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My rather slow progress thread

Discussion in 'A3/S3/Sportback (8P Chassis)' started by Sevv, Jan 18, 2013.

  1. S3Alex
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    S3Alex Rarely neutral

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    [Mar 2, 2014]
    They make excellent products.....we used a lot of their sheeting around the hot side of the engine on mine,to shield things like the diff,and some of the piping runs.

    I didn't coat any of the intake and to be honest,thanks to the WMI and ProAlloy intercooler,we don't have inlet temperature problems,and even under load it will sit a few degrees above ambient,prior to the WMI system.

    It may well be a worthwhile addition if you didn't have all of that,for sure.

    The rear battery well does have one other very good use.....the WMI pump is down there on my car!
    #81
  2. Sevv
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    Sevv Pushing the limits..

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    [Mar 2, 2014]
    thats a solid setup on the 3.2 looks good :); as for zircotec i think we do ill definitely look into it, its a rational and logical choice to choose that as its 1- less coast then to coat it and recoat it , and its just easier to apply; massive thank you; would you use sheeting for the DP as the manifold would be hard and only option would be to coat it i would assume. i just wonder how heavy would 2 -3 odd meters of cables weigh to move the battery to the back 5-7kgs?


    Zircotec Carbon Composite Ceramic and Metal Coatings

    that is truly bloody impressive; hate to see the cost though the 8P3 conversion eating into the BT build budget hehe
    #82
  3. S3Alex
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    S3Alex Rarely neutral

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    [Mar 2, 2014]
    Hi Sevv,

    I honestly wouldn't worry about a few kgs here or there,as you need to remove around 75kgs to gain 5% in power/weight.
    #83
  4. Sidhu88
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    Sidhu88 Active Member

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    [Mar 3, 2014]
    The gold sheeting is heat reflective whereas the ceramic coating is heat retaining. For all hot side stuff i'd defo ceramic coat, all cold side i'd use gold sheeting, but only in the areas where it will be hot.

    Again about the battery, consider your weight distribution; you may be adding a few kg's in cable but you're losing weight from the front and adding some to the back where theres not much weight at all. I'd of thought it would help with the handling.
    #84
  5. Sevv
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    Sevv Pushing the limits..

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    [Mar 21, 2014]
    So small update, car has been pulled apart, the crank is fine thankfully though the casing is a different matter has it has two holes in it thanks to Audi that bolt has done so much damage, unsure how it leaked from the casing but not the crank seal (go figure) doesnt makes sense to me though we inspected the crank today was fine.. thats all the matter, will be dropped off with the DP, exhaust manifold to be ceramic coated, and the gear will be rebuild i just hope the input shaft , gear etc.. are fine... and will fit the wavetrack LSD ARP bolts and new synchros and uprated selector fork.. so here are a few photos

    not mention look at the carbon build up cylinder 1 -2 werent as bad as 3-4 unsure if you guys can see this but that can really cause trouble with our heads TDI or FSI...


    [​IMG]

    [​IMG]

    [​IMG]

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    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

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    [​IMG]

    that is a polo gti, running a high flow K04 and a AGU bored out 2.0 ltr engine another project that has hogged the hoist at Euro Automotive


    [​IMG]
    #85
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  6. Sevv
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    Sevv Pushing the limits..

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    [Mar 21, 2014]
    forgot to mention im hoping the plan is to get it back by the end of april or first week or may i hope... and after that given the finances arent too strained let the M12 facelift begin :) fingers crossed all will be well.
    #86
  7. Sevv
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    Sevv Pushing the limits..

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  8. Sevv
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    Sevv Pushing the limits..

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    [Apr 4, 2014]
    some rather breaking news!!!

    im selling the guy either putting the same engine back in with new seals and belts and sell my parts for a low $7k compared to the $20k ive burned due to the unreliability of Australian workshops, as i would say bunch of immature people trying to run business, having to get yourself to beg them to do the work AFTER PAYING THEM!!!! they never give you a time frame , and well the workmanship is extremely shady with NO guarantee the box or engine would perform even on a daily drive. have no trust what so ever. anyone wanting to buy some parts that are in Australia (IF) your more then welcome as they are going cheap too..

    what ill get out of it is the car back with a used golf R engine in order to sell it which is in good condition. I hope that works or else im really screwed.

