superkarls overhaul

Yeh its coming together at last.
Will have more updates after Saturday. Picked up the TIP from the welders which is niiiice. And will try and fix my pas pump.
I really need to paint my pipework, but think I might just fit it all as is to get it running. Then tart things up once its on the road.
 
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Painting stuff is the future... I can recommend using the Rustoleum Hard Hat range of top coats along with a good etch primer :)

<tuffty/>
 
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See after seeing your painting masterpiece im now torn between wrinkle black which is easy and no top coat required. Or a nice clean colour which obv requires better prep and a little more care. My inlet mani is already wrinkle black tho. I might put some time on the rocker cover
 
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If you plan to just stick everything in to get it running then go with wrinkle. Nice quick easy job!
 
Good to see it all coming together.

You must be gagging to get it running again.....good luck!
 
Id be careful with wrinkle black mate, even when dry it deforms if pressure applied round charge pipe brackets etc and my cam cover has flaked like hell, even when properly applied etc.
 
Didnt do a great deal at the weekend.
Fitted the TIP which has been welded up.
Fitting power steering lines up, and also checked the pump and the inlet.

This is the inlet of it, with a rubber o-ring/seal on it, this just pulled and wiggled out with little force:


This is the inside of the pump:


There is literally no way other than inteference fit that this stays in, no locking ring, nothing. So im going to fit it and just let it do its thing, keep an eye on it.
 
had a weekend inspired by tuffty, firstly with heatshielding. First though id forgot to put a jubilee on the coolant pipe to turbo:

was fiddly.

So id bought a coilpack loom:

Which had a nice new piece of heatshield on it i could utilise:

some stainless zip ties:

and it was on:


same can be said for the oil drain and the other coolant pipe.

I also utilised the old heat shield jacket that went on the turbo outlet/elbow, and figured id do the same for this turbo as it has a silicone 90 (not a nomex one) right above the manifold:


Il permantently secure that once everything is sweet

Next i seperated the evap from the coolant line that goes acrss the bulkhead:



Other jobs included replacing the coilpack loom, which i think ive managed, westys guide wasnt loading up on my phone when i clicked the link in his index. My dad did most of it so im sure it will be ok. Old one was nakered:



Couple of issues, the N75 and N249 plugs looked like this:

so ive got new ones.

Fuel filter was installed:


Other jobs not pictured included making shims out of silicone for my S3 maf to fir the 90mm tip. Took the RS4 maf out for now for obv reasons.
And thats all for now

:superman:
 
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Its all the little jobs that seem to take the time but good progress :)

<tuffty/>
 
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Can't be bothered to look back through the thread as I haven't looked at this thread for a while, but I like what I see on this page!
 
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OK OK

I seem to be finding things to do now, rather than rushing into starting it, paranoia perhaps.
Theres still a couple of jobs need doing:
Decat
Fuel pump
Boost gauge
Fluids
forgot to put the sides of the undertray on

Progress lately has been getting it to this:


My main concern at the minute is tackling the fuel pump, ive forgotten what needs to be done so i need to do some more homework


Under the dash i cant figure out whats going on, thought i needed a second 409 relay which i have, but underneath the dash looks different to what i expected, and different to some guides online. i took this for my own reference/comparison:


Boost gauge, so i can see wtf is going on when i do eventually take it out. routed the boost pipe for it through a neat little gap behind the arch and into the door hinge cavity, where there is a grommet containing the drain tube for the sunroof, which takes the boost feed under the dash.


For now the gauge will be professionally velcro'd to the dash until i have a neat and more professional solution in the form of a pillar pod


Thats all i have for now. Need to sort out insurance before i go away at the end of the month, dont know if il get it all started by then or when i come back. Taking each week as it comes. trying to do things right = slowly
 
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P.s. Any links to a decent pillar gauge pod will be appreciated. Gonna have to spray that gauge surround black too, cant be doing with that silver looking at it
 
There's slowly and then there's dave's pace!

It is coming along nicely mate. Cracking work
 
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superKarl,

It is looking awesome!!!!!

Scullies has a custom Dual Pod that he fabbed into his S3. Perhaps he would be nice enough to share the pic with you :)

We have started work on my build also finally. WHOOOHOOOO. Keep on trucking!!
 
