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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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    [Mar 4, 2014]
    Managed to get half hour in the garage and started measuring journals

    Only had time to measure the mains

    [​IMG]

    I got these measurements which are pretty dam consistant journal to journal, which were all measured in multiple positions

    [​IMG]

    Will have to check them to VAGs tolerances when am next working on it

    I did check the mic to the setting gauge after and it appears it is undereading by 0.01mm so will add that to the recorded results :)

    [​IMG]
    hoffmanvp3, <tuffty/> and ScottD3 like this.
  2. StaceyS3
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    StaceyS3 Well-Known Member

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    [Mar 10, 2014]
    Not a great deal of time spent in the garage again as is all work with a very little bit of downtime in between

    Measured and inspected the big end journals and pistons

    The big ends have got a few scratches and marks on them which are pretty deep and can be felt easily with your nail and even by touch :(

    [​IMG]

    They also have a few horozontal marks which is almost like has been chattering or something of that description?

    [​IMG]

    Pistons are showing some wear already on the skirts

    [​IMG]

    [​IMG]

    The piston measurements were taken on the lower and higher parts of the skirts that are showing the wear and they were all taken from front to back on the piston

    The measurements

    [​IMG]
  3. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 10, 2014]
    Forged pistons need bigger clearance until there up to temp when they expand.
  4. StaceyS3
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    StaceyS3 Well-Known Member

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    [Mar 10, 2014]
    Yeah especially the JE's as iirc are made out of 2618 alloy which rate of thermal expansion is higher than your usual piston alloys??

    Main concern is that has already worn at least 0.05mm

    Ps had forgotten but will check the haldex for you ;)
  5. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Mar 10, 2014]
    No rush
  6. Sam_
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    Sam_ Down under

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    [Mar 10, 2014]
    Did you get any piston slap when cold? I heard the JEs slap a bit. Also, was the block bored with a torque plate?
  7. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Mar 10, 2014]
    measured the bores?
  8. StaceyS3
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    StaceyS3 Well-Known Member

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    [Mar 10, 2014]
    There was noticeable slap when cold and may have just being paranoid but thought it got worse the older it got

    Didn't use a torque plate but One wasn't used on the last block and that covered plenty of miles with no issues
  9. StaceyS3
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    StaceyS3 Well-Known Member

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    [Mar 10, 2014]
    Not yet that is the next task when get 5 mins, I know they were within JE's specs after machining as I thoroughly checked when questioned the rather large ring gaps

    Will post up dimensions when I get them down :)
  10. s3dave
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    s3dave TFSI Hybrid

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    [Mar 10, 2014]
    I thought Torque plates had to be used for an over bore? ..
  11. badger5
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    [Mar 10, 2014]
    not "have" but some say you do others say not required.

    I've not had any of mine done.
  12. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 6, 2014]
    Affraid nothing to report on the S3 apart from the car looks a mess and that it's rotting away :( have promised myself that once the 2 big secondary jobs are completed I'm having some time out which will allow car progress

    On another note done some work on the golf as had a mysterious clonk and knock which is different to the usual

    I had suspected the rear wishbone bushes

    I found that one of the antiroll bar mounting nuts had broken off of the inside of the wishbone so had to cut it open to remove it

    [​IMG]

    The bushes were very soft and a bit perished

    [​IMG]

    But found that the actual cause of the knocking must have been were a bolt had been rocking back and forth opening the mounting hole up to an oval

    [​IMG]

    [​IMG]

    Although I had a spare subframe sitting in the garage for the S3 I decided to repair the other in situ, but on another note it looks like the subframe I bought has solid mounts?

    [​IMG]

    [​IMG]

    I then went on to weld up the current one (complete pita under the car on stands upside down) , this is the results after welding and tidying up with the grinder and dremmel

    [​IMG]

    [​IMG]

    Hopefully that's the clunk all gone as was terrible and embarrassing whilst lift sharing lol

    Need to order some new mains bearings and next stage is plastigauging the bottom end
    <tuffty/> likes this.
  13. Prawn
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    Prawn My other car is a MINI!!!!

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    [Apr 6, 2014]
    Good work Stacey :)

    DId you build up the material around the hole then grind it all back to shape? Sounds like effort!

    I'd have just mig'd a big penny washer over it and called it fixed :laugh:
  14. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 6, 2014]
    Haha yeah that would of been the easier option that to be honest didn't even cross my mind

    Am so used to building parts up and remachining them with my old job where had no spares that I just delved straight in :)
  15. Gops
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    Gops 6th gear @7000rpm

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    [Apr 6, 2014]
    Good work Stacey! Need to read a few pages back, seems I've missed so much!
  16. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 16, 2014]
    Cheers mate but to be honest not a huge amount has happened apart from lots of talking about doing stuff and the car rotting lol

    Hopefully these were collected today and will be on there way to where they need to go

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

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    [Apr 16, 2014]
    Looks like you've ordered a massive dildo!
  18. Gops
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    Gops 6th gear @7000rpm

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    [Apr 16, 2014]
    Stacey you dirty bugger. Keep your "toys" in the garage!
  19. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 17, 2014]
    Haha dirty boys

    Ones the head which is heading to Andrew and other is crank and flywheel for journals to be polished and fly to be refaced and balanced

    On another note got an interview today :)
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  20. Jay A3
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    Jay A3 More power

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    [Apr 17, 2014]
    Bit more than a pocket rocket ;)
    Good luck with the interview bud.
  21. badger5
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    [Apr 17, 2014]
    hope that crank trigger wheel does'nt get bent in transit... :(
  22. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 17, 2014]
    Thanks, think it went well but will have to wait and see :)

    Car should hopefully go like a rocket when finished :p
  23. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 17, 2014]
    They would do very well to bend the trigger wheel as the fly is bolted on there and there's multiple layers of cardboard.....although this is yodel were talking about!