    THE LESSON:

    dont buy a VW AUDI in australia and dont try changing turbo's engine or gearboxes as they just rip you off; and you'll never see your car again.

    i have had workshops refuse to work on my car even when im paying them... i can list many workshops.

    end result im really being hopeful that i can sell that heap of rubbish we all call AUDI and stay well clear of them at least in OZ.

    other option is going through the build and having an unreliable car with the engine prone to fail along with the gearbox as fitting an LSD and new synchros apparently is like building a space shuttle.

    its been since the 20th of june and not a shred of progress has been made; so i hope to tell everyone good bye but ill still be on.. as i do like our cars just not in australia.. beyond a stage one become extremely complicated for Australian Workshops..
    #88
  9. S3Alex
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    S3Alex Rarely neutral

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    [Apr 4, 2014]
    Hi there.
    I'm really sorry to hear that but I totally understand.

    I hope you manage to get something back from it all and the best of luck for that.
    #89
  10. Sevv
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    Sevv Pushing the limits..

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    [Apr 4, 2014]
    yes the loss is insurmountable; i have yet to know today in 20 mins whether the tuner will take the mods for the ridiculously low price tag ; if only we had AMD and British Technicians in this country. Alex thanks for your support as you have been the lonesome one on that front. i might still go to court over this issue but the workshop doesn't have money huh.
    #90
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  11. S3Alex
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    S3Alex Rarely neutral

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    [Apr 4, 2014]
    You know I wish you the very best of luck for that.

    Unfortunately getting money back is as difficult as pulling teeth.
    #91
  12. Sidhu88
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    Sidhu88 Active Member

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    [Apr 4, 2014]
    unless u have the right tools :gun2:
    #92
  13. grchmason
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    grchmason Member

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    [Apr 4, 2014]
    Really sorry to hear this must be heartbreaking!

    All the very best with getting a result either way!

    .
    #93
  14. Sidhu88
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    Sidhu88 Active Member

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    [Apr 4, 2014]
    It might sound a bit farfetched. But given the fact u've spent as much as u have already. Would it not be worth shipping the car over here for someone to complete it?
    #94
  15. Sevv
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    Sevv Pushing the limits..

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    [Apr 6, 2014]
    actually it might be worth a shot tbh its a $4k return trip.. the fact they can't give me a guarantee of the workmanship of the box and engine is just wrong so im waiting till monday if the engine specialist show up its good if not i'm plugging a golf r engine inside of it with a k04 and selling it.

    not to mention the parts i got ill receive no workshop warranty on fitment or if anything goes wrong as it works like blame game engine specialist blames the box specialist, and they probably both blame the tuner, and then probably blame the workshop it goes four ways ; good old Australian vicious cycle.

    it really makes me wonder why people are so proud of the '' made in australia '' badge to me it means STAY AWAY!... they make a big deal out of everything.. ive had workshops tell me fitting a k04 to a A3 is a 'BIG' Job

    by the way the workshop that turned me away was Exotic Cars in Parramatta NSW.. the car is currently at Euro Automotive Girraween , and the box specialist its been to three now, Central Automatic Transmission Specialist, and now a place called Smithfield Diff and gear, that guy didnt even know what we were talking about reinforcing the back bearing on the input shaft to prevent play.. apparently machining the bell housing is also another 'big job' and he doesn't have the tools and doesn't know how to do it ... its quite laughable ....

    and Euro Automotive says its a BIG and complicated build.. not in my eyes when everything is straight forward bolt on mods.... seriously... no modification/fabrication needed.
    Last edited: Apr 6, 2014
    #95
  16. Sevv
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    Sevv Pushing the limits..