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Looks good mate! You got a part number for the coilpack loom?
 
sorry tops i don't have the part no handy, was just ordered from psi tuning.

Ok, so I've been away recently but I'm back now.
Before i went away i decided to turn the car over, no plugs in, just for the sake of it really, and to build some oil pressure.
Well it built up pressure, because it persisted to **** oil from around the oem water/oil exchanger.....i was a fool and forgot the rubber seal.

But more annoyingly was the water leak from here:

which is a pita. The o-ring was basically shagged, i have no idea how i didn't spot this when fitting:

So this saturday i will be sorting those two leaks out. I suppose its good to get them out the way tho.

But my biggest concern is this:
[ytv]rbwv8JYs9SM&feature=youtu.be[/ytv]

Which is the throttle body going absolutely mental with the ignition on.
If anyone has any ideas please pipe up. Not scanned yet but thats a priority.
Perhaps its related to my battery dying very very quickly when turning over? Or related to other sensors being disconnected? i.e. maf.
The really odd thing is that if you disconnect the IAT sensor, it changes its tune/beat.

so thats all i have for now. I am particularly worried about this potential electrical error tho :(
 
Music to my ears, i hope that sorts it. Cheers.

not long now.

another hiccup ive had is regarding insurance, im trying to be legit and declare everything as honestly as possible but with my girlfriend only being 23 alot of companies wont allow her on it with mods or the price is crazy.

not having her on it isn't an option as Il be away over summer and she will be using it as and when.

in a bit of a pickle
 
You tried all the specialist insurers Karl? Sky/Brent Acre/Green Light etc
 
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Best way Karl is to insure yourself as the main, add a few older "experienced" drivers eg. Parents or uncles etc. Put down that your partnered too, or "living together" (however it comes up). I have me, dad, mum and brother in law. Being our age they'll try n rape us with modifications too. Also try ALL the aggregator sites because some companies appear on one but not others. Admiral appear on confused (because they own it) but don't appear on compare the market. Let me know how you get on :thumbsup:
 
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Lewis583 said:
You tried all the specialist insurers Karl? Sky/Brent Acre/Green Light etc
Click to expand...
only sky out of those, they wanted every single detail so i gave them it down to the turbo model, only for them to say having my gf on was a no go, and then for them to say they wouldn't insure that car in Liverpool.

Gops said:
Best way Karl is to insure yourself as the main, add a few older "experienced" drivers eg. Parents or uncles etc. Put down that your partnered too, or "living together" (however it comes up). I have me, dad, mum and brother in law. Being our age they'll try n rape us with modifications too. Also try ALL the aggregator sites because some companies appear on one but not others. Admiral appear on confused (because they own it) but don't appear on compare the market. Let me know how you get on :thumbsup:
Click to expand...

my dad makes f all difference, it goes up. Been on confused today, comparison sites are unrealistic for modded cars.

i get AMAZING quotes for a stock car tho! Lol. Sub 500 bar
 
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It's still "stock" .. All you've done is improve air flow :D
 
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ImageUploadedByTapatalk1397778106165444
 
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So ive got myself a great insurance quote, only problem is they wont insure it without an MOT, and i cant get an MOT till i have insurance, and i cant get road tax till i have an MOT, and cant get an MOT till i have road tax.


WTF are you supposed to do when you've had a car sorn???


should i blag them and tell them i got an MOT today? Lol
 
It is SORN yeh. Although do you have to renew the sorn after a year, i recall getting a letter of some sort.



shall i blag the fella and say ive just had it MOT'd?

im urgent because i hear thereis an expiry on NCB, and ive not had my own policy for a year to this day!

im annoyed, he asked for payment method and i had card ready and he randomly asked.
 
very odd Karl, I've never once been asked if the car has an MOT for insurance.

Why do they want to know?
 
Prawn said:
very odd Karl, I've never once been asked if the car has an MOT for insurance.

Why do they want to know?
Click to expand...

ive never been asked either,but, they ask when was the car last insured or when did the policy expire don't they.

and ive said well its been sorn for a year, so perhaps that's prompted that question.
 
audi upgrades
when ever i have done it at the post office i have gone armed with a cheque, a certificate or motor insurance and an MOT.

Did it online this year and it only wanted the 16 digit number across the Road tax renewal reminider - i guess they have records of my insurance and MOT in their gov.database
 
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