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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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    [Jul 7, 2012]
    The pistons definately look a lot worse and looks like one of the pistons and rods has been changed as casting marks on the rods are slightly different and piston is in good nick with no damage, but iirc that was cylinder 3?

    Will chuck some pics of the pistons up shortly athough the markings/numbers have rubbed off so can't define which was no 1 :(
  2. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 7, 2012]
    I think this is the order they were in but not entirely sure

    [​IMG]

    First one as lined up in the pic

    [​IMG]

    Forth as they're lined up

    [​IMG]

    Cheers Andrew was hoping for your advice ;)
  3. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Jul 7, 2012]
    Thats bad

    Lots of det there

    Me personally would fit new pistons.
  4. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 7, 2012]
    Pistons will be new and probably 83mm bore this was just a spare engine I picked up on the basis I could build the bottom end up and just swap it with mine then same with the head at a later date ;)

    Do you think the head will be ok to use?
  5. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Jul 7, 2012]
    They look like theyve seen better days mate.

    83mm pistons, will that make the engine into 1900cc or just a bit over?
  6. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 7, 2012]
    Definately seen better days mate was hoping to recoup some money by selling bits but don't think they'll be any good for resale? :(

    Cc wise I'm not entirely sure what 83mm will achieve but I know that with a certain crank it's 2008cc iirc :whistle:
  7. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Jul 7, 2012]
    The head can be fixed easy

    Depending how much its been skimmed already but if it was me i would do a bit of welding to the face of it were the get has marked it then skim it to the minimum amount

    83mm bore with a 1.8 crank will give 1900, with a 2.0 crank 2008 and with the 1.9TDI crank 2067 like mine

    There are other cranks out there that can be used rather than the FSI crank
  8. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 7, 2012]
    Cheers Andrew appreciate the help :)

    Do you know if there is an area or notch that I can measure to work out if it has been previously skimmed and if so how much?

    I suspect I will be contacting you at some point for some prices for headwork, as much as I want to do it myself theirs only so much I could do and feel it'll probably be best left to the experts ;)
  9. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 8, 2012]
    I've not previously mentioned but had noticed some issues with my dv, and after discussions with various people and forge they sent me a refurb kit and a revised piston :)

    [​IMG]

    [​IMG]

    I then thought that whilst the box was off it was the perfect opportunity to mod the shifter to make a short shifter

    So far have done the forwards and back one and will do the side to side later on if nothing major breaks at work ;)

    [​IMG]

    [​IMG]

    [​IMG]
  10. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Jul 8, 2012]
    Stace, you are on a mission mate! Are you removing all this in the rain too? I just wan to take my car out for a spin as its been garaged for a week and I can't even do that because of the rain!

    Keep up the good work :thumbsup:
  11. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Jul 8, 2012]
    i think i have some info about and maybe able tell you how thick a standard unskimmed head is

    not a problem on the the head work
  12. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Jul 8, 2012]
    If the head measures less than 139.2mm high then its scrap

    I might have measurements for a brand new head somewhere?
  13. Sam_
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    Sam_ Down under

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    [Jul 8, 2012]
    Blimey that looks like some hardcore det. Was it knocking/pinking at at all?

    Probably explains the high EGTs?
  14. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 8, 2012]
    Cheers mate, not in the rain today as am at work all day but expect I will be tommorrow or another day this week as have got to fit the box and have got a week booked off holiday although I'm going to be in 1 day on ot already ;)
  15. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 8, 2012]
    Cheers mate ;)

    Have just measured it at 139.4 so not far off but not sure how much they usually take off when skimming it, suppose it all depends on the state of it?
  16. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 8, 2012]
    Don't have a clue how it was running mate as was removed from the car when I bought it and the reason I've done so, is so that I can build it up at my leisure and still have a running car to drive around in ;)
  17. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 8, 2012]
    Well had a bit more spare time this afternoon so have done the side to side shifter
    All in all I should have reduced the throw 30% and the side to side 27% which the forge throw is up to 40% and they don't state what the side to side is so just went with a reasonable position ;)

    [​IMG]

    [​IMG]

    [​IMG]

    I had to make some tools to stop things getting damaged and to support it when I pressed the pin out as the steel plate one is a lot more flexible than the cast and when pressing it out it wanted to turn into some U shaped thing lol

    [​IMG]

    I've also found myself a reasonable sized cable to do the battery relocation at some point, ideally I'd love to put the WMi in it's place but really can't be arsed so not entirely sure what I'll do as had originally planned to get a monstrous filter like bills green cotton but have already bought a k&n like hollies TT??

