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PaulyPaul's Build Thread.....Its HYBRID Time

paulypaul Apr 28, 2010

  1. paulypaul

    paulypaul S3 all the way Baby

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    Hi all,
    Ive been a member for quite a while now i joined when i bought my 01 S3 in 2008,The turbo blew a couple of months after i bought the car,i took the turbo out but like everything else it got put on the long finger and my S3 has been parked up since.I bought the car in England and i live in Ireland so there was no come back really,I didnt mind too much as i always had a car to drive,garage car or a customers but up until recently i was working in a VW,Audi garage as a technician and had been there for 9 years but things have gone quite so redundancy was offered and i took it and i thought what better way to spend a few quid and get my S3 right again.
    So after Hours and Hours,Days and Days of reading up on this Forum(what great info) i decided to go for the CR Hybrid Turbo and all the bits i need to go with it.
    So here Goes
    First job was to get her up on stands and start stripping.
    [​IMG]
    I had a Oem clutch kit bought for the car a while ago so that was the first job.
    I had been on to Bill about a hybrid turbo (Thanks)and then got on to CR Turbos about gettin my old K04 hybridized,I was happy with the price so off it went 2 weeks later it came back and it looks lovely.
    Same turbo Bill has put in to Speedy Steve's.
    OLD
    [​IMG]
    NEW
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Cr have done a great job on the turbo as you can see.
    Bill advised me to change the rods so i ordered a set of IE rods and a AH FMIC and all the pipe work from Tuffybloke's build thread (i have too say Thanks and what a build thread)
    next it was off with the head and out with the pistons
    [​IMG]
    [​IMG]

    Word of advice if you have never removed your sump and checked the oil pump strainer then do so,sooner rather than later.I have seen so many 1.8t engines ruined over the years from the stainer getting blocked and never checked mine and yes,it was blocked full of carbon deposits and the oil feed to the turbo was blocked too obviously the cause of the turbo failure.But if that didn't happen then all this work might not of happened.
    This is the lad,Almost fully blocked turbo side.
    [​IMG]
    Still no sign of me Rods so i went about cleaning all the parts and fitting the turbo
    [​IMG]
    What an easy job it makes it with the head off i remember removing the turbo with the head on and that was a pain in the arse.
    [​IMG]
    I got the FMIC and all the pipe work so i started to fit that its more or less button up just have to wait till the head goes back on before i fit the clamps,I must say fair play to Tuffy(Thanks)his step buy step made it very easy and looks the business.
    [​IMG]
    [​IMG]

    So this is where I'am at waiting on Parts rods and head gasket are the main ones,I have also ordered OCC and piping,boost hoses,phenolic insulator for inlet mani,THS Dog bone mount,boost gauge and i bought a second hand 42 draft designs downpipe from Ebay but the lambda probe bung has to be moved to fit in place.
    [​IMG]

    I shall keep ye posted.
     
  2. <tuffty/>

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

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    Nice work mate... looking forward to it :)

    <tuffty/>
     
  3. s3dave

    s3dave TFSI Hybrid Supporter

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    great job so far....looks like you have plenty of room thing going on there
     
  4. paulypaul

    paulypaul S3 all the way Baby

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    Thanks Man you were my inspiration to do it.
     
  5. finesse

    finesse Active Member

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    Excellent work both Paul's!!
     
  6. paulypaul

    paulypaul S3 all the way Baby

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    Yeup loads of room,out of the way i can tip away at it when i want,Its great.
     
  7. paulypaul

    paulypaul S3 all the way Baby

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  8. Dani_B19

    Dani_B19 Audi-sports own special child.

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    That's it, im stopping coming on here, there's too much bloody temptation, im going to end up cracking :no:
     
  9. ALPINE

    ALPINE Yes its diesel, now cry u lost

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    i know the feeling... my redudndancy doe was gonna be a Big turbo... .. .. shame it aint gonna happen now :(




    Good work paulypaul.. cant wait to see this thread grow
     
  10. Dani_B19

    Dani_B19 Audi-sports own special child.

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    My problem is a missus who wants a house, asked her why we just cant live in the car, its got heating, what more does she want lol.
     
  11. ALPINE

    ALPINE Yes its diesel, now cry u lost

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    hahahahaha!! i have also tryed that 1.. dont think the 2 kids would approve!! ill stick with a generic till my turbo blows up and i mite go hybrid. I know ill get slated for saying this, but i think if i want big power ill just buy another Jap car, 3K plus on my Audi just does not seem sensible. Works out alot cheaper to get another jap deffo.!
     
  12. s3dave

    s3dave TFSI Hybrid Supporter

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    unless you get your hands dirty :icon_thumright:
     
  13. ALPINE

    ALPINE Yes its diesel, now cry u lost

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    i always get me hands dirty!! lol
     
  14. voorhees

    voorhees Moderator Staff Member Moderator DSG

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    :asskicking:
     
  15. paulypaul

    paulypaul S3 all the way Baby

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    That's it, im stopping coming on here, there's too much bloody temptation, im going to end up cracking :no:

    Thats what happened to me too much temptation,I cracked
     
  16. 1animal1

    1animal1 The Clar!! it mouves!!! VCDS Map User

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    Dani at least you can resort to ya stage 1 for cheap thrills dood :)
     
  17. paulypaul

    paulypaul S3 all the way Baby

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    Thanks alot Alpine
     
  18. SteveBAM

    SteveBAM Black '03 S3

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    that turbo looks pretty spunky ..!!!
     
