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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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    [Aug 22, 2012]
    Yeah very true i remember reading somewhere that it is still a 35w lamp usually supplied in the 55w kit with 55w ballasts so in theory will still only be 35w of output
  2. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 2, 2012]
    Little update but not really been up to a lot though

    Can't remember if already mentioned but dropped the block off to be bored last Tuesday and still not heard anything so going to chase up Monday

    Stripped my head today ready to be shipped to Andrew, heres a few pics

    Pikey stand just using some studding lol

    [​IMG]

    Bare head

    [​IMG]

    [​IMG]

    [​IMG]

    I also painted the aux mounting plate as was badly corroded so just wire brushed it which did make it all nice and shiney but thought I'd still go ahead and paint it ;)

    In the process

    [​IMG]

    Finished product

    [​IMG]

    I do like it but am unsure wether to use this one or my current one that's on the car as one will be sold with my current engine and head once I've done a bit of work to it and refurbed it all (block decked main priority) so will decide nearer the time

    Besides that all is waiting on a 2.0tfsi crank and a few oem bits (in other words funds lol as not had ot for 5 weeks) but as soon as I've got these things it will really start moving

    Got 60 hours overtime next week so hopefully all will get rocking and rolling

    Shameless plug but if anyone knows of any 2.0tfsi cranks going at the mo could they pm me ;)
  3. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 2, 2012]
    Well on my short commute home i saw a distant relative chucking his mk 4 golf gti about that he has recently bought and he was doing so chasing an fiesta st so at the next round about doubled back to catch up and have a bit of fun then when we eventually got to a bit of clear road where it opens up to 2 lanes gone to pass them both, got to the top of 4th then into 5th just as passing them then pop ad loss of power....DOH! always happens at the best times and most embarrising times after pushing them along for a while

    Any ways usual procedure coasted to nearest turn off and have a quick chat and feel like a complete tit then unplug the maf and limp home

    When i got home i found

    [​IMG]

    [​IMG]

    Yes i know i should of heat sheilded it
  4. superkarl
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    superkarl MAN OF STEEL

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  5. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Sep 2, 2012]
    Christ! You've done that properly lol.
  6. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 2, 2012]
    Has certinally failed catastrophically but got to admit i had one fail straight after fitting the conversion but that was only a standard silicon hose so had put it down to that it was just a normal one but even this nomex one i got from QST for £130 iirc (was desperate and they done a sat morning delivery) certinally wont have my pants pulled down again if i can help it lol
  7. superkarl
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    superkarl MAN OF STEEL

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    [Sep 2, 2012]
    I reckon you love it.
    that is seriously expensive. and most of us think the forge one is a rip off!
    do you still have the original heat shield jacket thing? that would be ideal.
    has anyone found that sort of material at all?
  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 2, 2012]
    The Forge one for the K04 is actually cheaper than buying an OEM one... Forge is 50 ish quid vs OEM at 100 ish quid...

    The Forge one is more heat/oil resistant than a std silicon hose too... Stacey's looks like a generic hose tbh and certainly not worth the 130 asking price... thats MTM sadly and its technically smaller than the K04 one!!

    <tuffty/>
  9. superkarl
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    superkarl MAN OF STEEL

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    [Sep 2, 2012]
    yeh lined with nomex or something.
    (googles it to see what the hell it is)
  10. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 2, 2012]
    Karl lmao ;)

    Afaik the one i got is nomex and was made specifically for this kit but the biggest problem ive got is the hose i need is longer than normal 90 degree elbows and feel i may be using some joiners and couplers to get it sorted

    Dimensions on the hose are 90-51x180x140HT although it has been about 15mm shorter for a while as i cut through it with the jubilee clip, but pressume the HT stands for High Temp??
  11. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 2, 2012]
    Oh and forgot to say i did have the heatshield jacket but over time it has broken up and fell apart at the seems, i did keep stapling it together but over time started to run out of material
  12. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Sep 2, 2012]
    Is there anyway you could use mainly a metal hose with a 3" silicone joiner each end?
  13. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 2, 2012]
    Heatshield is key... I still use the original K04 heat boot whotsit on mine and its a std Forge/Silicon Hoses 51mm to 63mm reducer... granted I am not sure how long it would survive if I ragged it more regularly than I do but heat wrap and heat shield will be your friend and something that "always" gets overlooked on builds these days... I have seen quite a few shockers including the use of the foam back reflective stuff used behind a household radiator... fine for 60 or so degrees of radiant heat but not a 1000 ;P

    Nomex or not, that close to 1000 deg heat will ruin anything if not protected...