    The head has got hardboard cut to size to protect one side and an offcut of my laminate flooring on the other lol
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  24. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 20, 2014]
    Can anyone reconmend a good particular break in oil as doing an order tonight with opie oils with a 25% discount code?

    On another note placed a big order with euro's yesterday, just got a few OEM parts to order, cams, turbine housing and clutch :)
  25. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Apr 20, 2014]
    Inspecting the head next week
  26. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 20, 2014]
    Cheers mate kept meaning to drop you another text to check it had got to you safe and sound ;)

    How's yours coming along? Expect like me to much to do and no time to do it
  27. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 20, 2014]
    Cheers mate kept meaning to drop you another text to check it had got to you safe and sound ;)

    How's yours coming along? Expect like me to much to do and no time to do it
  28. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 20, 2014]
    I just used this from ECP..
    TRIPLE QX 15w40 Mineral Engine Oil 5Ltr

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

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    [May 2, 2014]
    Cheers Paul :) ended up getting some specific run in oil from opie in the end as was dirt cheap with the discount

    On another note I've just got a promotion at work :) , I'm over the moon that I'm now the engineering step up team manager and first day is on Monday.... not bad for coming out of probation 3 weeks ago ;)

    I've had some bits show up, nothing special only consumables but one of the packages from euro was soaked as the g12 had leaked so didn't accept that one

    [​IMG]

    Managed to get a couple of hours in the garage yesterday and finished mic'ing the bores

    Measured at the top front to back and side to side

    [​IMG]

    [​IMG]

    Also measured half way down front to back and at the bottom about 10mm in both ways

    [​IMG]

    These are the measurements I got, for speed as my mic is imperial I done a quick conversion which is noted in the bottom corner and used that as a gauge which will explain how I got figures down to 0.001mm

    [​IMG]

    [​IMG]

    I checked the journal sizes I've got recorded to vags specs and it's within tolerance but only just so that may explain the oil pressure? I will plastigauged it when I get it back and will go from there but may send it off for a regrind?

    The bores and pistons will check soon when I've dug out JEs specs
  30. StaceyS3
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    StaceyS3 Well-Known Member

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    [May 9, 2014]
    Managed to get a little bit of time on car stuff over the last week

    I thoroughly jet washed the block down last Sunday, followed by blowing out all the gallery's and leaving it to dry in the fine English sun

    After the cleaning I then masked the block up ready for painting

    [​IMG]

    After which only had a few spare minutes so looked at the oil filter housing....to which I made a discovery.....this one way/ pressure relief valve (unsure of its purpose) was loose free turning in the housing :(

    [​IMG]

    [​IMG]

    Suspect this could have had an effect on oil pressure although the strength of the spring inside the little critter can be blown open with my mouth which suggests it's more likely to be a one way valve or flow restrictor?

    I then this afternoon managed to get a couple of coats of hammerite on the block and to start stripping the box :)

    [​IMG]

    [​IMG]
    s3dave likes this.
  31. g60leigh
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    g60leigh Well-Known Member

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    [May 9, 2014]
    I had a oil pressure problem on my old A4 1.8T. Changed pump, pick up and all sorts. Turned out to be that little valve.
    May be worth replacing mate. Think it was about 3 quid from memory.
  32. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 9, 2014]
    Hah!... beat me to it on the gearbox lol :)

    Good work mate..

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

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    [May 9, 2014]
    Cheers Leigh hopefully will sort it out or at the very least bring the pressure back up some ;)

    It's frustrating how something so small and you'd think trivial can potentially destroy £1000's and hours and hours of hard work :(
  34. StaceyS3
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    StaceyS3 Well-Known Member

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    [May 9, 2014]
    It's been a long time coming as got 2 broken boxes both with knackered selector forks, maybe I need to be a bit more gentle with the DSG like shifting lol

    Also forgot to add that it is the reason the car was brought off of the road in September :(
  35. superkarl
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    superkarl MAN OF STEEL

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    [May 10, 2014]
    are you upgrading the selector fork??

    i remember looking at an aftermarket one, cant remember who made it
  36. Sam_
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    Sam_ Down under

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    [May 10, 2014]
  37. StaceyS3
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    StaceyS3 Well-Known Member

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    [May 10, 2014]
    Unless it's the brass part of the fork broken I will be strengthening it by just welding a high tensile bolt in there and grinding it off

    I will probably replace the diff crown wheel rivets whilst open with either some form of high tensile bolt or stretch to ARPS :)

    Am keen to hear other ideas suggestions and opinions of work whilst it's open
  38. Prawn
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    Prawn My other car is a MINI!!!!

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    [May 10, 2014]
    eek. Selector forks!

    These are my one big worry with the 02M.
  39. Sam_
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    Sam_ Down under

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    [May 10, 2014]
    Yeah, I don't think I can risk having to get it all apart again. Going to get the both forks I think (they don't do a 5-6). Wish I had the space/tools at home to do this sort of stuff myself...
  40. StaceyS3
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    StaceyS3 Well-Known Member

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    [May 16, 2014]
    Think they can be looked after, but if you don't treat the shifter with a lot of mechanical sympathy it will soon let you know about it

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