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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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    Last couple of little jobs done to get her ready for running in properly..

    Source of the coolant leak... CTS seal was perished... was actually crunchy when I squeezed it lol...
    [​IMG]

    Bill kindly welded the PCV pipework and catch can mods I had fabricated...
    [​IMG]

    ...and of course I painted them :)
    [​IMG]

    The pipework now in place...
    [​IMG]

    ...and of course all back together... just need to make a bracket...
    [​IMG]

    I have used a filter on the catch can for now... pretty sure it will end up smelling a bit so I do have some hose to run from it and under the car when I get around to it but for the time being it will be good enough to get the car on the road...

    <tuffty/>
     
  2. Vex182

    Vex182 Guess what I drive...

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    Mine is routed to under the car over the PAS rack without a filter and almost nothing comes out of it, certainly no massive drips of oil or anything like that.
     
  3. Sam_

    Sam_ Down under

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    I have mine setup to vent to atmosphere like that and I just always use recirculate on the AC. I might sort it out properly when the new engine goes in. Yours being so close to the filter might be a little bit of a difference but sitting in traffic, it's likely to smell a bit.
     
  4. Lavis89

    Lavis89 Well-Known Member Regional Rep Team Sprint Audi S4 Audi A3

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    I only notice mine smelling a bit when sat in traffic, easy enough to deal with
     
  5. <tuffty/>

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

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    So... ran the engine in today...

    [​IMG]

    [​IMG]

    [​IMG]

    Scores on the doors so far... not revved out to redline yet and only on actuator pressure... little bit of creep but manageable
    [​IMG]

    Next step is to dump the oil and filter, refill with some more mineral oil and drive around for a tank before dumping the oil again for the good stuff and of course then let the old girl rip :D

    Everything else seems to holding up ok although there was a very small wet patch under the car that appeared while the car was cooling down just off the dyno... I suspect its the oil drain but all things considered its a small leak like the coolant one so pleased with that... hopefully I won't have to remove too much stuff to fix it lol

    ...and of course a video :)


    <tuffty/>
     
    Last edited by a moderator: Aug 15, 2014
    Sean_S3, badger5 and Adam P like this.
  6. limbo118118

    limbo118118 LORD

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    awesome stuff!!! lovely looking engine bay too!! for the initial start up did you put any oil into the turbo first via the line port?
     
  7. <tuffty/>

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

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    Nope... just turned the engine over several times with the injectors unplugged...

    <tuffty/>
     
  8. limbo118118

    limbo118118 LORD

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    ah ok cheers, few people have mentioned to me that it might be worth puting a little oil in but your seems a better idea :)
     
  9. <tuffty/>

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

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    Gets oil everywhere this way :)

    <tuffty/>
     
    limbo118118 likes this.
  10. <tuffty/>

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

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    Had a look back at the actuator plot for my GT30...

    [​IMG]

    ...vs the GT35 setup on the stroker...
    [​IMG]

    very close all things considered and the GT35 setup is on less boost too currently..

    Should be interesting to see how it goes once boost is turned up lol

    <tuffty/>
     
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  11. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    on same graph... for clarity

    [​IMG]
     
    <tuffty/> likes this.
  12. Lavis89

    Lavis89 Well-Known Member Regional Rep Team Sprint Audi S4 Audi A3

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    The exhaust sounds brilliant, throaty but not over the top
     
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  13. russwuss

    russwuss Active Member

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    Tuffty, seeing your catch can has given me the inspiration to paint some stuff... Did you use normal black spray paint or special paint to cope with the heat? Thanks!
     
  14. <tuffty/>

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

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    Posted this a couple of times now but I use Rustoleum Hard Hat top coat and UPOL etch primer :)
    [​IMG]

    <tuffty/>
     
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  15. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    paint whore
     
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  16. vroomtshh

    vroomtshh Active Member

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    If you're going to do a lot of painting, its worth taking the car out of the garage :yum:
    [​IMG]
     
  17. russwuss

    russwuss Active Member

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    Thank you :) and sorry for making you repeat - eBay watch list has gained something else :)
     
  18. <tuffty/>

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

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    Managed to get the car up on the ramp this afternoon to change the oil and see where this leak was coming from...

