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My minor modding thread

<tuffty/> Jul 29, 2009

  1. <tuffty/>

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

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    500hp and a cat... let me think.... :)

    <tuffty/>
     
  2. Gops

    Gops Badger 5 Edition VCDS Map User Gold Supporter Audi S3

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    You rebel you!! ;)
     
  3. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    badgerwagen runs a cat :p
     
    Broken Byzan likes this.
  4. Prawn

    Prawn My other car is a MINI!!!!

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    haha, yea. I've seen that :laugh:

    :racer:
     
  5. <tuffty/>

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

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    Bit more done... getting closer :D

    Catch can turned up... has 19mm inlets but these are getting changed anyway to 25mm...
    [​IMG]

    ...and will go roughly here...
    [​IMG]

    Finished the wastegate pipe work...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    And tweaked the centre section to realign it....
    [​IMG]

    ...and made a start on the back box which managed to defeat me a little but its was gone 9pm and so I called it a day lol...
    [​IMG]

    Will have a look tomorrow when I am a little more with it :)

    <tuffty/>
     
    S3Alex likes this.
  6. Prawn

    Prawn My other car is a MINI!!!!

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    it's fecking tight in there isn't it!

    So amazingly close now mate :) Excited for you!
     
    <tuffty/> likes this.
  7. Marshall878

    Marshall878 Member

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    Phenomenal!

    Your fabrication skills are amazing.
     
    <tuffty/> likes this.
  8. limbo118118

    limbo118118 LORD

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    Awesome work with the exhaust there! Tackled mine today wasnt too bad. Can I ask what are you doing with the gear cables and linkages by the gearbox mine are fowling with the external gate being in the way :s problemssss!
     
    <tuffty/> likes this.
  9. <tuffty/>

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

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    I made the wastegate outlet so it would clear the cables on mine...
    [​IMG]

    I then wrapped them in the same heat wrap as the manifold/DP and made a heat shield to cover the lot... I'll take a pic tomorrow

    <tuffty/>
     
  10. limbo118118

    limbo118118 LORD

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    Ahh I see... will have to see what options I have with mine tomorrow... sure there not gunna fit currently tho :/
     
  11. <tuffty/>

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

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    More progress :)

    Sorted the oil drain issue with a bit of tweaking of the lower pipe to get the flexi to sit right...
    [​IMG]

    Wasn't happy about the speedo sender being as exposed as it was either as it will be quite close to the wastegate pipes
    [​IMG]

    ...so made a heatshield for it...
    [​IMG]

    ..also added a little more heatshielding where the wastegate is as it didn't come over as much as I would like...
    [​IMG]

    Bill finished welding all the exhaust bits I had fabricated so far...
    [​IMG]

    ...so I wrapped them...
    [​IMG]

    [​IMG]

    [​IMG]

    Once that was done I fitted the coolant lines... had a small issue though...
    [​IMG]

    [​IMG]

    ...that wouldn't end well for the brakes line so removed it again and put a small set in to clear...
    [​IMG]

    With those done I could fit the downpipe...
    [​IMG]

    [​IMG]

    Fitted the wastegate
    [​IMG]

    Connected it all up to the centre section so I could tighten all the vbands in the right place...
    [​IMG]

    Once that was done I then finished off connecting all the coolant hoses and all the other stuff I had left to do ready for the first start.... added fluids (power steering, engine oil and coolant), attached the battery and span her over with the injectors disconnected...
    [​IMG]

    ...and...



    Sounds a bit tappity in the video but I did another start after that to warm her up properly and the engine quietened down loads... only issue was the fans not cutting in when I expected... stopped the engine and carefully opened the reservoir and all the coolant suddenly disappeared! so topped that up again and checked the oil... will run her up again in the week and see if it was just due to an air lock or something but for now I am happy as larry :D

    Had a quick look around while she was running in the air and could see no obvious leaks which is a result... will hold off being totally happy until I know the fans are working ok and I can run her up to temp and leave her running for a while...

    Put the covers back on for now as it seems a safer place to keep them lol
    [​IMG]

    [​IMG]

    No too bad considering... I have also got hold of some fancy stainless fixings for the covers....
    [​IMG]

    They look a bit like this... I may paint them satin black though LOL
    [​IMG]

    There is a guy selling them in the group buy section here...
    http://www.audi-sport.net/vb/group-...fasteners-stainless-steel-conversion-kit.html

    I am going to ask Bill if I can do a few evenings this week so I can sort the back box out, bleed the clutch and basically get the car ready to get off the ramp..

