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Prawn and BigAls A3 Track Car

Discussion in 'A3/S3 Forum (8L Chassis)' started by Prawn, Dec 29, 2010.

  1. Paradox1
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    Paradox1 Active Member

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    [Dec 15, 2011]
    Also is a 4bar fpr recommended for a ko3 hybrid?
  2. 16Klappe
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    16Klappe RacecaR forward is RacecaR backwards. Supporter

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    [Dec 15, 2011]
    Personally my hybrid build list is,

    Obviously the hybrid

    4bar FPR

    A set of Vauxhall Redtop injectors

    VR6 MAF

    Mapping

    Factor in £1500 to get it all done and running right.
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Dec 15, 2011]
    You don't need a 4 bar FPR with S3 injectors... 4 bar FPR's make the fuel pump work harder and unless you have changed it recently is likely to make it want to give up the will to live...

    Std pump, 3 bar FPR and S3/TT/LCR (386cc) are plenty for hybrid K03's

    Prawn is using a hybrid K04.... that needs 550cc injectors

    <tuffty/>
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Dec 15, 2011]
    With a K03s the std injectors are pretty much maxed out at 230hp using a 3bar fpr... 4bar gives another 15% flow but at the expense of extra load on the pump...

    Unless you have compelling reason to do otherwise I would tune for 3bar FPR...

    <tuffty/>
  5. Prawn
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    Prawn My other car is a MINI!!!!

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    [Dec 15, 2011]
    Agreed 100%!!!

    I will absolutely be having it tuned with a 3 bar FPR.

    My plan is, just to get it running, I'll fire it up on the standard injectors, but whack a 4 bar FPR in as a temp to ensure that it's running rich rather than lean.
    Reason being, going from 206cc - 550cc the ECU isn't going to have a chance in hell of compensating, so it'd be SO rich I doubt it'd even start with the 550's and current mapping. Stock injectors at 3 bar can fuel 230bhp, so a bit more on a 4 bar so less danger of it running lean. I only want to put a few miles on to save the hasstle of it going wrong during mapping, and won't be using WOT at all.

    put simply, I'll bodge it so that it doesn't blow up on the drive to Bills!

    Then when i arrive at Bills I can throw the 550cc Genesis injectors in and let the fun commence!

    Getting pretty excited about it now, but have to have an epic ebay frenzy to raise the cash to pay for it all!
  6. Andy P
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    Andy P umop ap!sdn

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    [Dec 15, 2011]
    Lets hope it lasts longer than my attempt with standard rods. Final map to 3 bent rods and melted valve in 18 hours.
  7. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Dec 15, 2011]
    Jardo are they front wishbones? Where from and will they fit a s3?
  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Dec 15, 2011]
  9. 16Klappe
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    16Klappe RacecaR forward is RacecaR backwards. Supporter

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    [Dec 15, 2011]
    They are listed on USRT, yes they make them to fit an S3.
    Last edited: Dec 15, 2011
  10. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Dec 15, 2011]
  11. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Dec 15, 2011]
    If you fit the 3" maf with the standard mapping, you'll have underscaled the fuelling by around 38%. The ECU will also see 38% less airflow (and hence less load) and will increase the boost pressure to try and get back what it thinks is missing (no boost sensor on an AGU, so it does everything on MAF).

    The 15% increase from the 4bar regulator will give you some of that fuelling back, but you'll still be ~23% lean even at idle, and it wont stop the ECU trying to get its airflow back by upping the boost (although unplugging the N75 would ofcourse)

    The ECU will obviously attempt to adapt to the lean condition, but i'm not sure it'll adapt far enough to increase the fuelling by 23%

    Personally, i'd be leaving the standard MAF in until its ready to be mapped unless you have a really compelling reason to change it. At least that way the fuelling, ignition timing and calculated load are all correct.
  12. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Dec 15, 2011]
    Whats USRT?
  13. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Dec 15, 2011]
  14. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Dec 15, 2011]
    Its ok ive found it now. Sound good but bloody dear.
  15. Prawn
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    Prawn My other car is a MINI!!!!

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    [Dec 15, 2011]
    I wouldn't say it's that dear really, consider the cost of rebushing your standard lower arms, then spending £400 on KW abjustable toP mounts, you'd spend over £500 to achieve the same thing.
    These are £320+ shipping, do fairly reasonable I'd say!
  16. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Dec 15, 2011]
    Why would you need adjustable topmounts? Why would the wishbones counteract the need for adjustable top mounts also? Sorry if im being thick haha.
  17. sportstractor
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    sportstractor Chugger

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    [Dec 15, 2011]
    Because LCR and s3 wishbones have slotted holes for the ball joint which gives you camber adjustment.
  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Dec 15, 2011]
    Not always about getting camber mate...

    They are adjustable so castor can be adjust too as well as the fact they are more rose jointed for positive location so your camber/caster angles don't go all wobbly under braking giving you more consistency and of course confidence in the cars abilities...