  19. paulypaul

    paulypaul S3 all the way Baby

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    Iam looking around €2000 all done except for the remap and i dont know yet about the injectors have to see what Bill reckons.
    But doing the work yourself does help you know its done right and its fun doing it too.
     
  20. paulypaul

    paulypaul S3 all the way Baby

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    Spunky lol...Yeup it is a completely different turbo cant wait to hear it spool up.Cr do a Awesome job.
     
  21. SteveBAM

    SteveBAM Black '03 S3

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    its good to see you also went for rods aswell.. will be waiting to see how it goes..
    good luck:icon_thumright:
     
  22. ALPINE

    ALPINE Yes its diesel, now cry u lost

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    yep it is indeed. i rebuilt my Scooby engine my self and loved every minute of it. i learnt so much too. (like dripping the Vpower out the fuel rails over the nice new laminate floor pi$$s the wife off big time!!) I broke my back a few months ago and have nerve damage all over the place. Im limited to what i can do now days, unfortunatly, changing my head lights to face lift ones has mullerd me enough, still suffering today. such is life so they say!!!! Im just glad i have some really good mates with garages!! lol

    I look forwards to seeing you build a beast, Its studdy time for me now, ill leave the pratical for others!
     
  23. 1animal1

    1animal1 The Clar!! it mouves!!! VCDS Map User

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    yeah the G's are gonna reec havoc on ya back when the map comes :)
     
  24. ALPINE

    ALPINE Yes its diesel, now cry u lost

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    im sure my little Audi will be ok.. my mate Els 500+ bhp scoob is ok on me back!! lol I say its a good advert for those JOM coiovers i have too! lol
     
  25. Speedy Steve

    Speedy Steve Active Member

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    Looking good there! Your at a further state than me so maybe you will get it running before me the race is on!
     
  26. S3KO4

    S3KO4 Member

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    what price did you pay to have it hybrid?
     
  27. Andrew@A.L.D

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

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    +2

    It maybe some tome before i go BT
     
  28. paulypaul

    paulypaul S3 all the way Baby

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    Bill beat me too it with a Build thread but i'am alot further away from Bill than you are so you might get it all done first,time will tell.
    How is yours going are you driving it?
     
  29. paulypaul

    paulypaul S3 all the way Baby

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    CR do a few different options they quoted me between £425 to £575 plus carriage plus vat to have my own turbo reconditioned depending on its condition,The exhaust housing was cracked so i knew it was gonna be closer to the 575.For a finish the only original part left on the turbo was the inlet housing it cost £565 +vat +P&P.
    Cracking looking turbo though as you can see,Lets hope it will perform as good as it looks.
     
  30. paulypaul

    paulypaul S3 all the way Baby

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    I didn't intend to get rods as everything i had read said there good for 400 odd ponies but after speaking with bill he advised me to do so,and this man obviously knows his stuff so i placed the order.Peace of mind is a great thing if the boost needs to be turned up.
     
  31. optio

    optio New Member

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    Any chance of SW build a droid parts here too?
     
  32. S3 Johnny

    S3 Johnny The grass isn't always greener

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    Hi mate, Where did you get your FMIC from? I'm looking at getting one myself.
    Thanks.
     
  33. <tuffty/>

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

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  34. Speedy Steve

    Speedy Steve Active Member

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    You may be further away but with the chance of buying a house soon it may take me a little longer. Mine is running but not mapped so N75 is disconnected( no Boost ) I drove it back from Bills some 90+ miles with no problems just slower than normal> Im currently waiting on my hoses and FMIC to come in after ordering it all
     
  35. paulypaul

    paulypaul S3 all the way Baby

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    Ha?
     
  36. <tuffty/>

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

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    Yep... lost me too :think:

    <tuffty/>
     
  37. paulypaul

    paulypaul S3 all the way Baby

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    Question..I have a K&N panel filter is it worth changing for a green cotton or another air filter.
     
  38. <tuffty/>

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

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    K&N tend to be oilier than Green Cotton ones and can cover the MAF element in oil making it fail prematurely (not that it takes much to make them fail any other time)... I used to have a Pipercross foam filter but changed to a Green Cotton...

    <tuffty/>
     
  39. paulypaul

    paulypaul S3 all the way Baby

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    well i have been on to jbs about there manifold for k04 and it doesn't look like i get one any time soon they wont say when but they will contact me,
    I wont hold my breath.
    so i think i might have a go at porting the oem one,i wonder has anyone tried this?would it weaken it?

    [​IMG]
    [​IMG]
    The manifold is already cracked the gasket was split in 3 pieces,but ill have to make do with it welded up.
     
    Last edited: May 10, 2010
  40. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    I have ported the k03 manifold and achieved same flow performance as the "hi-flow" ones I have also fitted/mapped..

    K04 one however is already thin and weak..
     

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