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S3 PE1820 big turbo build

Welly Mar 29, 2011

  1. Welly

    Welly VX220 SC Driver :)

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    I hope so....
     
  2. Welly

    Welly VX220 SC Driver :)

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    No, not flap wheels, I'll photo the implement used - it's like a flap wheel, but a rotary bit with just a harsh grade sand paper outer.

    I've got a spare TB here so I don't mind messing about with this one. I'll see what it's like and then maybe do a bit more.
     
  3. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Cheers welly.
     
  4. Andrew@A.L.D

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

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    I use a number of different burrs and emery clothes inc flap wheels
     
  5. Dani_B19

    Dani_B19 Audi-sports own special child.

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  6. Prawn

    Prawn My other car is a MINI!!!!

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    Looks awesome Welly!

    Best of luck dude, REALLY looking forward to seeing the results you get from this!
     
  7. Welly

    Welly VX220 SC Driver :)

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    Another milestone on the road to completion yesterday - the head.

    I'm a bit nervous of the 20V heads due to their tightness on the inlet side, so enlisted the help of a friend who has got some reasonable experience with them....

    Tuffty!

    All his work on the head, stem seals and cam seals have all been replaced. The stem seals were a bit weepy and the cam seals were completely shot and leaking. So hopefully no more leakyness now.

    Photos:

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    Head is now back with me at home after collecting yesterday.

    Big thanks to Tuffty for doing this - a lot of skill, work and time went into it to complete it. Thanks dude :thumbsup:.

    Awaiting oil and coolant line's completion tomorrow and we should be good to go on building back up...
     
  8. Welly

    Welly VX220 SC Driver :)

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    Oh, also trial fitted the TIP to see how it fits - well is the answer....

    [​IMG]
     
    Last edited: Apr 11, 2011
  9. <tuffty/>

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

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    Welcome mate...

    <tuffty/>
     
  10. Welly

    Welly VX220 SC Driver :)

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  11. superkarl

    superkarl MAN OF STEEL

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    Is that a worthwhile bit of maintenance to do when I remove my head, stem and cam seals? Expensive parts?
    Thanks
     
  12. Welly

    Welly VX220 SC Driver :)

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    The head set to buy is around £70 - includes a HG, stem seals, cam seals, chain tensioner seals, inlet manifold gasket, exhaust manifold gasket and a rocker cover gasket. Not bad all in all.

    I would say they are worth changing once the engine gets over 100K - the seals tend to become dry.
     
  13. Welly

    Welly VX220 SC Driver :)

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    Turbo hoses are done..... yay!
     
    Last edited: Apr 11, 2011
  14. Welly

    Welly VX220 SC Driver :)

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    OK, so had a night on it tonight.

    Initially concerned that the turbo oil return hose was a little short - however it turned out to be fine.

    Many thanks to Bill for grabbing them for me today :).

    So... here they are:

    [​IMG]

    Score. Total cost of £136.96 wasn't the cheapest, however they are made out of PTFA internal braided hose - so should be pretty heat proof.

    I have also heat wrapped (two layer, firstly with exhaust wrap, and then with silver foil tape followed by SS wrap straps) the two pipes that will run underneath the manifold.

    [​IMG]

    Thats done, it was time to start rebuilding..... Started by fitting the exhaust mani to the head, and then the head to the car. Only mocking at this point.

    Fitted the oil lines to the turbo and then the coolant lines. Basically I followed my normal rebuild procedure... lol. Torqued the head, fitted turbo, fitted remaining coolant lines, etc etc etc.

    Have finished up the night in this state by close of play tonight...

    [​IMG]

    Engine bay as is.

    [​IMG]

    Coolant return pipe coming out of the turbo and winding it's way around the bay to the original coolant K04 return feed.

    [​IMG]

    Here, Bill has welded the 007P directly the the TIP 76mm joiner. This is purely a space saving measure as it means less hosing in the engine bay.

    [​IMG]

    Oil return, coolant feed and oil feed pipes visible along the bottom of the head/turbo area.

    So, all in all a good night. Spent a little while standing back admiring it.... lol. (sad...)

    On a side note, the funny story from the evening is as follows.

    Get home, start fitting the oil return line and the gasket falls down somewhere in the engine bay. ****. It's grey so finding it in a black engine bay is next to impossible.

    Spend an hour or so poking around looking for it. Nowhere to be seen. Stopped briefly as Dane came to pick up the hybrid from my yard, then eventually found it luring down on one of the heat shields.

    Now, we have a new (and bonkers) labradoodle puppy, who has taken to sitting under my car (as she's up in the air). I suspect she has actually eaten some missing bolts that were under there - and aren't now.

    I manage to poke the gasket out from where it was, and it dropped to the deck.

    At which point the puppy promptly saw, and ate it (it was only a paper gasket). Amused I was not. In fact I went absolutely bonkers having spent an hour looking for the damn thing.

