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Stacey's Belated Yo Yo Build Thread

Discussion in 'A3/S3 Forum (8L Chassis)' started by StaceyS3, Feb 7, 2012.

  1. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Well have been meaning to do this for a long time and is a bit ironic to be doing it now considering that i have probably completed the best part of the project already, but i have been polluting other peoples threads for to long now and have a fair few of my own which i will link to here and try to consolodate all further tat in one place :)

    Ive followed this forum for some time now but really wished i had found it and followed its advise and experiances sooner but we all live and learn, as this was the first car that i had persued the route of performance modifing so has been a very steep learning curve and this forum and the people have been invaluable, as well as making some good friends along the way with hopefully many more to follow :beerchug:

    Any how this is the only photo i have got of it in standard form, i know its a **** photo but its the only one ive got (wish i got some more along the coarse of the project)
    [​IMG]

    The modding journey all started with an AMD stage 1 map and 007p (after i promissed the family and over half i wouldn't modify this one as it was fast and nice enough)
    The map when uploaded gave me 2hp originally but after a few boost leaks were sorted and breather pipes replaced this was the outcome
    [​IMG]
    Which was pretty chuffed with but that only lasted about 2 months till when i bought a milltek res cat back and high flow cats, and powertec induction kit and went back to AMD for stage 2
    The results were very impressive although i have later learnt that their rollers can be quite happy
    [​IMG]

    After this i then started to research a little on th net but not always getting good information including some bad information at the time on a bad front brake set up which all became very clear why my front brakes were ****e about a year later on here
    [​IMG]
    [​IMG]
    Boxster S/996 carrera rear set up, tried various pads etc and they're on 325mm disks from daveb but always didn't quite cut the mustard but had sold the standards so just changing back was not an option

    By this time i had followed audisport for a while and thought might as well join and started posting the odd coment and was finding very good advise on this site and sure i will continue to do so

    Any hows i had done a few more mods in the process including coilovers, ah v1 fmic, andymac stealth sub and bought the liquid guage which to this date has been an amazing bit of kit for diagnosing faults etc and would highly reconmend it to anyone
    [​IMG]

    Next step which i know some people would say is over kill but after nearly being killed due to ****e brakes multiple times i managed to pick up and ecs kit for a mk 5 golf with the cayenne 6 pots for £500 on ebay, and sold the mounting brackets, discs and old set up it only cost me the cost of the paint (£20) with new ebc discs :yahoo: athough hadnt bargined for how expensive some decent pads would be for them
    http://www.audi-sport.net/vb/a3-s3-forum-8l-chassis/134097-ferodo-ds-ebc-stuff.html
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    And of coarse the ecs discs
    [​IMG]

    To be continued...
    Last edited: Feb 7, 2012
    #1
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  3. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Just a few random photos of the stage 1 and 2 states of tune
    [​IMG]
    [​IMG]
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    [​IMG]

    Well after the crave for more power i bought a turbo conversion (MTM) off of ebay which turned out to be a user on here "Pat", i fitted the kit in january 2011 along with and uprated clutch and flywheel as mine had already strated to slip with stage 2 :(
    I got the turbo refurbished as it had seen quite a lot of work and set about fitting it all
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    I choose this kit as was advised that would be fine on standard internals by the tuning co that deals with these kits so in my eyes was a no brainer as didn't want to fork out on the internals but if i was would have gone for something that make a bit more power, oh hindsight is a wonderful thing :)

    Link to a thread with discussion on MTM/QST and my experiance with them http://www.audi-sport.net/vb/a3-s3-forum-8l-chassis/147868-mtm-conversions-while-now-ive-wondered-why-they-soooo-expensive.