    Excited much ;P

    <tuffty/>
     
    Last edited by a moderator: Aug 15, 2014
    Vex182, sssline, StaceyS3 and 4 others like this.
  12. JUS3IN

    JUS3IN 14.0 @ 98mph 2s 60ft

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    very nice, i have you on the coolant bottle tho mines cleaner!-)
     
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  13. S3Alex

    S3Alex Rarely neutral Team Ibis TFSI Owners Group Gold Supporter Audi S3 DSG

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    Thats fantastic.

    From the top of the engine,you'd hardly be aware of all the work you've done underneath.

    Really neat and stealthy.
     
    m19lte and <tuffty/> like this.
  14. <tuffty/>

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

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    Hah!!... :D

    I will be changing it once the car is run in and mapped... I have some touch up work to do on the top charge pipe and inlet (as I managed to chip the paint last night :/) and a new bottle is on the list...

    Thanks dude... have had loads of peeps say that it couldn't be done and that my OEM++ mission would be out the window with a top mounted GT35... I believe this answers that question :)

    <tuffty/>
     
  15. S3Alex

    S3Alex Rarely neutral Team Ibis TFSI Owners Group Gold Supporter Audi S3 DSG

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    It's always great to prove doubters wrong.

    I've had a few people telling me my engine will melt,that it will misfire,that it will never run cleanly without X's injectors/software etc,the EGT's will be insane,and various other tales of woe.

    Somehow,it's still going.
     
  16. dusty

    dusty Active Member Team Nogaro Blue Audi S3

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    This is a work of art totally inspirational, a must read for anyone thinking of modifying there s3, your standard of work is second to none you should be really proud of what you've achieved,
     
    <tuffty/> likes this.
  17. Rice

    Rice Active Member

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    Ohhhh dang! One of those pictures is like heatsheilds on heatsheilds! Looks like youre well prepared for the extra heat :)! Fantasic work, looking forward to drive by videos ;)
     
    <tuffty/> likes this.
  18. <tuffty/>

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

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    Thanks all for your kind words :)

    Did an evening shift at the workshop lol (which after a rather rubbish day at work was welcome)

    Bled the clutch, topped up the coolant and faffed a little under the bonnet... still need to sort the catch can out but thats next after.... the back box...

    The elusive metal centre exhaust bracket that Audi decided not to fit on later cars... the system I have is quite heavy so it will benefit from the extra support..
    [​IMG]

    So fitted that with a powerflex universal exhaust jobber and welded a hanger to the centre section...
    [​IMG]

    Next up was to join the centre section to the back box... this didn't go so well Saturday night so I attacked it slightly differently and bingo....
    [​IMG]

    Test fitted the tail pipes but its clear I need to tweak that area a little as they stick out too far...
    [​IMG]

    [​IMG]

    [​IMG]

    By which time it was gone 11pm so thought I had better call it a night lol... put the covers back in the engine bay and jobs a good un :D
    [​IMG]

    Tuesday night I plan to finish the back box (tweaks to the tailpipes and the hanger for that side to do) so that hopefully if Bill has a bit of time he can weld it all up and if I have time I will make a start on the catch can...

    All in all a good end to a rather crappy day :)

    <tuffty/>
     
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  19. Prawn

    Prawn My other car is a MINI!!!!

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    Amazing stuff mate. can't believe it's all finally come together in the last few weeks.

    Looks so perfect, can't wait to see how it runs :)
     
    <tuffty/> likes this.
  20. jojo

    jojo Looking for Boost! Staff Member Moderator Team Daytona Audi S3 quattro Audi A6 Audi Avant Owner Group

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    It may even go round corners quick once he gets the chassis sorted! :cool:
     
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  21. <tuffty/>

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

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    Bit more done last night... main focus at the moment is to get stuff done so I can get the car off the ramp... I won't be rushing to tax her for this month as lets face it there is not much left of it so as long as I can get her off the ramp and run in on the dyno all is good in the world...

    So after a couple of tweaks the back box is ready for welding :)
    [​IMG]

    [​IMG]

    [​IMG]

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    I also spent a little time finishing off some other little jobs and made a start on the catch can/PCV stuff... I am not in a rush to get that done at the moment but will need something in place before I can get her MOT'd which should be towards the end of next week

    <tuffty/>
     
    Sam_ and fanta like this.
  22. Adam P

    Adam P Active Member

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    Looks awesome mate, i like the greddy catch can, im running a hks fmic and the jap items are good quality.
    Bet its going to sound lovely. Very jealous!
     
