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Relentless 3" Downpipe, decat and Powerflow System Fitted! Lots of Pics!!!

Discussion in 'A3/S3 Forum (8L Chassis)' started by Benjiman46, Jul 31, 2012.

  1. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    First of all, I would like to say a MASSIVE thank you to all the guys at Top Gear Performance who carried out all this work and put up with me taking loads of pictures :D

    The first thing to do then is remove the old, heavy, restrictive exhaust...


    [​IMG]


    [​IMG]


    Then, instead of dropping the subframe, and seeing as my flexi was already knackered and needed replacing, we decided to butcher the old downpipe to remove it, chopping it just above the part where it splits in two.

    [​IMG]


    [​IMG]


    Look how restrictive this part is :S

    [​IMG]


    The next step was to make access to the top of the turbo/downpipe area.

    Remove the charge pipe.

    [​IMG]

    Then you will have a bit more room to reach the downpipe to turbo nuts.

    [​IMG]

    Removing the top one is easy enough

    [​IMG]

    But the next one required this special tool we threw together...

    [​IMG]

    The last one should then be on the bottom and clearly visible (makes sense to leave the easiest till last)

    [​IMG]

    Downpipe removed! (After about 5 hours)

    [​IMG]

    Look at the comparison between old and new... Unleash that turbo!

    [​IMG]

    Fitting the new downpipe was a lot easier and took only an hour to do, but we had to chop the hanger off the new downpipe to allow us to fit it (as we didn't drop the subframe) Don't worry, it gets welded back on later...

    [​IMG]

    All fitted and nicey nice :) Not much room at all though!

    [​IMG]

    We used new loc-nuts as the old ones were nyloc nuts (very stupid idea on a turbo) hence why it took so long to remove them, the nylon had melted into the threads.

    [​IMG]

    Now to fit the de-cat and the rest of the system!!! I was very excited at this point :D

    [​IMG]


    [​IMG]


    [​IMG]

    The first part of my system was bent into shape and offered up to the car...

    [​IMG]

    These were the boxes I chose (Didn't want it too loud)

    [​IMG]

    First box tacked in place

    [​IMG]

    Second pipe bent into shape and tacked in place

    [​IMG]

    The final stages of bending for the back box

    [​IMG]

    Back box offered up and tacked

    [​IMG]

    To make the 180 degree bend, two 90 degree bends were TIG welded together to make a nice pretty finish (and optimum flow) Then the t
    ailpipe offered up and tacked in place...

    [​IMG]

    Constant checks were made to see if it was level and to ensure the exhaust didn't hang too low and f
    inally the whole thing was removed and precisely welded to ensure perfect sealing...

    [​IMG]


    The exhaust was then put back on the car, level checked, then all the hangars that were needed to utilise the existing rubbers were welded into place and it was finished!!!

    [​IMG]

    Later that day once the car was thoroughly warm, I thought I'd make a short video to demonstrate the sound... Beautiful :)

    Audi S3 3" Downpipe, Decat and Powerflow Exhaust - YouTube

    Thanks for viewing and I hope it was educational or informative to a few people on here planning on doing this :) Big shout out to Top Gear Performance in Doncaster Top Gear Performance Doncaster

    Ben
    #1
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  3. Nogmeister
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    Nogmeister Member

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    [Jul 31, 2012]
    How much did it all cost ya mate?
    #2
  4. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jul 31, 2012]
    What size is the exhaust? 2.5"?

    Shame they havent used a proper mandrel bender :(

    You need to do a video of the car on the move, rather than just revving while stationary. Stationary revving always sounds a bit limp and ghey as theres no load on the engine.
    #3
  5. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    Hiya mate, for fitting the downpipe and decat, and making and fitting the custom exhaust it was £508, I bought the downpipe as well as a manifold from relentless for $450 (£296) so add a percentage of that to the £508 for the total cost :)

    It is 2.5" yeah, They use a different type of pipe bender, but I'm not sure what it's called... Just as good and plenty enough flow for my needs :)

    and I'll be getting some drive-by videos done soon to show the sound properly, I only got the exhaust done last week :)

    Ben
    #4
  6. JtotheD
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    JtotheD Events Moderator

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    [Jul 31, 2012]
    exactly the same set up i have mate. i have a sports cat tho. i'm impressed with mine. how you finding yours?
    #5
  7. s3clarke
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    s3clarke Money grabbing s3!

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    [Jul 31, 2012]
    looks good ben :)
    #6
  8. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    Nice one :) It's awesome pal, pops and bangs alot without the cat though lol But I don't mind that ;)
    #7
  9. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    Ahh cheers dude :)
    #8
  10. Dan-Jnr
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    Dan-Jnr Well-Known Member

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    [Jul 31, 2012]
    Looks like a tasty exhaust system.
    #9
  11. s3gazz
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    s3gazz Well-Known Member

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    [Jul 31, 2012]
    look great and sounds great mate does the downpipe touch the subframe once u cut the hanger off
    #10
  12. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    Well it did, but it got welded back on when the rest of the hangars were made up so now it doesn't. I've noticed it vibrates when turning and accelerating, which probably means it's touching the subframe every now and again.. Nothing a red dog bone mount can't fix ;)
    #11
  13. s3gazz
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    s3gazz Well-Known Member

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    [Jul 31, 2012]
    em thought it might mine does now but is the v1 thinks its pipewerx for me
    #12
  14. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    I'd go for the V2 relentless mate if it was my money, if you get them direct from the USA and they're very cheap.