    Long story short took my car for mapping and after having talks about future mods etc came to the conclusion that my inlet temps were to high so he put a base map on and sent me on my way to return with lower inlet temps at a later date

    Well all was going ok and was waiting for the ah v2 to arrive at some point the current week as well as some ad08's for nurburgring and me and my friend dave decided to soak the intercooler with a hose to see how much it brought inlet air temps down and it was shocking my temps dropped from >60 degrees to low 20's which in july i though was really good but it only lasted <5miles before suddenly car started missfiring, and sounded like a scooby on idle :think:

    Thought it was bound to be the normal coilpack failure etc etc so thought it was a perfect time to take it in to chelmsford audi for the coilpack recall as i was elegible

    They first of all told me that my coilpacks weren't the originals with the part numbers in question (they had already been replaced) so wouldn't cover them but they said 2 of mine were dodgy and would replace them but would be at my cost, so as i wanted the car sorted i said go for it to then after paying for the parts and going to leave my car still sounded like a bag of nails, for them to try and shone me off saying it heavily modified and could tell they weren't particularly interested as was using every excuse in the book

    So this is where it got interesting, took it home took the plugs out and done a compression test which produced shocking results
    Theres another thread here with more in depth details and pics http://www.audi-sport.net/vb/a3-s3-...plug-broken-up-ouch-large-port-questions.html

    After dismantling moust of the engine and aux in the car we measured the bores and pistons to find they were out of spec, link to thread http://www.audi-sport.net/vb/a3-s3-...1-best-way-remove-block-what-piston-size.html
    So that then ment that the block had to come out after all, just a few pics in no particular order during the rebuild
    [​IMG]
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    The head that got damaged by bloody yodel
    [​IMG]
    [​IMG]
    #2
  4. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Now a few pics of the rebuild, which was quite lucky that i could do it at work in my own time of coarse ;)

    Block just after rebore
    [​IMG]
    [​IMG]
    [​IMG]

    My friend Afjal giving me a hand as he builds engines for a living @ JD Classics who run classic racing cars and participated at goodward festival of speed[​IMG]
    [​IMG]
    Plastigauged all bearing surfaces for clearences
    [​IMG]
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    [​IMG]
    [​IMG]
    [​IMG]
    Last edited: Feb 7, 2012
    #3
  5. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 7, 2012]
    Is that Dave in the background in the workshop? You didn't let him near your car did you?! :)
    #4
  6. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Na my friend Afjal but he is friends with Dave, hes currently building a monster efr turbo'd celica gt4 but is long awaited as been working on the chassis for 2 years and last i heard was scrapping off underseal and was going to get it acid dipped ;)
    #5
  7. Welly
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    Welly VX220 SC Driver :)

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    [Feb 7, 2012]
    Now that is commitment!! lol
    #6
  8. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Can see in the last photo that the manifold is new as the previous one had cracked, the main downside is that the wastegate flange had been machined at a slightly different angle so the down pipe wouldn't fit but thought it was a good way to then change over to a 3" downpipe set up and get one custom made but thats another whole incident

    In the meanwhile the block kept leaking oil from the headgasket behind cylinder 1 so thought after 2 attempts of doing the headgasket with the same issue would get the head checked (although it was skimmed it got dropped by yodel so wanted to make sure it hadn't bruised at all) the head checked out all alright with less than half a thou difference accross the surface
    [​IMG]

    Next i tried my best to check the block without removing it from the car and puting it on a datum etc so put a machined bar accross the surface of the block to run a dti along it to clock it
    [​IMG]
    There was less than 0.1mm difference accross the block but this obviously must be enough to not quite seal propperly on that corner?
    Any how another friend suggested using a product called wellseal as he uses it on his race car and never had any issues, after looking it up seems it was a really common substance to be used with classics and older cars but he sware by it so gave it a go and it worked :)

    Well sort of... you can see evidence of a leak there but can't physically see it leaking where as last time there was a puddle on the floor after 5 mins of idle, and it uses probably 0.5 litre of oil to 1000 - 2000 miles or so, so am happy with that until i get the chance to rebuild it again ;)
    #7
  9. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    At a later date once i stripped the old pistons and rods down i found one to be slightly bent which must of coarsed the broken valve due to the way it had bent
    [​IMG]

    [​IMG]

    Whilst the car was off of the road in many pieces and nurburgring was blatently out of the window at this point i cracked on fitting and moding loads of other bits that were long awaited
    Polybushed the whole car which was a complete arse
    [​IMG]

    [​IMG]
    Most of the car currently being stored inside it :)
    [​IMG]
    Little did i know but my car had been in an accident at some point and had different wishbones on it one was an extremely rare tt cast one that was a recall but this meant that the bush sizes where different... what a PITA, so had to get the correct wish bone and bush it to later find out that it put my camber massively out on that side leading to me buying adjustable top mounts :(