    <tuffty/> likes this.
  23. fanta

    fanta Active Member

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    Thanks for all the time spent taking photos and updating us tuffty! I feel strangely connected with your powaa journey :)
     
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  24. <tuffty/>

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

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    ...just say'n :D

    <tuffty/>
     
    Last edited by a moderator: Aug 15, 2014
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  25. Vex182

    Vex182 Guess what I drive...

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    It moves! Seen it wheelspin but no spin at the back?
     
  26. jojo

    jojo Looking for Boost! Staff Member Moderator Team Daytona Audi S3 quattro Audi A6 Audi Avant Owner Group

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    Urgh! Filthy PT!
     
  27. <tuffty/>

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

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    normal for a std haldex controller... takes a reasonable amount of rotation before it kicks in... had to get its lardy **** over the bridging section of the ramp on a slippy floor :)

    Yep... snow foam and wash tomorrow :p

    <tuffty/>
     
  28. dave_ph

    dave_ph Member VCDS Map User

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    Not the most interesting car based youtube clip i've ever seen :p but great to see it moving nonetheless!
     
  29. <tuffty/>

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

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    Very true lol... I suspect a video of me acting like a giddy kid high on sugar at the prospect of actually driving my car off the ramp would have been more appealing but it is what it represents thats important :D

    I will make up for it video wise once the engine is run in and she is mapped to her full potential :p

    <tuffty/>
     
    vivalacoulter likes this.
  30. superkarl

    superkarl MAN OF STEEL

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    sounds very well indeed!!
     
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  31. dave_ph

    dave_ph Member VCDS Map User

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    Some vids of it during the mapping process would be cool as well :)
     
  32. willh92

    willh92 Active Member TFSI Owners Group Silver Supporter Team Brilliant Black Audi S1

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    +1^^

    Looking forward to hearing that turbo spooling and dumping on the dyno!
     
  33. <tuffty/>

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

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    Last piece of the puzzle nearly done... have altered the catch can to suit my requirements...
    [​IMG]

    Might use the filter initially but suspect I will change to a hose running under the car to get rid of the smell...

    Sorted the lack of fans issue too... essentially an airlock... ran the engine up to just over 80 degrees when the stat should be open (left the expansion tank cap off)... jacked the car up and drained a little coolant out the radiator drain tap while the engine was running... this was enough to sort that issue and the fans kicked in as they should..

    To make JoJo happy I also washed the fleet...

    [​IMG]

    ...and pulled her in for a wipe down and a quick once over with Werkstat Jett Acrylic... (I love that stuff...)
    [​IMG]

    ...and did a little under the bonnet too :)
    [​IMG]

    I also managed to find a small leak... typically on these builds you do find the odd leak here and there... comes with the territory but after a few runs up to temp she appeared pretty much water and oil tight then I noticed the tell tale pink tinge of G12... the CTS was leaking :/

    [​IMG]

    Not much but enough and prob wouldn't have noticed it until she was under load on the dyno so pleased I spotted it when I did...

    I can report that the exhaust is amazingly quiet with a nice deep undertone... obviously no idea what its like when driving yet but plan is to run the engine in on the dyno Sunday and take her for an MOT early next week... I will then tax her for the beginning of April...

    <tuffty/>
     
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  34. Gops

    Gops Badger 5 Edition VCDS Map User Gold Supporter Audi S3

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    How bizarre, how bizzare... Ooo babaaay, Ooo baby your making me crazaaaaay! What a tune!
     
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  35. Airs

    Airs Active Member

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    Absolutley unreal thread this is <tuffty/> spent the last 2 days looking through the whole thread and WOW what a read :)

    glad to see its all up and working now :) got some good little hints nd tips for mine whilst reading, would be awesome to see in the flesh :)
     
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  36. g60leigh

    g60leigh Well-Known Member

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  37. rupe

    rupe A3 TQS In Devon

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    Sam_, <tuffty/> and g60leigh like this.
  38. Sam_

    Sam_ Down under

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  39. g60leigh

    g60leigh Well-Known Member

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  40. <tuffty/>

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

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    Thanks Sam... it was seeing it on your thread that prompted me to get one...

    For completness..

    [​IMG]

    <tuffty/>
     
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