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    [Apr 12, 2014]
    another botched update... so after allot of arguing, guarantees, threats... I have managed to get the build happening again must say was immensely stressful and the following day the engine builder appeared from the shadows to pick my damn engine.... and gave the go ahead ONCE AGAIN for the 3rd box specialist to do the work...

    to start off with the synchros AREN'T being changed as they said they would last another 60,000miles I HOPE... and they stated they guarantee there work which was a condition of mine.. we are changing 8 bearings including the rear bearing on the input shaft and the gearbox is fine... modifying the selector forks and putting new seals... along with the LSD and the arp bolts... HOWEVER... the box specialist 'smithfield diff & gear'' don't know how to modify the selector forks we had to order it of ECS tuning with the hope they show up end of next week and have the gearbox the following week..

    AS for the engine WELL thats another story

    the head is done everything machined ported and the oversized valves installed, along with the block all the clearances and measurements and have taken and internals balanced HOWEVER the girdle plate from Integrated is botched this is a direct quote from the engine builder..

    ''Below is the issue I have with your Integrated Engineering girdle.

    The plate itself is warped/twisted. It is certainly not flat. Across the rear of the plate (when fitted to the mains and torqued to 60 ftlbs) it is warped .022". High in the middle and low on the outer edges.

    To reliably fit this engine mains girdle, would require the plate to be machined flat first. I am not willing to fit it and rely on the bolts to pull it straight (or distort the mains tunnel in the process).

    I am also not too keen on just fitting the plate as is and then line honing/tunnel boring the mains.

    The instructions that came with the girdle indicate that the spacers for the mains studs need to be machined so that the plate when fitted is aligned within .001" of the sump rail. That is just not possible with the warped plate.

    Additionally is it really necessary to have the spacers for the mains studs approx .060" longer than required? Surely .005" or .010" would be enough to allow the customer to "fine tune" the fitting to any block.

    Please note that my reservations with this plate are not without prior experience of poorly designed or fitted mains girdles. I have stripped plenty of engines which have had a mains girdle fitted, distorting the tunnel enough to cause serious bearing/crankshaft wear. In my experience a laser or water cut plate is not dimensionally accurate enough to be used as a mains girdle without some finish machining.

    Please let me know how you want to proceed. You also might want to contact Integrated and let them know about this problem.''



    so at this stage IE have been great and if not mistaken they will be sending me another girdle plate (free shipping thank God) which is due to come out of manufacturing in 2 LONG WEEKS ughhhhhhh!!!! Then the hope is its all good and the plate doesn't hit the trigger wheel and is straight at least to within 0.01'' of the mains...

    now the girdle comes with its own challenges, the block will have to be drilled to accommodate for the oil chain tensioner of the 06A 1.8T oil pump.. the kit also came with the 1.8T oil filter plate to also install a 1.8T oil filter housing and cooler ... so; so much for moving forward; so ill be using good old 8L oil filter which should be fun... no special tools to fiddle with it

    Integrated Engineering 2.0T FSI Crank Girdle/Bedplate Kit DIY | IE AutoBlog

    see step 4 of the blog

    though the workshop is worried about the fitment due to our TFSIs' have one hose to the cooler compared to the 06As' two hoses so that will be interesting

    the aim is for the 7th of may THIS YEAR haha ... it quite demoralising all this bloody hassle with Seb from Euro Automotive leaving on the 21st of may i hope it will be done before then maybe im too optimistic or naive but ill keep pushing for that deadline as it was originally the 30th of april otherwise i wont see the car until the end of june if lucky but ill be properly pissed if thats the case
    Last edited: Apr 12, 2014
    #96
  17. Sevv
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    Sevv Pushing the limits..

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    [May 2, 2014]
    small update.. car might be ready 2 weeks from now which is good the gearbox is finally been done 1 year later.... and waiting on the engine .. should be ready next week by friday.. engine builder has yet to pick up my new girdle..

    i also got some leather interior to fit.. as try to fit the USP LPFP however ive ran into some trouble. the red clip hose and (creamy C-shaped plug also doesn't fit) i think its the suction pump.. here are a few picture hope some one can help me namely MR. Alex [​IMG]
    [​IMG]

    these are the hoses/ clips... that won't fit .. now i can take that hose of the OEM pump and put it solving that issue I THINK?