    Thankfully it turned out to be just the gearbox where I found the crack on the filler stub...
    [​IMG]

    This is good news as I knew there was potential for the gearbox to leak from this crack but it at least means everything else is still oil/water tight... I spent a good ten minutes looking everywhere I could think of at every angle I could mange to see if the oil drain or any other point was leaking... nothing!!... result :D
    [​IMG]

    So while I drained the engine oil I took the gearbox filler plug out and cleaned everything up.... used a bit of sealant on the threads and bunged it back in... hopefully that will stem the leak long enough for me to get the other box built..

    After all that I decided to have a go at repairing the crack in the trim panel for the washer bottle/expansion bottle... used a kit I got from eBay and will see how it looks after its fully cured...
    [​IMG]

    So... thats pretty much the car ready for the road... I have a load of little things to do but nothing thats going to stop me driving her for an MOT Saturday and to work on Tuesday :D

    Excited much (Bill and Mark can tell you exactly how excited I am)

    <tuffty/>
     
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  19. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    As excited as a kid in a sweet shop after having eaten all the blue smarties
     
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  20. sssline

    sssline Active Member

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    Well done mate, that's serious dedication and effort. The title of this thread is slightly misleading though, stopped being "minor" a long time ago ;)
     
    <tuffty/> likes this.
  21. vrbob

    vrbob Thats no Moon, Thats a space station!

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    Top work Tuffty as always this thread is a joy to read :)
     
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  22. Lavis89

    Lavis89 Well-Known Member Regional Rep Team Sprint Audi S4 Audi A3

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    Hopefully i'll be able to see this beast in the flesh when i get around to fitting the bits to take me to stage 2. got the cooler ready to go and can get a exhaust made up next month, just finding the motivation/time to fit the cooler! Then it's back up to see bill and unleash a few more ponies
     
    <tuffty/> likes this.
  23. Vex182

    Vex182 Guess what I drive...

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    I've got a split in the plastic of my cover over the washer bottle and coolent up near the screw fixing if that's the same as yours?
     
    Last edited: Mar 27, 2014
  24. <tuffty/>

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

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    Mine cracked here..
    [​IMG]

    <tuffty/>
     
  25. fanta

    fanta Active Member

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  26. S3_DAVE

    S3_DAVE Active Member

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    Hey Tuffty,

    Loving your thread it has helped me out once or twice so I think a massive thankyou is in order :)

    Do you happen to have an ebay link to the repair kit you used?

    Thanks

    Dave
     
    badger5 likes this.
  27. audiholic ste

    audiholic ste Member

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    Tha day of the tax disc is so close now .
     
  28. <tuffty/>

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

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    Thanks dude... I used this kit CAR BUMPER PLASTIC Repair Kit broken split cracked Weld adhesive trim lugs | eBay

    Its sorta worked but not as well as I would like... think its more I didn't apply enough in certain places... not looked properly yet but will try and post pics later

    Innit :)

    <tuffty/>
     
  29. scott6452

    scott6452 New Member

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    Even as a lurker (albeit a full time one) I've been checking for days now about the mot/tax/ on the road update! Any news?
     
  30. <tuffty/>

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

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    Sorry all... its been a very busy couple of weeks... obviously been working hard to get the car ready for the MOT last Saturday which thankfully she past with flying colours... I have also been recently made redundant from my day job so I have been busy dealing with recruiters, doing phone interviews, dusting off my suit and pinching the wifes 'hold in pants' so I can get into the suit trousers lol...

    Been a little while since I have had to wear a suit and I think Saturdays traditional 'chip - o - clock' and my love of Dr Pepper may have taken its toll on my waistline a little :D

    Anyhoo... I have been driving the car in to work this week... have racked up 190 miles so far and all seems well... suspect there will be another 60-100 miles on her by the weekend as I have interviews this week so will dump the oil at the weekend and top up with the good stuff..