    Then had to go to Bill's to get another suitable gasket.

    Bloody dog! :mad:
     
  15. Welly

    Welly VX220 SC Driver :)

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    LOL, post from last night now added after some ASN weirdness.....

    Cheers Tuffty :thumbsup:
     
  16. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User quattro Audi A4

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    Gotta love the dog,LOL

    Feed it headgaskets, you must have 20 in stock.LOL
     
  17. superkarl

    superkarl MAN OF STEEL

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    Must be great working on a turbo that's so much more accesible than a ko4 hey!
     
  18. Welly

    Welly VX220 SC Driver :)

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    I fed it's **** my foot. I was not happy at all, bloody thing. It fell in the pond the other day as well. She is sooo skatty.
     
  19. Welly

    Welly VX220 SC Driver :)

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    Yeah, some things still a challenge like actually doing up the oil return flange with the turbo in situ - but still far easier than any K04 work.
     
  20. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    bolt drain onto turbo 1st then turbo onto mani
     
  21. Welly

    Welly VX220 SC Driver :)

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    Normally what I would have done - however pipe angle constraints stopped me from being able to....
     
    Last edited: Apr 12, 2011
  22. JD09

    JD09 I'm not modding, I'm improving VCDS Map User

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    Lol! Reminds me of the dog in Gone in 60 Seconds eating the Merc keys!
     
  23. Welly

    Welly VX220 SC Driver :)

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    Another long night spent in the garage last night, however it did bear some fruit....

    It's done - a few odds and sods aside at least. Awaiting delivery of a few pipes and fittings, however, the bulk of the work is now completed.

    Usual stuff done last night, timed the engine, fitted the timing belt covers, inlet manifold etc etc etc.

    So, will finish up tonight, and then it's ready to roll up to Bill's at the weekend - which is nice.

    Photos:

    [​IMG]

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    [​IMG]
     
  24. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    :D
     
  25. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

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    This weekend? Im so there, let me know when and I'll pop over.

    Good work man!
     
  26. Welly

    Welly VX220 SC Driver :)

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    I'm only bringing her up there for some work on Monday dude - she is lacking a downpipe currently....
     
  27. s3dave

    s3dave TFSI Hybrid Supporter

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    Well done, you certainly move fast, your oil will still be warm from your hybrid..lol
     
  28. Welly

    Welly VX220 SC Driver :)

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    lol, it's new oil..... :p
     
  29. Westy

    Westy Well-Known Member

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    Nice work Welly, you do get things done quickly.
     
  30. Welly

    Welly VX220 SC Driver :)

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    The missus is off for a week, so had to capitalise on having a WHOLE week to get on with no aggro.... lol
     
  31. Dane

    Dane Had an 8L S3, a B5 RS4 now I have a B8 S4

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    apart from the dog :laugh:
     
  32. Welly

    Welly VX220 SC Driver :)

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    Yeah, the dog.... :mad:
     
  33. Westy

    Westy Well-Known Member

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    I only see my gf at the weekends so I have loads of time during the week for late night mechanics ;)

    It's just a shame my mechanical skills aren't as good as yours!
     
  34. Welly

    Welly VX220 SC Driver :)

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    It doesn't work yet..... lol. Rumours of my skills are greatly exaggerated.
     
  35. S3 Nattie

    S3 Nattie Quattro ist für sissies

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    Nice work buddy and liking your sticker.

    Welly 2 questions, whats the name of the turbine housing outlet flange, and I thought you was running a catch can, cant see it in your pics tho. What one have you got if you have that is.
     
  36. Welly

    Welly VX220 SC Driver :)

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    The name of it? Ummmmm, pass. It's just a boggo IHI outlet to be honest dude - I don't know if it has a specific name.

    Secondly, I was running a catch can, however ended up binning ti as it was a pain during the cold weather. It was metal, and thus got cold at night, combined with a warm engine just caused condensation and I ended up emptying water out of it most of the time.
     
  37. S3 Nattie

    S3 Nattie Quattro ist für sissies

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    I wasnt to sure if there was a name for the outlet either, thats why I asked. I was just thinking if you was having a custom downpipe made up what would they called the flange thats all as its a pretty strange flange.

    Did you upgrade your breather hoses to Forge ones then, any links for the can you did have mate.
     
  38. Welly

    Welly VX220 SC Driver :)

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    It Flangetastic..... Turbo Flange SUBARU Liberty Legacy IHI VF38 VF44 VF45 | eBay UK

    Just made my own out of silicone hosing mate TBH.
     
  39. S3 Nattie

    S3 Nattie Quattro ist für sissies

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    I suppose you would just called it a subaru/IHI flange then lol.

    Cheers for that welly
     
  40. Welly

    Welly VX220 SC Driver :)

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    Yeah, they're pretty common to be fair, all of the VF series have that flange.
     

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