    Coilpack loom was buggered so replaced this
    [​IMG]

    [​IMG]

    [​IMG]

    Then sunk my teeth into the ah cooler exchange ( v1-v2 ) and the pipe work to go with

    Cooler but with pipes pointing the wrong way :(
    [​IMG]

    [​IMG]

    Ah V1 & V2
    [​IMG]

    [​IMG]
    Pipework is now all sprayed matt black
    [​IMG]

    Big thanks to tuffty and bill for putting the effort in to get ah to produce this core and another to bill for his efforts with the 3" tip, it made me want one on my car as they use a normal forge/samco tip with a 4 inch long extension with a 55mm bore iirc to go between the turbo and the tip
    Started turning a billet adaptor which due to room will then had a 45 degree 3" alloy section welded to it followed by the rest of the tip
    [​IMG]

    [​IMG]

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    [​IMG]
    #8
  10. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Once the car was starting to take shape i cracked on with some more trivial ****e :)

    [​IMG]

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    Then went on to the wmi which once again same as everything with this car had its issues

    [​IMG]

    [​IMG]
    Can just about see the nozzle at the bottom
    [​IMG]

    Whilst having that area of the dash out i thought i would hardwire the liquid gauge in like tuffty has done so you don't have to renter a password every time you dissconnect the plug
    [​IMG]

    [​IMG]
    #9
  11. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Nearly forgot.... the back brakes were upgraded with a kit that i got hold of off DaveB

    [​IMG]
    Pic for Paul?? iirc asked me about the rear kit and i said about a spigot ring on the iside of the disc..you can sort of see it in this pic
    [​IMG]

    The car was at this point ready and all booked in at Hayward and Scotts for custom exhaust and downpipe

    [​IMG]

    The car was then run in for over 700 miles for when i decided to take it to bills for a rolling road day, i ummed and ahhed for most of the morning and eventually got it stuck on bills rollers for a couple of runs, one with the n75 unplugged and it looked reasonable but a bit lean
    We then tried a run with the n75 plugged in and it boosted rediculously high and ran very lean so bill backed out of the run, just goes to show how much difference the flow makes as before the rebuild it would only make 24psi and on exactly same mapping it was making 32psi

    [​IMG]

    [​IMG]

    The car was currently booked into QST to have the finalised mapping done the week later so all being well would have been on the road all running correctly in the very near future... o how wrong was i
    Turns out Kim at QST couldn't or didn't want to map it so back to the drawing board and all booked in at Badger 5

    A thread that has got my experiances and feelings about QST post 11 (worth reading if considering using them) http://www.audi-sport.net/vb/a3-s3-...ow-ive-wondered-why-they-soooo-expensive.html

    This is the thread that Bill used to pass on any info or details about the problems he was coming accross with my downpipe set up, once again worth a read as some of this really is quite shocking http://www.audi-sport.net/vb/a3-s3-forum-8l-chassis/133324-nightmare-headgasket.html

    The downpipe was that loose bearing in mind i had taken it back to them before leaving essex for glouchester and it was loose by the time i got there!

    Bill had the car in his capable hands for a few weeks as the ecu had to be sent off to have the mtm eprom removed and of coarse had to try and rectify the downpipe situation, but the final result of leaving bills was that it was producing as much power as the kit should but with less boost and producing a lot of heat due to the tiny size of the hotside of this turbo set up

    [​IMG]

    [​IMG]

    And just a final couple of up to date pics, some with the A8 wheels that i HATE (long story but got stitched up) and some with my new OZ's which will be due for a refurb when the weather picks up

    [​IMG]

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    Last edited: Feb 7, 2012
    #10
  12. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    That pretty much brings it up to current date, theres plans in the pipe line ;)

    [​IMG]
    A new toy also arrived today
    [​IMG]
    So will hopefully be using this to keep egts a bit lower and will be modding to run with wmi and use a relay to drop boost off if a fault occurs

    The only other bit have been thinking about is whether this manifold and flange will limit my possibilitys with a bigger turbo?

