT, so close now!
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  5. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 15, 2014]
    I'm using my old DMF but the cover plate from the mysterious benefactor :)

    <tuffty/>
  6. audiholic ste
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    audiholic ste Member

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    [Feb 16, 2014]
    This should be published . I bet this could have everything in it a good book needs . Love heartbreak sore knuckles and engine porn . Defo a best seller under the right title . I must say this is a great read and we'll done .
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  7. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 16, 2014]
    Got the manifold back so clamped it firmly in the vice and got started on wrapping it :)
    [​IMG]

    Quite tricky trying to work out how much to cut off the roll to do a runner plus with everything so close it makes for an interesting time to say the least!
    [​IMG]

    [​IMG]

    [​IMG]

    ...and after a bit of time (and itching like a mofo!) you end up with this...
    [​IMG]

    ...and finally bolted to the engine
    [​IMG]

    Fitted the turbo to check it still fits lol
    [​IMG]

    ...and so I could make sure the oil drain would still fit (which it did) so Bill welded it up for me :)
    [​IMG]

    ...of course I had to paint something lol...
    [​IMG]

    And thats it for today... the closest the engine and the car have been for nearly six months!!...
    [​IMG]

    Tomorrow the engine will be going back in... waiting on a delivery from TPS for the engine mount bolts and will be sorting out the flexi's for the coolant lines and oil drain

    <tuffty/>
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  8. Sam_
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    Sam_ Down under

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    [Feb 16, 2014]
    I've heard wetting it can help reduce the itchiness. Also might mean it'll stretch a little more giving a tighter fit.

    Not looking forward to doing mine :(
  9. CazzaVR
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    CazzaVR Member

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    [Feb 16, 2014]
    As above- had the wrap sat in a bowl of water while I did the 6-branch for my Corrado. Wore gloves and used plastic cable ties to hold it all in place before using the metal ones. As the wrap dries out it shrinks a bit onto the mani :)

    That mani looks like it belongs in the Amazon, preying on Capybara! 'Tuffty-conda'!
  10. daz-20vt
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    daz-20vt Well-Known Member

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    [Feb 16, 2014]
    Do you have a finish date in mind? You must be dying to get this back on the road!! It just looks awesome though. OCD at its best!!
  11. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Feb 16, 2014]
    His finish date was 2013 iirc
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  12. daz-20vt
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    daz-20vt Well-Known Member

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    [Feb 16, 2014]


    Pmsl. So i guess the new date is 2014??
  13. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 16, 2014]
    I have used the wet method before and yeah it helps reduce the itchyness (prevents the fibres flying around) and can help the stretch but so does a vice and a 14 stone bloke tugging on the end of it (fnarr!) :)

    If I was to do it again then I might do it wet but its such a ballache to do on a mani like this I have no intention of doing it again... EVER!!... LOL

    Good luck Sam! ;P

    tbh I never planned on it being off the road this long but one thing led to another and this is where its at... I want the car on the road next month... I will take a week off work if need be but I have been trying to take long weekends instead so I don't spank all my leave like I normally do... this way I can make better use of the time rather than have a day or so waiting on parts or similar which has happened in the past...

    I set little milestones which makes the work more focused... once the engine and box is in the next milestone is to connect everything up and get the front back on properly... then after that its the DP, wastegate pipework and finish the back box...

    Home stretch now though :)

    <tuffty/>
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  14. Lavis89
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    Lavis89 Well-Known Member Regional Rep

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    [Feb 16, 2014]
    make us a nice video when this goes on the rollers!
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  15. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 17, 2014]
    Bit more done today... little jobs that take the time :)

    Tweaked the bracket for the coolant lines...
    [​IMG]

    ...captive nut so I can use p-clips to hold the lines...
    [​IMG]

    Bit more heatshielding over the hotside of the turbo to protect the turbo outlet hose...
    [​IMG]

    Then had a shuffle and got the car and engine ready for final fitting :D
    [​IMG]

    In the meantime Bill sorted a set of PTFE lined flexi hoses for the coolant lines and oil drain
    [​IMG]

    I tacked these in place ready for welding...
    [​IMG]

    After what seemed like ages of faffing with the oil drain I got it all where I wanted it and tacked it ready for final welding...
    [​IMG]

