A3 Quattro TDI Re-Shell Into Audi TT225

[Airs]

They`d match my car colour...

Take it you got them from regal?

yeah they came from regal, bit of a nightmare to get a hold of but once they eventually went and looked of the mounts and posted them they where here next day lol

 

[Paul_TDi]

Awesome project you have going on here.

I'm going to look like the thick one but how does the charge cooler work? are they air con pipes going into the core?

 

[Airs]

Awesome project you have going on here.

I'm going to look like the thick one but how does the charge cooler work? are they air con pipes going into the core?

dont be daft dude, its all about learning

the charge cooler runs from a seperate water bottle with an inline pump, and just recirculates it it has a small radiator somewhere at the front to cool the water down

 

[Paul_TDi]

Ohhhh, same as a water cooled PC set up then. Cheers.

Shame it's not going back into the A3, I have a A3 Quattro TDi myself.

 

[Airs]

Ohhhh, same as a water cooled PC set up then. Cheers.

Shame it's not going back into the A3, I have a A3 Quattro TDi myself.

yeah basically the same as tht mate, ahh really you done a thread or put pics o it up??

 

[Airs]

im not doing to well at posting frequent updates but here is another 1 for you guys

all that have read through my thread know that their is a change in shell coming, so i have been working on that the last couple of weeks and its taking great shape

diesel fuel pump is all changed over and now in tank,
filler neck is all modded to take diesel neck,
glow plug wiring and relay all in and ready to be connected up,
engine harness and ecu all in place and unlocked,
fuel lines all fitted and diesel cooler ready to be mounted
full car re-done in braided brake lines

But now the time has come for the new shell reveal i bought a black y reg 225 TT back in july as a nice cheap doner car with all the usual 225 spec, xenon lights, full black leather, twin exhausts, all the normal stuff lol with the intent of making it something different

ive managed to loose the pictures from when i first got her but here is some progress pics of her

started stripping ready for the cage to get installed





and here is some of the cage in mid fitting







decided to cover windows at the start with application tape from work to save grinding and welding rash all over them lol



decided to do some trial fittings to see how i wanted the door bars to fit and this is what i had initially decided on



since i had decided on how my door bars where going to sit, i thought id start getting the seats into position



and glovebox mounted ( with abit modification too lol)



got back in the car this weekend and got the cage all painted up but changed my mind about the door bars whilst welding them in, as its going to be a daily i decided to just go with this setup instead







still making it safe and easier to get in and out of as its a daily

also got these couple of bits, adaptor to mount my gauge in the vent, and the startings of my tubular manifold, also hoping to have my fully built head back this week aswell with pics to follow



hope you are all enjoying the read and look forward to reading your comments and PRAWNS " i told you so" speech

 

[Jason.s]

Diesel TT track car. Epic haha

 

[Sam_]

Are you going to gusset the cage to the A + B pillars?

 

[Prawn]

That, is 100% amazing! Absolutely LOVE it!!!!!

i told you it would be a TT

 

[Airs]

Are you going to gusset the cage to the A + B pillars?

na sam_ its just staying how it is, that is how custom cages spec'd it mate

 

[Airs]

That, is 100% amazing! Absolutely LOVE it!!!!!

i told you it would be a TT

haha thanks alot mate i thought no one has really fone it, so why not be the knacker that does lol

yeah you did, but i couldnt give it away that easy lol

 

[superkarl]

Good that youl have 4wd to put down all the torque

 

[Airs]

Good that youl have 4wd to put down all the torque

Yeah karl that was my main thing for the new building, my bora is running 1 of these turbos already at around 230 bhp and it just spins the wheels up for fun lol

 

[Jason.s]

what sort of figures are we looking at? On darksides website it seems they run anywhere between 230 and 300 with like 360 torques?

 

[Airs]

what sort of figures are we looking at? On darksides website it seems they run anywhere between 230 and 300 with like 360 torques?

im hoping for around 320+ jason, those figures you mentioned are based on:

1.9 bottom end - mine is now a 2.0 with bigger pistons
fard +80%injectors - i have +120% injectors
standard cam - i have an uprated cam
standard head - mine is all ported and gas flowed along with inlet manifold too ( plus not using a standard 130 tdi inlet, i have something alot different lol)
standard/uprated intercooler - im running a charge cooler so will get lower inlet temps
plus i will be running water meth so that will help a little too

have an update coming later today hopefully as my head arrived back yesterday all built and was at darkside picking up some more goodies too lol

 

[Jason.s]

Should be a proper animal then!

Look forward to more updates and pictures.

Possibly one of the most exciting builds to come from here in a while. Shame most people will probably see diesel build and ignore it.

 

[Airs]

Should be a proper animal then!

Look forward to more updates and pictures.

Possibly one of the most exciting builds to come from here in a while. Shame most people will probably see diesel build and ignore it.

yeah im hoping for it to be abit of an animal and really surprise some people lol

i will see if i can get more updates today mate

cheers for the comment, i really appreciate it, i wasnt even going to do a build thread at the tart tbh, but im glad i have now as their has some genuine interest in it

 

[Prawn]

definitely one of the more exciting and different builds on here, really looking forward to it!

Certainly has the potential to re-write the rule book on soot chuckers!

