Oct 1, 2012
Good job here bud! Decided not to go hybrid?
Wow great progress mate.
Nice picture of the adapter on the Turbo I had no idea it was that big
Cheers mate, its been and still is a massive learning curve for me but it has been great fun and i can't wait to fire it up! I had a look into the hybrid route and decided to strengthen the engine as i was half way there anyway incase hybrid or BT happen in the future. Top end stage 2 will do me nicely for the time being.
Almost there dude
Yeah am getting there now, spent this evening fitting/tightening up the driveshaft and propshaft, modifying the removed heat shield and reinstalling, fitting power steering pump, alternator and tensioner and lining up the down pipe and decat properly to meet the exhaust system. One annoying thing tho, i have lost one bolt, the long one for the dogbone mount i suppose if i have only lost one out of the lot i can't complain.
I am getting close now, just have the wiring and pipework plumbing left to do. On the wiring front i have a spare complete loom which i will be using to replace burnt/damaged wires and broken connectors/clips. Whilst the fuel rail was off and disconnected i decided to give the injectors, rail and FPR a clean. Big thanks to S3 Dave's "how to guide" in the stickies section for injector cleaning. The amount of muck which came out of them definitely made the job worth wile. Here is a picture after they had been cleaned.
Mineral running in engine oil and filter will be here Friday and im waiting on a dog-bone bolt.
Finally i have completed my first engine rebuild
Iv just got back from taking the car around the block and she feels brilliant.
After another weekend dedicated solely to the s3 its complete. Came across some minor issues, power steering pump noises, relocation of sensors, clutch bleeding and gearbox oil all over the place but its all good now. Anyway a few pics below.
A bit of soldering in the sun whilst fitting the badger 5 tip
FMIC and pipework reinstalled and levels checking
Wheels back on and securing front headlight ballasts
The final product
I have reset the mileage counter and ready to start my run in period now. The car really feels healthy and ticks over nicely. The down pipe and decat give a nice tone and i have no leaks from the block or pipework in the engine bay. Finally i can put my feet up and relax now the car is complete. Its been worth it, when i started it up for the first time i was as happy as a fat kid in a cake shop!
The car is filthy so please excuse the state, it will be washed asap and then some more mods before mapping. I want to say a big thanks to everyone on here who has helped and advised me with this rebuild project. I really don't think i would have been able to do it without this forum and a good group of mates. :beer chug:
Top work fella and congrats on turning around a major issue and making something positive about it. onwards and upwards now my friend so bring on the POWAH!!!!
Well done dude... great feeling isn't it
Cheers mate! yeah it was awesome! there have been some highs and some lows thats for sure, but absolutely chuffed its back on the road.
Iv just sent you a pm ref a couple of items but not sure if it sent as my wifi dropped out.
BRAKES NEXT :read it:
Nothing in my inbox mate
Update time, the car is now 350 miles into its initial run in period. The car feels great much tighter than before and runs smoothly and sounds great especially with the down pipe and decat now on there. Anyhow, last week saw a couple of small niggles arise. I noticed a small oil leak when under the car at the mot station and this was due to the oil level sensor not being tight enough in the sump, cleaned up the area then tightened and there are no more leaks. The car passed with no advisories which was a nice surprise! The second issue was initially worrying but thanks to the 'fountain of knowledge' also known as Tufty everything is now sorted and the car is fault free. The car cut out a couple of times and through up a fault on the scanner, so with advice from tufty i replaced the cam sensor then the crank shaft sensor and this has solved my issue. I want to upgrade my fmic then head down to bill for mapping once the engine has been run in. Just washed the car this evening and can't wait to get down to badger 5. Treated it to a sticker too.
Also went to Good-wood festival of speed a couple of weekends back so here are a couple of pics for you other enthusiasts. ENJOY!
Ok so a small update. I have now clocked 1000miles on the new engine and everything has settled nicely. All levels are good and no oil leaks or faults. I am booked into long life exhaust centre in basingstoke for next weekend to have a few exhaust niggles sorted out, they are raising the centre, sleeving where the de-cat meets the rest of the system properly and welding a few bits for me. (only so much i can do on a stoney driveway) Next on the list is double checking the propshaft and driveshaft bolts and replacing a nackered cv boot. Having read other members builds and taking advice from Bill my current HKS FMIC is inadequate so before making the trip to badger 5 i thought it was worth while getting the recommended wellycooler. So it turned up today, just waiting for a bit of pipework to arrive monday then will fit it.
The final piece of the jigsaw is another oil change then it will be the exciting trip up-to see Bill in October. Cant wait!
So today has seen the wellycooler change colour to black. Reason for this is for the more stealthy approach and depending on whether you believe what you read and watch apparently having it black increases its performance. Here is a video if anyone is interested :
Anyways here is the cooler now in satin black. I personally think it looks a lot smarter in black but others may disagree.
This morning i went down to my local long life exhaust centre to have a few issues sorted out. The back box had a small leak which was welded up, the centre section of the exhaust was hanging lower than the rest so a new centre pipe was made up with new brackets to raise it and i had the down pipe and decat aligned properly to prevent knocking and re sleeved to the rest of the system getting rid of any leaks.
Very very happy with the guys down there, the system they made up for me when i first got the car has been great and the work they have done today was top class, its also nice when the engineer speaks to you and lets you get under the car and discuss what you want. So thats one more thing off the list. The remap is booked with Bill at Badger 5 for the beginning of November so that gives me a little time to get these small jobs done.
Right this weekend was operation FMIC upgrade from the HKS to the famous Wellycooler.
First thing was to strip down the front of the car and size up the new cooler and how it was going to sit compared to the old one.