    Pulled the lines and the turbo off the engine and..... Yay!!... its in!!
    [​IMG]

    ...next job is to sort this little lot out LOL...
    [​IMG]

    Phew!... been a long time but finally the engine is back in... need to reconnect everything before cracking on with the downpipe and new TIP etc :)

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

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    [Feb 17, 2014]
    Good work. Nice hoses those. Very nice.
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  17. sssline
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    sssline Active Member

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    [Feb 17, 2014]
    Literally cannot wait to see the final product....well done mate.
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  18. Vex182
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    Vex182 Guess what I drive...

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    [Feb 17, 2014]
    Looking awesome. Are you working on it tomorrow? Possible to pop by and have a look?
  19. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 17, 2014]
    No mate... back to actual work tomorrow.. :(

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

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    [Feb 17, 2014]
    Ah no worries! Maybe another time, I'm the opposite and off work for a few days.
  21. limbo118118
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    limbo118118 LORD

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    [Feb 18, 2014]
    Awesome job there wrapping the mani! I know alot of people do the DP an possibly decat but not sure on the pros/cons to the mani!?:s yours seems to come together so quickly too! :( (jealous)
  22. S3Alex
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    S3Alex Rarely neutral

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    [Feb 18, 2014]
    More art there,my friend.

    That engine is beautiful,and the quality of the work is superb.
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  23. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 18, 2014]
    Pro's are the same as wrapping a downpipe mate... heat management... lots of metal with 900 degrees or so of heat... wrapping lessens under bonnet temps, keeps gas speed up and prevents stuff from melting... cons is its a ballache to do and itchy lol

    Ceramic coating is the alternative buts its 35 quid and a few hours of faffing vs 400 quid and 15 working days turnaround...

    I don't know about coming together quickly... 6 months off the road LOL... but its gathering pace now and I have another long weekend coming up to get it progressed a bit more

    Thanks mate... appreciated :)

    <tuffty/>
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  24. limbo118118
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    limbo118118 LORD

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    [Feb 18, 2014]
    Ahh fairenuf! Id quite happily give it ago agaisnt paying the 400! I did get a quote for getting my manifold coated but didnt realise it costed so much! Mines been nearly a year now :( hopefully running in during april :) carnt wait to see what this makes tho!!
  25. S3Alex
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    S3Alex Rarely neutral

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    [Feb 18, 2014]

    Credit where credit is due.

    We looked at a few methods of restricting heat transfer on mine,and thought about ceramics also,before the issues of time/turnaround,and also in my case,heat retention in a cast manifold.

    Eventually settled on a lot of Zircoflex around the critical areas such as transfer case and pipework,and a jacket on the hot side of the turbo,plus an uprated bearing cage.

    So far......so good.
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  26. Kuvi-S3
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    Kuvi-S3 Active Member

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    [Feb 19, 2014]
    Awesome progress there tuffty
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  27. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 21, 2014]
    Another day off and more progress :)

    Been busy connecting stuff back up, had to paint a couple of brackets too of course lol... I also changed the injector plugs to EV14 ones so I could do away with the adaptors
    [​IMG]

    [​IMG]

    [​IMG]

    Removed the EVAP charcoal filter as I plan to relocate the fuel filter there
    [​IMG]

    Lots more bits in and done up etc including the slam panel and FMIC/crash bar
    [​IMG]

    ...obviously its while putting stuff back together you discover other small issues... like the injector leads being too short... wasn't because I cut the wires short, its due to the injector spacers so will have to come up with a fix...

    Test fitted the turbo to see how stuff will fit around it and ready for sorting the downpipe
    [​IMG]

    ...which will go down here somewhere lol...
    [​IMG]

    Bill had welded up my coolant lines and oil drain in the week... (thanks dude)
    [​IMG]

    Was a long day but worth it as she is starting to look like a car again :D
    [​IMG]

    I also have Monday off so with any luck I should have the DP tacked up and the stuff I have done so far spanner checked in case I missed something

    <tuffty/>
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  28. superkarl
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    superkarl MAN OF STEEL

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    [Feb 21, 2014]
    Interested in the location of the fuel filter idea.
    I was thinking of repositioning the pas reservoir further into the wing, leaving a nice spot for the filter.