    Initial impressions are that the car drives very well considering its the old map (unchanged from its GT30 days)... throttle response in all gears is much better than before... the stroker certainly making a difference here... most notable is third gear... just seems to be ok with everything... pulls up hill from 2000rpm with no real issue...

    I am using map 3 of the 5 I have... spools to 1bar then rises to 1.5bar essentially... LTFT's are at -16% so I don't appear to be running out of fuel yet but haven't really pushed the car too often as tbh I am happy to wait until we can get her on the dyno and plug in the emulator for mapping...

    Will check her over again for leaks and stuff once I have her on the ramp for the oil change but have checked under the car a few times and nothing so far.. which at least is a good sign...

    Issues I have had (as lets face it there are always going to be a few with a build like this)...
    I REALLY need to sort out the catch can as the smell is getting right on my boobies... I have ordered some plastic elbows and some hose to sort this out

    The back box hits the rear towing eye mount when it gets hot... this is because stainless expands like a mofo and makes the exhaust grow... will review the options when she is up on the ramp but this isn't a major issue and thankful this is all thats happened considering the amount of fabrication I have had to do...

    Still the biggest disappointment is the boost creep... kicking myself that I didn't go 2" from the collector for the wastegate outlet... its not enough that it can't be mapped around though and confident its not going to be an issue in the long run... seeing as she has held 2bar of boost at 7k rpm on the highest boost map I have available then its all gravy...

    Another thing I didn't expect was surge... on the highest boost map the boost hits about 1.5bar @4.5k and surges until around 5k and then all is good in the world... this is no biggy as it can be mapped around but shows how well my setup actually spools if getting surge with a 2ltr and GT35.. cams are on the cards too ;P

    A proper mapping session will sort all these issues out though and thats not too far away hopefully subject to Bills workload but I am planning to take a few weeks after my leave date helping him get on top of his current bookings so would be nice to get her sorted for the dyno day in May

    Few little jobs to do but nothing that will prevent me driving her at the moment...

    Only other thing I am looking to do is buy another car as a daily... I am set on a 51 plate Audi A2 with the 1.4tdi engine... as much as I love my Mk2 Golf it looks like I will need to commute further for the current crop of jobs I am interviewing for so I realistically need something more suitable for that purpose...

    ...and look... a whole post with just writing, no pictures or no mention of me painting anything!!.. :D

    <tuffty/>
     
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  31. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    Sorry to hear about your Job as we had to let two people go at are place, Times are hard and i wish you luck in the new job hunt.

    Your car can always be put on the back burner if needed but i'm sure you will get it sorted soon
     
  32. audiholic ste

    audiholic ste Member

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    That's bad news pal about the job . Hope all goes well in the job search . Always believed these things happen for a reason . Meaning good things happen to good people .
     
  33. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    thats too much information and has mentally scarred me imagining what that must look like.. lol

    and nothing painted in a week, you must be well into withdrawal now

    btw. good work dude
     
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  34. newbster

    newbster Active Member

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    I think this is one example of "pictures, or it didn't happen" would be inappropriate

    good luck with the job search,
    /m
     
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  35. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    lol..

    that would be funny..

    :p
     
  36. <tuffty/>

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

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    Here you go... (no hold in pants required!!!) :D

    [​IMG]

    <tuffty/>
     
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  37. voorhees

    voorhees Moderator Staff Member Moderator Team V8 Audi S5 s tronic

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  38. Chlippo

    Chlippo Member

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    Hey there :)
     
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  39. newbster

    newbster Active Member

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    almost OEM :)
     
  40. S3Alex

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

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    Hi there....sorry I didn't reply to this earlier,and just wanted to say how sorry I am about your job loss,and to wish you the very best for something better,and soon.

    Good luck.
     
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