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

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    [Sep 2, 2012]
    Great minds think alike :friends:

    Was just looking on ebay for that exact thing and think it will be easiest solution as will need 1 alloy 51mm 90 degree elbow and was looking at 51mm x 250mm straight coupler in black to cut and use each end and will have spare left over for future blow outs lol

    Had decided a while back that on the new charge pipe would probably only use a straight coupler or reducer and try to do the rest in alloy to eliminate as many issues as possible
  15. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 2, 2012]
    Is it 51mm at both ends? thats crazy...

    I modded my OEM charge pipe (MTM mod it too I believe) like this...
    [​IMG]

    Short silicon reducer and heatshielding... :)

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

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    [Sep 2, 2012]
    It has been popping up in the back of my mind for a long time but just kept telling myself that will all be changing it shortly so hadn't bothered (not the right attitude i know) lol

    Suppose it doesn't help that mine naturally runs red hot with normal use :)
  17. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 2, 2012]
    The reducer/modded charge pipe is embarrising they stick a pipe inside a pipe and same again to reduce it but the welding is terible and not tidy at all certinally not what you would expect for the price of their conversions, gops has only had his a week or two and was asking me how bad my charge pipe looked as he though his was a bit of a joke
  18. superkarl
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    superkarl MAN OF STEEL

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    [Sep 2, 2012]
    google tells nomex starts to degrade at 500 degrees. no melting point though, but obviously the silicone does.
    if i were you stace id do what tuffty has done to his, use so plain thick ply silicone, and make a shield like prawns.
  19. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 2, 2012]
    Yarp... silicon isn't good with a lot of heat... check out this pic of one of Bill's hoses from the 'turbo coming loose' incident...
    [​IMG]

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

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    [Sep 2, 2012]
    Had found a extra high heat hose made out of a glass fibre but is £££££ and 5 week wait so a definate no no

    Think will do it with an alloy 90 and 2 couplers as is readilly available and can get it sorted quickly

    Will it be ok to drive it to work with the maf disconnected and keeping it stupidly low revs to stop the turbo from over spooling as was no where near as bad as when used to blow a hose off of the k04 and could hear it spool its nuts off every time you hit the throttle, as this could drive without hearing the turbo spinning like mad with no resistance??

    Main problem being unfiltered air being drawn into the engine i suppose??
  21. Lewis583
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    Lewis583 Active Member VCDS Map User

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    [Sep 2, 2012]
    [pikey_mode]

    Gaffa tape the hole up until you get a replacement in place and stay off boost

    [/pikey_mode]

    :jump:

    Better than having a big hole in the system
  22. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 3, 2012]
    Gaffa tape lol think I would be worried it'll all go up in flames

    Well left the car at home and got the misses to give me a lift to work at quarter to 6 the morning, which I think she wasn't best pleased about ;)

    Anyhow have made a few phone calls and have ended up getting a 90 degree 51mm alloy elbow and 250mm of straight black silicon hose 51mm so will have some left over for if it happens again and all will be here tommorrow ;)
  23. Prawn
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    Prawn My other car is a MINI!!!!

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    [Sep 3, 2012]
    that's failled exactly like mine did Stace! ******* things. since fitting my heat shield it's been fine, but i'd rather get some form of wrap around alloy shielding around the hose as well.
  24. beachbuggy
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    beachbuggy Well-Known Member

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    [Sep 3, 2012]
    Could you not use Exhaust heat wrap?
  25. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 3, 2012]
    I think for now will chuck some form of exhaust wrap or just knock up a heatshield to get me through to when I rip it all out, certainly hasn't got to be anything pretty for the short duration ;)
  26. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 5, 2012]
    Pipework arrived yesterday and bodged it in there in the dark last night to limp me to work this morning

    I've had to cut a fair bit off of one of the alloy legs but it all sits alright now, I was tempted to use some alloy mig wire to put some beads on there but haven't got the correct gas :(

    So for now have cowboyed it a bit and have scored the pipe up as well as a small amount of superglue as well as te obvious jubilee clip, not sure how it will hold up with the heat but should be alright lol

    Couple of pics in which you can also see the glorious welding on the charge pipe reducer

    [​IMG]

    [​IMG]

    Will put some heat protection on there when I get a chance, but at least I'm on the road again ;)
  27. Prawn
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    Prawn My other car is a MINI!!!!