    Btw, you wouldn't happen to know which fuel line is feed and which is return?
  29. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 22, 2014]
    There are arrows marked on the ends but the feed goes to the actual box section fuel rail and the return is the tube running along the side that comes out of the bottom of the FPR housing...

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

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    [Feb 22, 2014]
    oh PT, it's beautiful :s3addict:

    Must be really inspiring seeing it back in the bay and so close to completion.

    I simply cannot wait to see what kind of stupid face I am able to pull when you open it up and show me what 500bhp feels like :laugh:

    :hubbahubba:
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  31. willh92
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    willh92 Member

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    [Feb 22, 2014]
    Looking spot on! love that mani - especially wrapped - looks the tits!

    What paint did you use on your dog bone mount? Might paint mine whilst poly bushing it.
  32. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 22, 2014]
    [​IMG]

    2114 white aluminium and 2500 high gloss clear

    <tuffty/>
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  33. Rice
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    Rice Member

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    [Feb 23, 2014]
    Giggidy.

    Havent been on here in ages, but great work Tuffty :). Loving how clean it all is.
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  34. Sidey
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    Sidey Active Member

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    [Feb 24, 2014]
    Looks fantastic!
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  35. <tuffty/>
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    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    [Feb 24, 2014]
    Just like to say thank you everyone for your kind words... its all very much appreciated :)

    Another day off and some more stuff done :)

    Popped into Forge and got a service kit (with the new style piston) for my supersize and the coolant hose that was missing from the test kit they gave me (the one that goes to the after run pump along the front under the inlet)...
    [​IMG]

    [​IMG]

    And so on to the next task on the list... the TIP... just need to join the 100mm elbow from the turbo to the RS4 MAF whilst keeping the airbox still looking like an airbox... how hard can it be lol... I cut up the 180 degree 100mm alloy bend and...
    [​IMG]

    ...not that hard as it turns out and the airbox still looks like an airbox :)
    [​IMG]

    There is a turbo there somewhere :)
    [​IMG]

    Next I made up the inlet for the dump valve...
    [​IMG]

    ..and Bill (the hero that he is) welded it on...
    [​IMG]

    ...so I painted it :D

    While that was drying I moved onto the downpipe... decided to go 3.5" instead of 4" as it was quite tight and I fancied a little more wiggle room... had to kink the top over a bit to follow the bulkhead heatshielding but its looking good so far...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Test fitted the TIP...
    [​IMG]

    Little bit of fine adjustment needed and I need to make some proper brackets to support the airbox too
    [​IMG]

    Ran out of day again but at least I have broken the back of the last little bits of fabrication... will be looking at finishing the DP at the weekend all going well

    I am always getting told that I am going to have to give up the OE look now I have gone top mounted GT35.... to those who are in any doubt I give you this little sneak preview...
    [​IMG]

    How do you like them apples!!! :yes:

    <tuffty/>
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  36. Marshall878
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    Marshall878 Member

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    [Feb 24, 2014]
    Dayumn.

    That's a naughty engine bay!
  37. CMcKenzie
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    CMcKenzie It's supposed to do that..

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    [Feb 24, 2014]
    To the untrained eye, that engine bay wouldn't look like it's harbouring a monster..
    The level of detail that has gone into your build Tuffty is amazing, I often drop in from time to time to see what you've been up to, and the quality and eye for detail is something else.
    Callum.
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  38. MartinRagnhildstveit
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    MartinRagnhildstveit Member

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    [Feb 24, 2014]
    WOW, you've done some proper work mate!! Keep it up, I'll be following this thread :)
    <tuffty/> likes this.
  39. Sam_
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    Sam_ Down under

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    [Feb 24, 2014]
    I only wish my build will be as awesome.
    <tuffty/> likes this.
  40. daz-20vt
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    daz-20vt Well-Known Member

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    [Feb 24, 2014]
    Im waiting for the twist in the story line when we find out at the end it is standard. Lol
    You must seriously love this car. I couldnt put 10 percent of your effort into mine without giving up ages ago.
    Fair play you deserve the great end result, you've earned it. Daz
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