    [​IMG]

    [​IMG]

    I did do all the calculations and the port size on mine has a surface area of 1846mm2

    Where as T25 is 1775mm2

    T3 is 2623mm2

    But if i port mine to the point you loose the ring on the flange mine will be 2374mm2

    The t25 and t3 are only correct if the dimensions that i found are correct for them?
    http://www.jgstools.com/turbo/tk010p.jpg
    http://www.jgstools.com/turbo/tk030p.jpg

    All it is that im looking at fitting a GTX3071r with a 0.63 turbine but in a k26 turbine housing, as they supply these housings for gt28-gt35 but don't want to hit the same obstruction as before (being limited by egt temps) due to the turbo or manifold being a bottle neck?

    When Bill mapped it he said you could definately see that the turbo hotside was the restriction on my current set up as it was glowing rather hot ;)

    I want a bit more go as now have got supporting mods all round to take it but would like reasonable spool time hence looking at garrett ball bearing turbs as have got a friend thats got a k26 hotside with k27 coldside turbo where as im told the one ive got has a k24 hot and k26 cold but these turbos are old technology and don't particularly want to go down that route?

    Your thoughts and opinions are all welcome ;)
    #11
  13. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 7, 2012]
    T25 vs T3...
    [​IMG]

    [​IMG]

    <tuffty/>
    #12
  14. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Cheers tuffty but the problem im having at the mo is trying to compare the k26 ones they make for the garrett series as theres not many pictures or details on them :(

    This is off of the ATP turbo site Audi 5 Cyl. K26 flanged Turbine Housing - GT/GTX30R .63 A/R : atpturbo.com

    Lots of other places sell them but only have the same details and pictures and cant really find a lot of info on them on the net as i think a lot of cars that had k26's and k24's and run these hybrids don't have egt sensors like the older audis :(

    Keep thinking about a top mount t3 mani with the gtx3071 but its just more money again getting downpipe modded etc where as should just drop straight into place with the k26 housing but its a gamble whether will be able to extract the power from it?
    #13
  15. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 7, 2012]
    It is what it is mate... feel you r pain... been there a few times myself...

    <tuffty/>
    #14
  16. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Yes mate definately we can both share the pain ;)
    #15
  17. wheatobear
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    wheatobear Member

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    [Feb 7, 2012]
    awesome thread and tbh u sound like my perfect woman u love cars!! haha :)
    #16
  18. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Cheers but you really don't know how wrong you have got it LOL ;)

    All ill say is i didn't get to pick my name :)
    #17
    Big Bang Yam likes this.
  19. wheatobear
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    wheatobear Member

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    [Feb 7, 2012]
    meh im new i dont know anyone here lol
    #18
  20. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Thats alright mate no probs am really quite used to it after all these years ;)

    The best one is arguing with my bank or something over the phone when they ask for miss stacey fenton and refuse to talk to me until i put a couple of f's into them and they realise and are suddenly very apologetic lol
    #19
  21. wheatobear
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    wheatobear Member

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    [Feb 7, 2012]

    lol sounds like a right laugh...why do u hate them A8 wheels they look rather cool it could look as **** as mine with standard wheels on!
    #20
  22. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    I had one of the rstt reps crack in 2 places due a pothole and had a local tyre dealer come out and pic me up and the knackered wheel, as my car had no spare at the time and me and my other half both used the car to commute to work days and nights as she did't have her own car so was pretty desperate to get it sorted asap so paid the tyre dealer to get some newer rs4 reps in that day in the idea id be back on the road same day, and when they came back after waiting 2 hours for them to get them they had the A8 wheels and they claimed that they were the ones i told them that i wanted etc etc and knew that i wasn't in a position not to have a car so had to buy them and the cocks wouldn't even give me any money off as it wasn't they're cock up?? and said take it or leave it with my car stuck in a public car park on an axle stand, think it cost me <£600 for reps :faint:

    Gradually over time each time i looked at the car i started to dislike them more and more in frustration

    They're personally not my favourite alloys but i never used to dislike them think its just the thought of wanting to squeeze this little tyre dealer through the gap in the spokes ;)
    #21
    dj enzo and wheatobear like this.
  23. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 7, 2012]
    LMAO!!!