    Well at least I've got it for when I need it

    [​IMG]
  18. Sam_
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    Sam_ Down under

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    [Jul 8, 2012]
    Ah, this is the donor engine! Oh, that's cool then. And yeah, good idea to build it along side. I plan to do the same. I've just sourced an AGU lump for my build. Still about 1,000 miles away mind you heh
  19. Rosso TT
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    Rosso TT Member

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    [Jul 9, 2012]
    Hi stacey, didn't you weld the pins in the levers?I did weld mine in although the gear lever is made out of cast iron, i welded it with some weldall rods (high nikel content rod) for peace of mind, still going strong after 5 years.
  20. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    Think that's certinally the way to do it wish I had on my first build although that wasn't planned it was reactive ;)
  21. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    No didn't bother welding them, they had to be pushed in on a press but had counter sunk the hole on the other side and crowned it over with a ball pein hammer (riveted) like it was originally ;)

    Idea is if I don't like it I can return it back to how it was easily enough and to be honest didnt even cross my mind about welding it lol
  22. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    Well TSR have pulled through and the Mani has turned up and to be honest im impressed with the quality and the way it's made, the collector looks quite intricate

    Pic next to my old MTM one

    [​IMG]

    [​IMG]

    Collector and have noticed the v band looks like it's had a dink at some point around the top of the v band and has been polished out

    [​IMG]

    The v band on the wastegate looks like it's had a file run over it to remove some spatter or something not sure if this will effect things

    [​IMG]

    I pressume if this isn't a nice smooth/ground finish it won't seal without a gasket?
  23. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jul 9, 2012]
    Looks like they have fattened up the wastegate outlet but still in the same place as the one the LCR had... that means the Tial is gonna hit the gear cables...
    [​IMG]

    [​IMG]

    Do a test fit mate...

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

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    [Jul 9, 2012]
    ...although now looking at them side by side yours looks like it doesn't curve round towards the flange as much... maybe its what they did improve the clearance?

    <tuffty/>
  25. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    Yeah after speaking to bill and reading James thread the wastegate tube should be bigger and the v-band for a tial 44mm wastegate ;)

    The new tial mvr wastegates are supposed to be considerably smaller than the old 44mm but how that compares to the 38mm I haven't a clue?
  26. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    I know that tsr did actually speak to bill directly at one point after I had spoke to them about my concerns and afaik he did advise of certain changes but not sure what changes and which ones they went ahead with.....time will tell ;)
  27. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jul 9, 2012]
    44mm MVR...
    TiAL Sport.com

    38mm MVS
    TiAL Sport.com

    The LCR had an MVS like mine... that hit... I would imagine the MVR is a little taller... I would still test fit it though mate..

    <tuffty/>
  28. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    Yeah will be best bet, I've even got a spare gearbox, block and head now ;)
  29. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Jul 9, 2012]
    Guys. I'm well out of my depth in this thread now :( I lost count of how many times I had to say to Stacey "I don't have a clue what you're talking about" when we were talking at Inters lol.

    What's the benefits to an external wastegate?
  30. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jul 9, 2012]
    a non compromised hotside, and better management of boost on high flow...
  31. superkarl
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    superkarl MAN OF STEEL

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    [Jul 9, 2012]
    noob


    stace, thats some nice engineering porn you have there.
    really nice piece of kit!
  32. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    Lol iirc the main one was talking about a screamer pipe which is when using an external gate the pipe from the wastegate goes straight to atmosphere rather than back into the dp ;)

    But all in all advantages are what bill said and to work on though I swear they're as a whole a complete pita
  33. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    Lol ;)

    Cheers mate I nearly made a mess in my pants infront of the misses when opening it ;)

    She did get the hump after a while asking how long I was gonna bloody look at a lump of metal lol
  34. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 9, 2012]
    Cheers for that bill I certinally couldn't into words like that ;)

    What's your thoughts on the wastegate pos and the finish on the v-band?
  35. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 10, 2012]
    Well hopefully should have it up and running today as spent 5-6 hours on it yesterday and have got box + transfer in, subframe bolted back up, mounts on, dp on, one driveshaft and a few other bits and bobs ;)

    Question just wanted to clarify is that can anyone confirm how much oil the box needs as my local audi dealer seemed a bit unsure but said 2.6 litres?

    Cheers
  36. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jul 10, 2012]
    the seal face is the fire ring which will sit into the small counterbore, the other face should be ok. Not usually a linished finish tho I have to say.
    position... hard to tell from the picture.. the manifold is subtley different to james's LCR one.
  37. Rosso TT
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    Rosso TT Member

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    [Jul 10, 2012]
    That mani is a work of art.BTW what size are the runners, thickness of the tubes and diameter of the turbo vband?
  38. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 10, 2012]
    Cheers mate I do love it ;)

    Will have a measure when I get in although won't be that accurate as not got any Calipers at home but will try my best with a tape


    Car is all up and running and have been out for a few drives today and it is going like the clappers lol

    The short shifter is taking a bit of getting used to but is an improvement

    The boost problem I had previously I think could have also been related to the dv spring as boost is now going higher than I have ever seen it since it's been mapped I'm now seeing spikes around the 1.65 bar mark, which I had never seen prior but it does seem to be holding the boost better as well :)
  39. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Jul 10, 2012]
  40. StaceyS3
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    StaceyS3 Well-Known Member

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    [Jul 10, 2012]
    Thank you very much mate, didn't have to go to the lengths of starting another thread for me :) :beerchug:

    Suppose that'll bring my compression up reasonably with the thin gasket and that much removed off of the head?

    I've just ordered over the weekend, some JE 9.0 CR pistons so expect that'll raise comp a lot? Read somewhere that the thiner gasket raises it 0.3 or 0.4 on the CR so expect with the head will be knocking on 10.1?

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