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    [Sep 5, 2012]
    Beast. Looks proper ebay spec that does!
  28. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 5, 2012]
    Good old mr silicone ;)
  29. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Sep 5, 2012]
    Looks properly pikey haha.
  30. Sam_
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    Sam_ Down under

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    [Sep 5, 2012]
    This month's calendar looks alright.

    Also, nice work on the engine... Jealous of people having loads of room/tools to work :(
  31. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 5, 2012]
    Cheers for the comments guys....maybe I like the tackyness lol

    I'll try to include some more calendar shots just for you sam I do quite like September on another calendar in the workshop, may sling a photo up just for you ;)
  32. Sam_
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    Sam_ Down under

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    [Sep 6, 2012]
    Good work... Just don't let the mrs see this thread
  33. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 6, 2012]
    Lol she started secretly reading it a little while ago as noticed she had mentioned a couple of things I had talked about on here and when I asked her she said she had read a tab I had left open on the laptop

    Anyhows the other half picked up my block for me yesterday (no lifting just taxi service lol)

    All seems good and well, the bores have been machined to the piston specs and had the deck faced as was 3 thou discrepancy across the face in various places and as some of you may know I have had problems in the past with headgasket sealing due to the current block face that is in the car

    Here's a few pics

    [​IMG]

    [​IMG]

    One just for Sam ;)

    [​IMG]

    The 1.8t cupboard at work is getting there lol

    [​IMG]

    Am hoping to gap the rings this weekend if I get a chance :)
  34. Sam_
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    Sam_ Down under

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    [Sep 6, 2012]
    Awesome looking 1.8tea cupboard.

    Also, the block with a September backdrop looks awesome.
  35. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 9, 2012]
    Well i thought id crack on and gap the rings ready for when i find a crank

    The oil ring were straight forward enough and only 2 needed some material removing, but have to say the extra oil support ring that sits under the usual 3 was a bit of a pita to get on as this one hugs the piston tight rather than the bore compressing it, but once had got the hang of it, it was alright

    JE's advised gaps

    [​IMG]

    The middle rings where really inconsistant and had gaps of up to 23 thou before any material was removed which is strange??

    This then lead to checking the bore dimensions and clearances but all was ok there??

    After putting the rings one by one into the same bore at the same position it become clear that 3 out of the 4 had a reasonably bigger gap than they possibly should do and the last one was 16 thou which is alright as it gave me something to play with to get the correct gap of 18 thou

    The top rings all had 12-13 thou gap and i took all of these to the required 16 thou, so this leads me to believe that i may have got some middle things that must have passed Q.C or something?

    Will be in touch with IE and JE shortly to see if they could send me 3 more rings?

    Heres a couple of pics although nothing to interesting

    [​IMG]

    [​IMG]

    [​IMG]

    Like to say cheers to Prawn for pointing me towards this ;)

    [​IMG]

    And also a cheers to Bill for the usual question answering and advice :)
  36. BuuBBa
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    BuuBBa Member

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    [Sep 9, 2012]
    Looks sweet!

    Whats the dome volume of the pistons?
  37. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Sep 9, 2012]
    I need to get me one of them sumps at some point

    You will find the JE rings will need very little if no work at all when it comes to end gaps thats if you have had it bored to JE specs
  38. superkarl
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    superkarl MAN OF STEEL

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    [Sep 9, 2012]
    just a bit of advise stace, dont be using that tomato ketchup as assembly lube. Hp brown is MUCH better
  39. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 9, 2012]
    The pistons are 83mm 9.0cr pistons made to IE's specs which when mated with a 2.0tfsi crank will give 2008cc

    Hope the info you wanted is in there somewhere?? As for actual volume for the dome I've not got a clue ;)
  40. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 9, 2012]
    The sump plates are brilliant especially for the money, and is quite handy I've got a spare sump to chuck them in ;)

    As for the rings it's just the fact that they're so inconsistent in size with the middle rings as the top rings all gave a gap within 1 thou to each other and were quite a bit tighter than the smallest specced gap where as 3 of the middle ones where quite a bit different?? Will see what ie say? :)

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