    Sorry Stacey but you must get that alot ;P

    wheatobear... you have no idea lol

    <tuffty/>
    #22
  24. wheatobear
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    wheatobear Member

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    [Feb 7, 2012]
    wow u got royally shafted!! shud have paid him then beat him up and took ur money back... lol
    #23
  25. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Certinally wanted to at the time was very close to ringing his neck each time he said another word lol
    #24
  26. wheatobear
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    wheatobear Member

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    [Feb 7, 2012]
    haha im sure we have all been there before... i need to find some new wheels... got my coilovers... just want some better wheels!
    #25
  27. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Feb 7, 2012]
    Looks like another homebrew inlet using a Excessive plenum
    #26
  28. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 7, 2012]
    Lot of it about lol

    <tuffty/>
    #27
  29. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Yeah will be using an excessive plenum saw them months ago and it was between that the rmr d plenum and the obx inlet Mani (rmr manifold knock off) with even coming very close to buying an sem but had eventually decided to go with the cheapest option....well what I thought was until I went to check out and they seriously rape you on the postage (rmr plenum) :(
    But seeing you doing yours has really urged me on to do mine and go the same route as in plenum as there's not much in it price wise ;)

    Is it going to be long till yours is on the rollers as should definately be getting good results with your set up ;)
    Last edited: Feb 8, 2012
    #28
  30. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Feb 7, 2012]
    I have more to come as i'm going to ditch the maf and make a 4in/102mm TIP [​IMG]
    #29
  31. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Mmmm maffless lol
    #30
  32. sportstractor
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    sportstractor Chugger

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    [Feb 7, 2012]
    intrested thread, never realised you had so many problems... must have missed nearly all of your posts. It seems like nearly every job has had to be done at least twice.

    lmao wheatobear
    #31
  33. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Yeah certinally feels that way my advice to anyone else don't try and cut corners or do things on the cheap, or sometimes not even on the cheap do it once and do it properly with tonnes and tonnes of research ;)
    #32
  34. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Meant to be a bit homer simpsonish mmmm doughnuts ;)
    #33
  35. ANDYMC_TQS
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    ANDYMC_TQS FIRE UP THE QUATTRO

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    [Feb 7, 2012]
    awesome thread really enjoyed reading it makes me wanna go to tuning college or somethin lol. im good with cars id say but nowhere near this good
    #34
  36. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Thank you very much but I knew nothing before hand I'm a time served mechanical engineer and now a qualified electrician, although got lots to learn on the electrical side yet (having the bit of papers not everything) as I'm only 24 but needless to say always been a petrol head and had a basic understanding of how an engine worked but my biggest problem was I was more than capable to do 90% of things due to my trade but confidence with cars was through the floor as only changed my first set of plugs just before stripping the engine to bits ;)
    Have to say had a MASSIVE amount of help and advise from bill over the coarse of the build as most over tuners answer was well if you bring it to us and we'll have a look
    I also had a friend help me build the bottom end as had never seen one in bits and it was a no brainer as he does it for a living but all in all it's a lot less scary than everything first seems :)
    #35
  37. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 7, 2012]
    Stacey you sounded like my perfect woman till I met you and I think you're a bit to butch for my liking :moa:

    You have had some serious bad luck here bud but you know that engine like the back of your hand now.

    I'm pretty sure you'll have the turbo situation sorted in the near future :eyebrows:
    #36
  38. ANDYMC_TQS
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    ANDYMC_TQS FIRE UP THE QUATTRO

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    [Feb 7, 2012]
    i think i just worry too much about always having to get things right first time but from now on im just gonna try ideas and if they fail try another. il get there with my build one day. to be completely honest i just wanna pull my engine out and rebuild it
    #37
  39. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 7, 2012]
    Couldn't even finish the first sentance without pissing myself laughing ;)

    And I think your right mate will definately sort something out...... But what is the question ;)
    #38
  40. Alais DJA
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    Alais DJA Member

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    [Feb 9, 2012]
    The first picture in the build should have given it away
    #39
  41. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Feb 9, 2012]

    .......but will you ever actually get it finished and running is the question... mod after mod after mod, delaying the actual getting it running bit...

    you scared of what it might do or summat? :p lol

    and as for 4" intake - enjoy


    [​IMG]
    Last edited: Feb 9, 2012
    #40

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