    [​IMG]

    [​IMG]

    the girdle..

    free of charge and free shipping very nice of IE.. also got a drill guide kit for the 06A tensioner and pump

    [​IMG]

    picture isnt too good as it was dark and couldn't car on work with only the cell phone light...

    [​IMG]

    the flywheel that has 6 instead of 8 bolts of Awesome GTI big thank you for Mike best service as usual which i could say that about workshops and businesses in australia

    [​IMG]

    the wreck as it stands gave it a wash clay and polish to keep that paint in good condition given its under the sun and rain for over a month... also found out my rear door on the drivers side as been dented and a big scuff mark its safe to say he will be footing the bill on that particularly $350+ 280 to blend it in

    [​IMG]

    [​IMG]
    #97
  18. S3Alex
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    S3Alex Rarely neutral

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    [May 2, 2014]
    Hi Sevv,

    Yes....there are reported issues fitting the pump system you have there,and I think this is the correct thread on VAGOC.

    RS3 Intank Fuel Pump - Page 2 | VAGOC.co.uk

    What I have on mine is one of these....

    USP Stage 3 auxiliary Low Pressure Fuel System

    It's an auxiliary pump system used in tandem with the existing LPFP system,and as I understand it,from discussions with USP a while ago,the pump system in the S3 is good for around 440bhp before it starts to run out of flow,and that leaves two ways forward.

    One is the auxiliary system I have,and the other,which you have,is a complete new pump with higher flow on it's own,but it does require an uprated PWM controller also.

    The RS3 and RS6 pumps do have a few issues,and hopefully that thread will help.
    #98
  19. Sevv
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    Sevv Pushing the limits..

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    [May 2, 2014]
    great so a hassle in its own right i doubt the workshop will know how to fit this... and my old pump well he left outside for a few months under the elements so im pretty sure thats ****ed

    Originally Posted by Nobber View Post
    Well today I had a new RS3/TTRS in tank pump installed. So far it seems spot on with no issues.

    This is however not a drop in solution for a 07 S3. 2 pipes/adapters had to be changed don't ask me which ones but the pumps are slightly different, but it was easy enough to do.
    can you find out what needed to be changed? looking at doing this shortly.. this is basically what the problems i
    ve been having

    another post...

    '' have installed this pump (rs3/TT-RS) and i have a problem.

    when i pull the car for 3-4 times until rev limit... sometimes the car turn off. and i see in

    the logs that low pressure fuel pump drops . Do you have an idea?!''

    so basically this pump is junk i need to invest in another one.. ill have a word with USP as they said it would fit just fine
    #99
  20. Sevv
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    Sevv Pushing the limits..

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    [May 3, 2014]
    Alex thank you very much indeed for the link to the thread it basically affirmed my suspicions, the breather hoses need to be detached from the C-shaped clip and feed the black hose of the breather directly into the LPFP's basket.. and take the hose of the old OEM pump and hook it up to the RS3 pump and that should be sorted...

    as for the PWM i think as it will be on a run in tune ill give it a go and try it with it and see if it cuts out at 3-4k RPM if not well thats a 549$ saving.. USP was great and solved the issue on the phone ASAP my phone bill wont like it but oh well a well spent 30mins to the US.

    so big big thank you appreciate all the help mate.. i just cant wait to have her back its been so long i forgot how it feels like to be in the cabin and driving it , quite literally sad as the workshop owned the car longer than I HAVE! so im growing very impatient and frustrated waiting for it to be completed i hope in 2 weeks from today!

    its just australians in general work in slow motion quite honestly.. they never have a sense of urgency..and they whinge too much like whores on crack lol quite hopeless.

    neway the engine builder was supposed to pick up the girdle on friday as it arrived from IE on thursday however 'after saying he would show up on friday HE DIDNT!!!!!!' thats 5 stars right there for reliability... not to mention the workshop tells me you think you are more important than others; WELL YES I AM as i have paid for everything 7 months ago... pure arrogance; all the while others haven't paid a penny
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  21. S3Alex
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    S3Alex Rarely neutral

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    [May 3, 2014]
    Hi there,

    Really glad some of that helped!