    Top mounts will of course aid this too... together they can be used to fine tune handling on the the car..

    <tuffty/>
  19. 16Klappe
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    16Klappe RacecaR forward is RacecaR backwards. Supporter

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    [Dec 29, 2011]
    Come on Prawn, Christmas update!!!

    [​IMG]
  20. Prawn
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    Prawn My other car is a MINI!!!!

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    [Dec 29, 2011]
    haha, cheers J-Rod, excellent pic!

    Will upload some photos now, and then add a bit.

    it's not that interesting though - it broke, we fixed it.
  21. Prawn
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    Prawn My other car is a MINI!!!!

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    [Dec 29, 2011]
    Been a fun day, nothing interesting to report, but fun all the same.

    Jardo came over this morning, hoping to fix a knocking rear top mount (we thought)

    Jacked it up, and it started raining, then, to make matters worse, we couldn't undo the top mount bolts with the limited tools I've got here at home.

    [​IMG]

    After jacking it up, and removing the lower shock bolt, it became pretty apparent what the knock was:

    When plunky had removed the rear ARB, he had put the longer shanked bolts back in, and they'd run out of thread before tightening. Didn't have any shorter bolts, so added a spacer, and problem solved.

    Whilst J-rod was doing that, I trial fitted his new steering wheel on my car, just to see if the snap-off boss would bring the wheel too close for me:

    [​IMG]

    Bloody lovely wheel, but unfortunately the QR boss just puts the dished wheel too close for me. Only solution would be a flat wheel, so we'll leave it for now.

    [​IMG]

    [​IMG]

    All sorted, we went for a little drive, I drove Jardo's car, because he wanted to stand by the roadside and hear how it sounded, I'll let him add a vid if he wants to

    Jardo gave me a new badge, I didn't ask for it, but I won't dispute it ;)

    [​IMG]

    'The Twins' as they seem to have become known....

    [​IMG]

    We jumped in mine to go for a spin, pulling up hill out of the village, I heard a really loud noise, and something bounced down the floorpan. I said it fell off the car, Jardo said it was a stone, we checked the car over, seemed fine, so we turned round and headed back to look for engine bits on the road - nothing so we carried on.

    1 mile later a loud ticking sound started, and a slight vibration through the wheel - BUGGER!

    We limped it home, and made up some ghetto ramps to get under it:

    [​IMG]

    I went inside for coffee, and Jardo took a look - found the problem instantly!

    [​IMG]

    Bloody driveshaft bolts had come loose, and one bolt was missing (the noise I had heard) and the ticking was the lock tab bashing on the gearbox casing. it was bent and snapped in half. ohps!

    Luckily, the TDI of joy came to the rescue!

    [​IMG]

    New D/S bolts and lock tabs sorted :)

    New bolts fitted, and Jardo was trying his absolute best to not look like a moron (his words - not mine!). Clearly he needs to give this more work!

    [​IMG]

    Went for a spin, all is great, I think J-rod confirmed that whilst mine isn't the most amazing thing in a straight line, it doesn't half carry speed well, even in the wet :)

    Will post more pics soon when parts start arriving!
    Last edited: Dec 29, 2011
  22. 16Klappe
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    16Klappe RacecaR forward is RacecaR backwards. Supporter

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    [Dec 29, 2011]
    If you were serious about weight loss you'd de-badge it.

    Had a rad day Bob, so pissy about my manifold though!
  23. Prawn
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    Prawn My other car is a MINI!!!!

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    [Dec 29, 2011]
    S'ok dude, you can have my ko3 mani when it comes off next week.

    Cant wait to get stuck into this hybrid project finally! 5 months after I got the turbo it'll finally be going on!

    had a rake of sales on ebay tonight, so I'm now armed with cash to order a TIP from Bill, then it's down to TPS for all the gaskets and crush washers I need!

    XS power 3'' DP ordered, VR6 MAF is here, WMI kit is confirmed, just need to pick it up, then just the FMIC and EBC to go before mapping.

    Will get it running on the current FMIC/MAF/Injectors, then fit the new kit as soon as possible!

    Seriously excited now!
  24. Prawn
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    Prawn My other car is a MINI!!!!

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    [Dec 30, 2011]
    It's all coming together now!

    [​IMG]

    [​IMG]

    Just ordered a black 80mm V2 TIP from Bill, and Nordlock washers for the turbo-manifold studs :)

    Aside from a trip to TPS for a load of gaskets, I'm now ready to start work! heading home Wednesday night.

    So, the big question, colour scheme!

    Black and orange will be the theme, but do I do a black inlet manifold and orange rocker cover? Or orange manifold and black rocker cover?

    FMIC charge pipe under the bonnet will be black :)
    Rogue-24-84 likes this.
  25. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Dec 30, 2011]
    Personally mate from my experience the mani gets more scuffs then the rocker cover. Go orange for the rocker and black on the mani. When I do mine I'm doing the rocker cover red and the mani will get re done in matte black.
  26. ScottD3
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    ScottD3 I want your faulty electronics Supporter

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    [Dec 30, 2011]
    [​IMG]

    Farmer Giles in the back ground!! :)


    I got a part list up together for the B5 if you ever break it. :)


    Orange rocker gets my vote.
  27. Prawn
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    Prawn My other car is a MINI!!!!