Old vs New
After a few measurements were taken it was time to cut the crash bar to suit the wellycooler.
Managed to make up some spacers and use my old home made brackets and adapt it to suit, the cooler sits nicely and I'm pretty happy with it.
The bumper is now back on the car and i have had to do a little trimming to accommodate the larger pipework etc, but my fogs are still in place and i have something I'm currently working on for the grill surrounds but we shall see how they turn out. All in all a good sunday! Will finish off the trimming tomorrow evening.
awesome work bud really happy its back on the road again
Thanks mate, its taken time, blood, sweat and moneys but in my opinion totally worth it. Nice to see yours is back on the road too!
I have just ordered up the oil and filter for the change after 2nd run in period. Have now clocked up 1800 miles since the rebuild on actuator pressure with no faults. The car feels great. Getting closer and closer to mapping with Bill now, still a month away tho, but will hopefully be worth the wait. Decided to order up the EM Tuning interior LED kit found in the stickies so will fit them this weekend to liven up the dull standard ones. Just wanted to say how impressed i was with t8ups, fast response to PM, great price and arrived quickly. Will put up some pics when they are in.
I'm still on 1st oil, only done 170km or so but I'll be changing to fully synthetic on Saturday I'm racing sunday.
Feels good to build something and it drives with no issues
Nice work mate! That LED lighting kit looks the business, cant wait for our trip up to ADI next weekend just a shame we arnt taking either S3 lol
Cheers mate iv put a clearer picture below, really happy with them and it finishes off the interior nicely and brings it up-to date.
Yeah its ashame but on the plus side we can fill the van up with the parts were collecting!
Installed the LED kit from EM Tuning, very happy with the results!
Quick update, was my first time at ADI this weekend. Had a good day and met some new faces and some more well known ones. Was good to see prawns car and the badger wagon on track as well. Here are a couple of snaps from the day, didn't take too many pics.
JOJO on track
Oh and i picked up these beauties from JOJO, new pads, refurb kit and new decals have turned up, just got to order my braided lines from Bill this week.
Hopefully will have them on in a couple of weeks if all goes to plan.
Really loving your work, wish I had the skills to do this. Have you just learnt yourself.
Cheers mate, appreciate it. I have always worked on a got involved with cars from a young age and learnt from my dad. It also helps that my friends are also mechanically minded so over the years iv learnt so much. With the s3 this was my first 1.8t and it took a while to learn my way around it but places like this forum and the users on here have helped me endlessly. Its literally been my bible during the engine swap.
Over the last week the s3 has developed a chatter when letting off boost. The culprit was the baileys Motorsport dv30 recirc valve i had, quick search on the forum and a chat with tufty i ordered up a replacement oem valve and swapped them over today, problem sorted chatter gone.
Next i went to tackle the lcr brembos which i collected from jojo at ADI. Started with the carriers which i sanded down, degreased and painted. They came out really well.
Next was the dreaded task of stripping the paint down on the callipers, as most of you will know they are red as standard but they were painted orange so i set to work with a tin of nitromors and a wire brush on the end of a drill as they are going to be black with the brembo decal in white.
Removed the old pads and let the paint stripper eat away.
Some more sanding and paint/ lacquer removal and we are getting there now. Still more work to do tho. Braided lines from Bill @ B5 should be here this week and i have pads here ready and fluid. Hopefully my next update will be the finished article but its time consuming.
Much more fun than watching the shitty x factor tho!
Cracking thread! Been quite a roller coaster for you, but hopefully no more probs with the car!
That clip about the black intercooler is quite something. Will remember that for if i ever get to stage 2. Just starting out with my S3 experience, and learning so much from this site & threads like yours. Thanks
Cheers mate appreciate it. This is where i started, reading builds on the forum and speaking to people on here. Its a great place to learn.
Nothing major to report, braided lines from Bill turned up today. Really chuffed with them, great quality and a top service from Bill as always.
Popped to GSF and picked up new oil filter and oil for the final oil change before mapping. Getting excited now, luckily the brake refurb is keeping me busy for the time being.
Today i have spent prepping the car ready for my trip to see Bill tomorrow.
I removed my cupra r front lip so we will have no issues getting onto the badger 5 rollers, cleaned inside and outside, checked all fluid levels and did a scan to make sure the car is fault free. The car is sat ready for an early start tomorrow morning. Oh and loaded in tuftys beers!
So this afternoon i decided to finish off the brembos. Really chuffed with the finished product. You won't recognise them now JOJO!
Have some time of work coming up so will get round to fitting these and service the haldex as that needs doing too.
Treated myself to a decent 2 tonne trolly jack designed for lowered cars.
CANNOT WAIT FOR TOMORROW! fingers crossed it will all go to plan
Looking at this post i haven't updated it in nearly a year! WOW time fly's!
So Bill mapped the car just before Xmas and i came out with a big smile on my face which always happens when i leave Badger 5!
Great service as usual and the car is great fun to drive now after the boring running in period after the rebuild. The only thing i have added to the car is Tuftys old alpine stereo which finished off the interior nicely. The car is now at a point where i am not going to take it any further which is a shame as i did the rods etc and its screaming out for a hybrid turbo and one of Bills manifolds, however my circumstances have now changed and i need to sell. It has an MOT booked for next weekend so it will have a fresh 12 month ticket. Then it will be advertised. I would like to say a big thank you to everyone who has helped me on here, its been a great place to meet new faces, buy parts and get advice. A special thank you to Paul, Bill & Rob for all there help over the years as well as many others. Hopefully one day I will be back. If anyone is interested in the car feel free to send me a message. I will post a link up in the classified within the next week or so.
Never the best when you have to sell stuff because you have to rather than you want to...
Good luck with it dude and all the best
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