    I know what you mean re the frustration of waiting for stuff to happen,from when we(AMD and myself) were waiting for the pistons and rods.....every day was another delay,until the bits arrived nearly 2 months late.

    USP were great with my build as well,and answered emails really quickly and sorted all of the problems straight off.
    Really good guys.
  22. Sevv
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    Sevv Pushing the limits..

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    [May 3, 2014]
    Oh they Are mate; good service and technical advice must say with Jesse, and Gregg. all the companies i've dealt with have been great if i'm honest from Awesome-gti to IE to USP and ECS.. can't say the same for the workshop and his engine/box builders... they have tested the very limit of my patience and tolerance i think it has surpassed the humanly possible threshold heh...
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  23. Sevv
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    Sevv Pushing the limits..

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    [May 6, 2014]
    tiny update well the girdle according to the workshop was picked up by the engine builder; God knows if its true though as he sent me the message as i pulled up for the second time that day 80 miles of just pure running after him to push things along... though when i got there the gate was locked so come friday when i'm 'supposed' to get the engine back i will know whether 1- its been picked up and 2 if the engine is back so i get started on degreasing the engine bay for the second time and give it a wash...

    ive also bought 50 meters of bubble wrap to wrap the car and protect it from any more damage that he has already caused.
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  24. Sevv
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    Sevv Pushing the limits..

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    [May 20, 2014]
    update... engine and box are back.. with some pictures along side.. i also went ahead and put the coilovers on sway bar control arms balls joints.. which i paid for to be done by the indie.. and did myself in 4 hrs... with the help off a good friend... until the rear sub-frame got dropped on my head silly me.. so any know the workshop is assembling the head and block which is already taken 2 DAYS!!! no result yet only cams are in.. im hoping to receive the 'curse' on friday.. i think thats its new name haha.. the unbearable trouble this has caused...

    though i have a problem the flimsy black plastic baffle tray thats sits on 06A blocks between the oil pump and the sump so ill be running WITHOUT one until i figure out how to fit one as i got the girdle in the way..

    sway bar...

    [​IMG]

    the box...

    [​IMG]

    Block....

    [​IMG]

    Head and sump...

    [​IMG]

    [​IMG]

    Cleaned the engine bay again.... was so clean you could rub your hand around and have no grease or black dust.. :D

    [​IMG]

    Rear Shocks...

    [​IMG]

    Control Arms...

    [​IMG]


    Better Pic of the leather seats i

    [​IMG]
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  25. S3Alex
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    S3Alex Rarely neutral

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    [May 20, 2014]
    Verrryy nice indeed.

    Someone has been busy with the spanners.

    Excellent update and good lcuk with the work.
  26. Sevv
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    Sevv Pushing the limits..

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    [May 20, 2014]
    Yes have been never done this before so was proud of myself todo it .. I must say if I can do it anyone can its easy.. but im just worried about the baffle playenif I run without one inrisk starving the engine of oil and we all know what happens next
  27. Sevv
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    Sevv Pushing the limits..

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    [Jul 8, 2014]
    hello again been a while since ive been on needed a breather from all this so updates are as you can see turbo engine and engine full assembled and just needs to be put in the bay.

    the transmission shop i've used Smith Diff & Gear might or seem to have bodged up a A4 1.8T quattro wagon which leaves me at a loss if i will have the same problem so im hoping not.

    To Do
    fit a baffle plate of a 06A engine
    get a Custom alloy discharge pipe running to the turbo IC and turbo inlet.
    Weld and plum the screamer pipe running of the waste gate to the exhaust so i save myself 15K of a potential fine...

    also got the whole front end all new parts as i couldnt source used ones which hurt the wallet BIG TIME! i still need the Bonnet and unsure whether i need the xenon level and central electrics unit which i hope i wont. maybe some one may shed some light on this matter.. i got these P/N off PH1Ls' thread..