    Just ordered a red dog bone mount poly bush off the 'bay :)
    #13
  15. s3clarke
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    s3clarke Money grabbing s3!

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    [Jul 31, 2012]
    #14
  16. s3gazz
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    s3gazz Well-Known Member

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    [Jul 31, 2012]
    thanks mate iv already got the red dog bone mount on just sick of the vibrating noise.

    what v mani u running im after the v3 when its out
    #15
  17. [Dave B]
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    [Dave B] Daddy

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    [Jul 31, 2012]
    Thanks for the pics, helps to give me an idea of what I'm getting myself into when I get around to fitting my Pipewerx downpipe/cat and miltek system...looks like I should have the grinder/dremel handy!
    #16
  18. carl-1968
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    carl-1968 A4 sold, lots of bits available, ask for details

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    [Jul 31, 2012]
    Looks sweet, I had a 3" custom made for mine and it sounds superb, even though its a Diesel lol
    #17
  19. jamie408
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    jamie408 New Member

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    [Jul 31, 2012]
    quick question. having not fitted a cat does the EML not light up????
    #18
  20. superkarl
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    superkarl MAN OF STEEL

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    [Jul 31, 2012]
    it will do eventually, mine came on after a week. doesnt cause problems though and can be coded out
    #19
  21. S3 Rav
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    S3 Rav Well-Known Member

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    [Jul 31, 2012]
    Your near side tyre is the wrong way around.
    #20
  22. jamie408
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    jamie408 New Member

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    [Jul 31, 2012]
    coded out using VCDS??
    #21
  23. superkarl
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    superkarl MAN OF STEEL

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    [Jul 31, 2012]
    no in a remap. any decent tuner could do it
    #22
  24. jamie408
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    jamie408 New Member

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    [Jul 31, 2012]
    thanks mate
    #23
  25. Ryan_W
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    Ryan_W Member

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    [Jul 31, 2012]
    No it's not mate. Vredstein Ultrac Sessanta tyres are made that way.

    [​IMG]
    #24
  26. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    #25
  27. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    On an APY engine (what I have), it doesn't have a post cat Lambda sensor, so it won't ever come on, on the AMK and BAM engines, it will though because they both have post cat lambda sensors.
    #26
  28. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    And plus 1 on Ryan's post, very good diagram too, thanks :)
    #27
  29. jamie408
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    jamie408 New Member

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    [Jul 31, 2012]
    ok kool in the process of geting a 52 plate s3 so what engine is that?? BAM??
    #28
  30. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    Yeah will be BAM, it should have a bit of a facelift.. Slightly different back lights and tiny bit different interior and badges.. OH... and 225bhp as standard ;)
    #29
  31. jamie408
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    jamie408 New Member

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    [Jul 31, 2012]
    happy days. its got white leather and 225bhp 4x4 and a cat back system 100.000 miles payin £3k for it the door cards look real nice i think with black and white leather
    #30
  32. marknjayne
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    marknjayne Member

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    [Jul 31, 2012]
    fantastic buddy...im over at exhausts uk on friday having a 3" downpipe and 200 cell cat itted to my tt225...getting it ready for big power
    #31
  33. jamie408
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    jamie408 New Member

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    [Jul 31, 2012]
    yeh im wanting get a downpipe too
    #32
  34. Danny22
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    Danny22 New Member

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    [Jul 31, 2012]
    Sounds very nice.....Where did you get your plates from mate??
    #33
  35. s33nyboy12
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    s33nyboy12 Well-Known Member

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    [Jul 31, 2012]
    Sorry for hijacking .......... £3k is a bargain! Bit too cheap I think, I'd get it checked by someone who knows s3, borrow a vcds and scan it. Fsh? Hpi clear?

    Use buying guide on here in stickies , cheers, Sean
    #34
  36. jamie408
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    jamie408 New Member

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    [Jul 31, 2012]
    hehe its not what u no its who u no tbh mate. its got FSH shed loads of receipts. body work is perfect and no fault codes. thats what you get when people fail to pay for a car mate. it is hpi clear aswell
    #35
  37. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 31, 2012]
    Got them from Dub Meister mate, they make them in Germany from genuine German plate materials and ship them over.

    Ben
    #36
  38. s3clarke
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    s3clarke Money grabbing s3!

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    [Aug 1, 2012]
    cheers bud, seems decent priced if its good
    #37
  39. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Aug 1, 2012]
    Yeah apparently they stop the engine rocking and make gear changes faster and smoother... But also increase engine vibration inside the car. Hense why I went for the red one for the diesel A3 and not the yellow one for the S3. They're awful for vibration apparently!
    #38
  40. Dan S3
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    Dan S3 Member

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    [Aug 1, 2012]
    I was told either dog bone mount will wear in after few hundred miles and the vibration becomes a non issue
    #39
  41. Jambo26
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    Jambo26 Member

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    [Aug 1, 2012]
    Could you do a video for sound purposes please would like to hear yours please

    Jamie
    #40

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