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    [Dec 31, 2011]
    thanks Scott, I'll let dad know! that's his daily driver at the mo! Over 250k and still going strong!

    had a good night tonight. Picked up an ibiza 60mm charge pipe to make the start of my new 60mm FMIC pipework :)

    So aside from gaskets, i'm ready to bolt the turbo on. half my new pipe work is sorted, and I've covered enough on ebay for lots of the other kit :)

    Going to be a fun few weeks ahead!
  28. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Dec 31, 2011]
    Good luck d00de... looking forward to seeing the end result :D

    <tuffty/>
  29. 16Klappe
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    16Klappe RacecaR forward is RacecaR backwards. Supporter

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    [Dec 31, 2011]
    Going to Barnstaple in the beast today, will be like going back in time 3 years!
  30. 16Klappe
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    16Klappe RacecaR forward is RacecaR backwards. Supporter

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    [Jan 3, 2012]
    Just found these from a few years back, she was a handsome beast! -

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
  31. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 3, 2012]
    it was beautiful once long ago wasn't it?

    Now it just looks angry :p
  32. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 3, 2012]
    well, an update, although not a particularly happy one!

    New years eve came, jardo got very excited, and arrived at my house whilst I was still in bed. (bastard)

    We loaded up the beasty, and set off on the most amazing cross country drive from Cornwall up to Barnstaple where we were to celebrate new years.

    Only, we didn't make it :( Accelerating off a roundabout in second, the box started to make a horrific noise, and BANG, seemingly, the bearings on second gear have collapsed. it still had drive, but also a horrific knocking noise and it sounded like a bag of spanners.

    Bugger.

    No worries I thought, this box was rebuilt in July with a 12 month warranty, so I didn't say anything on here until now, and I called them this morning.

    turns out, my warranty isn't worth the paper it's written on, theyre claiming that although they 'rebuilt' the whole box, because they only 'replaced' the diff bolts, only the diff bolts are covered on warranty.

    Not happy at all. We asked at the time why the price for the work was high, and we were told it was because the box hadn't just been stripped, but fully disassembled, checked, and rebuilt from the ground up.

    Does anyone have a decent condition 1.8T 02J gearbox I can buy ASAP? I need to get my diff removed from the dead box and fitted into a new box asap so I can crack on with this hybrid project!
  33. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 3, 2012]
    All wasn't lost though, we still made it to Barny in Jardos time bomb, and much Wrongbox was consumed to drown my sorrows!
  34. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Jan 3, 2012]
    Bad times matey. I can't believe the way some companies will wriggle out of warranties! Bloody diff bolts covered only, did you laugh at them down the phone?! What a pathetic excuse.

    Hope you get it sorted soon as I know how much grief the clutch and box has given you over the last year.

    Ps. Love the timebomb reference ;)
  35. 666markyboy
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    666markyboy Well-Known Member

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    [Jan 4, 2012]
    your not having much luck with the drivetrain are ya pal ? i do wonder if your having all these probs with the state of tune your at at the mo how is going to be with the hybrid ???
  36. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 4, 2012]
    it'll be fine! Don't mention it!

    Seriously though, it's ALWAYS been driven hard, I'm fairly keen, and to be honest, I think this box has been cursed from the outset. I didn't know it when I bought it, but it'd blown up once before and been welded, then it was run in a 400bhp ibiza before mine, so perhaps it wasn't the best base to start from.

    Just want to find a nice standard 02J box now, that I can have stripped down and have my diff built into it, then see how I go from there.

    thankfully, this gear desutrction doesn't seem to have got through to the bell housing, so my 3rd clutch in the past 12 months should be ok!
  37. ScottD3
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    ScottD3 I want your faulty electronics Supporter

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    [Jan 4, 2012]
    Bad luck mate, at least you made it to the party.

    I assume a quattro box wont fit?

    There seems to be alot of S3 being broken at the moment if any of their boxes will fit I don't know.
  38. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Jan 4, 2012]
    You assumed correct scott....:)
  39. Welly
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    Welly VX220 SC Driver :)

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    [Jan 4, 2012]
    Worth the outlay on a recon box? VW /Audi 02j 5speed 1.8 & 2.0 Rebuilt Gearbox | eBay
  40. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 5, 2012]
    This one has been fully rebuilt now Welly, TWICE!

    Meh. Not fussed about that anymore anyway, picked up a new box today, and will be changing the shafts over to later 108mm flanges too with stronger CV's.

    Tonight I started mocking it up:

    [​IMG]

    This was hugely exciting! B5 80mm Tip and XS downpipe in place :)

    [​IMG]

    [​IMG]

    Suddenly I'm not fussed about changing the box!

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