    Central electrics unit – P/N 8P0 907 279 K
    Xenon Leveller unit - P/N 4L0 907 357


    what is left basically is the coolant hoses, alternator AC compressor thermo housing and oil filter housing/cooler of the 06A
    Prop shaft and Drive shafts along with the inlet manifold injectors and the autotech HPFP.. and the car should be ready finally i hope...

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
  28. Sevv
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    Sevv Pushing the limits..

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    [Jul 23, 2014]
    car how its stands as of today.. all i can say is Euro Automotive is the worst workshop anyone in Sydney can go to with shocking he wants another 6 month to finish the vehicle.... which leaves me no where .

    i should but here is a very VERY tiny extract of his superb customer service for a CLIENT that has been waiting almost 15 months!!!!!!!!!!

    and plowed 33,000$ into nothing

    [​IMG]


    some of the Bullshi*t i deal with.... 15 months later and the bill fully paid...

    [​IMG]
  29. Ash187
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    Ash187 Audi-Retrofits.co.uk Site Sponsor

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    [Jul 23, 2014]
    Wow! I would get some mates to go pay him a visit! That's just not on!
  30. Sevv
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    Sevv Pushing the limits..

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    [Jul 23, 2014]
    .
    Last edited: Aug 23, 2014
  31. Sevv
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    Sevv Pushing the limits..

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    [Aug 22, 2014]
    UPDATE!

    so after a few months the Beast HAS AWAKENED!!!!

    im thrilled as this means i finally get her back if everything goes well logging her up and down the street goes according to plan...

    some bits i had to do ...

    custom 3" throttle body with MAP sensor... as the oil filter/ housing is literally 1cm away from the radiator fans...

    had to fabricate a hot side from the turbo to the IC

    get a Golf R MAP and fuel pressure rail sensor..

    4" CAI custom pipe to scale the MAF

    the numpty truck driver closed the bonnet and the cable attached the lever inside the car wouldnt work as it was detached... had to pull the front end off and do it myself as both workshops wasted 3hrs to no avail.. who knows.. got that sorted in 20mins after a good 1.5hrs drive

    welded the screamer pipe.. and got the exhaust to go 3"all the way to the back box and sorted out gaskets that the CTS kit didnt come with

    had an oil leak on first start up and the oil feed to the turbo which got sorted...

    as it stands waiting on a boost tap from CTS (as it doesnt come with the kit mind you its a 6K$$ kit bloody useless if you ask me only used the turbo manifold DP of their kit everything else had to be custom made...) "BOLT ON MY ASS id say to any RHD supposed kit"

    got the wheels on with some michelin super sports at 180AUD a corner was a bargain for a 2014 manufactured tire..

    TO DO: hopefully by monday or wednesday..

    tighten the head bolts as its only had its first 30mins start which checked out fine...
    wire the O2 sensor and plump the wastegate ... and tighten the exhaust and thats that off to getting logged and me finally driving the damn thing

    anyways here are a few pictures....

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    S. likes this.
  32. Sevv
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    Sevv Pushing the limits..

    Joined:
    Jan 27, 2011
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    [Sep 5, 2014]
    Small update or well not even... mark parso at recode has been at it trying to tune the car however the latest file mind u its file number 4 had rendered the car 25% richer on idle not ideal tbh plugs were buggered black as s hit so im hoping for another file.. and contact seth at giac usa hopefully they can sort me out with a file to get the car on the road as it seems hopeless trying to get it to start as the rs4 injectors and the ecu dont communicate and car doesnt start but cranks fine i guess i should be thankful...

    just hope that the next file will work but im not beting on it as he cant calibrate it giac atm seem to be the most promising but yet again after asking for the ecu part number workshop still doesnt want to give it to me.... he is a pain in my back side tbh...and thats about it... maybe in the next month the car will start trying to hastle everyone to do their job isnt ideal... i just dont know where and who in australia can tune this car its unbelievable

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