Hurry up and do something else that we can look at

 

[Airs]

Got a nice phone call from my dad yesterday saying there was a couple of big boxes arrived for me at home midday yesterday whilst i was already on my way to darkside for more toys lol (boost gauge isnt connected atm)



this is what i came away with, not the best photo but all bundled up nicely on me passenger seat lol



brand new GTB2260vk, Braided oil feed, Custom oil return pipe and 6 speed clutch slave cylinder

so upon arriving home i seen this laying in the middle of the floor in my unfinished living room (house is undergoing and extension so its totally upside down atm lol)



i was like a small child at Christmas unwrapping presents
first box contained my inlet manifold, which is possibly going to spark a few questions lol



it came back absolutely gleaming and freshly painted silver

next was a slightly bigger box, i wonder whats inside this 1



any guesses yet?? and yes that is my tumble dryer in the living room lol



and here it is











i was totally astonished when i opened the boxes to see them, their was never any mention of them being painted and being made to look so new, the service i have received from HIGH FLOW HEADS is 2nd to none, this is 1 guy that i will definitely be recommending to people for work to be done, so any1 after and head flowing, or any head or engine work at all hit up Andy at high flow heads, he is a sound guy and will help you every step of the way

more updates to come, keep your eyes peeled guys

 

[Airs]

definitely one of the more exciting and different builds on here, really looking forward to it!

Certainly has the potential to re-write the rule book on soot chuckers!

Hurry up and do something else that we can look at

haha thanks a lot prawn i appreciate it

their is a little update for you lol

 

[Prawn]

i was like a small child at Christmas unwrapping presents
first box contained my inlet manifold, which is possibly going to spark a few questions lol

I'm sure there's a genuinely exciting reason why this should spark off a few questions, but I think the honest truth is, that so few of us know anything at all about these engines that most of us won't have a clue what it is myself included!

perhaps that's why it's so interesting, it's all unknown and new to everyone.

either way, I think it's awesome.

 

[Sam_]

I remember High Flow Heads from my Peugeot days, although his results in those days weren't anything to write home about. Hopefully he's better these days! That was like 6 years ago now.

 

[Airs]

I'm sure there's a genuinely exciting reason why this should spark off a few questions, but I think the honest truth is, that so few of us know anything at all about these engines that most of us won't have a clue what it is myself included!

perhaps that's why it's so interesting, it's all unknown and new to everyone.

either way, I think it's awesome.

you may well be right the PRAWN, i keep forgetting ive been doing this for a few years now lol

on all the 130/150 bhp diesel golfs/boras etc etc this is 1 of the standard inlet manifolds



the are a good manifold for upgrading the small bhp diesels, but for the power im wanting i thought if i can get a bigger inlet manifold is should flow alot better,



this manifold is actually from a 6 cylinder volvo none turbo that they use more over in europe, they are as rare as hens teeth over here, so with a little guidance from 1 of my friends i got may hands on this 1 and decided to lop 2 of the ports off and re modify the internal ports from being oval as standard to the D shape that the standard 1 is

but the realy strange thing about this manifold is that its all stamped with VW part no's lol priced 1 up from TPS and they wanted £750!! i nearly collapsed lol

sorry for the little rant, just thought id explain lol

 

[Jason.s]

It`s all interesting stuff dont worry. Ramble on lol

 

[Airs]

I remember High Flow Heads from my Peugeot days, although his results in those days weren't anything to write home about. Hopefully he's better these days! That was like 6 years ago now.

yeah sam he does alot of pug/cit stuff for the rally cross boys, his work seems to be very very good i had a flowed head on my old clio 172 a few years back, and holy hell it revved like their was no tomorrow!!

 

[Prawn]

you may well be right the PRAWN, i keep forgetting ive been doing this for a few years now lol

Why is my name Shouted :'(

 

[Airs]

Why is my name Shouted :'(

Sorry dude, i glanced at it on your avatar and thought it was caps lol apologies Prawn

 

[aragorn]

Its a D24 manifold, they're not that uncommon!

They're used on older VW LT vans, as well as the Volvo 240 and 740 diesels.

I guess its just that the vehicles they were fitted to have mostly rotted away at this point, they're a bit harder to get hold of!

 

[Airs]

Its a D24 manifold, they're not that uncommon!

They're used on older VW LT vans, as well as the Volvo 240 and 740 diesels.

I guess its just that the vehicles they were fitted to have mostly rotted away at this point, they're a bit harder to get hold of!

yeah thats what i thought mate but this is different to the LT model, my mate ARD has 1 similar to this aswell

 

[aragorn]

Its not different, its the same part number thats listed in ETKA against the LT 2.4 Diesel

There were a few other manifolds used as well though, on the turbo models.

 

[Airs]

Another small update, with more to follow at the weekend

managed to get alot of my interior trim back into the car over the last weekend, along with so much needed bmxing and a charity do lol

some of the trim needed to be modify to go around the cage but looks ok now its in







i need to make some ducts to fill in the gaps where the dash was cut for the cage and to point the vents up on the windows too
but A pillars went back in with modification lol



and centre console



plus the roof linking which im chuffed about yo can see where i had to trim the A pillars as the go right accross the top of the doors, but the cage touches the roof sides so needed modding



and couple of bits i had laying around that i forgot about, my 2.0 8v head gasket, custom tdi head studs



spent an hour or so last night in next doors garage painting my engine with another couple of coats, was looking glossy but hoping it finishes up matt, will follow up with pics tonight hopefully.

Roll on the weekend, hoping to get the top and bottom mounted together and some ancillaries put back on her keep your eyes peeled

 

[Airs]

just another small update,

decided it was time to start fitting more engine parts, so got the head studs out the box and fitted those, plus ancillary bracket, thermostat, modified oil filter housing and couple other small parts







started to fit the head all on and started torquing it down, and had a small mishap with 1 of the studs, so this has knocked me back a little with the engine, but its getting dropped off tomorrow to hopefully get sorted out,

my tubular exhaust manifold is vey near completion (eventually!!) so hoping to receive that back in next couple of days and will upload some shots of that too.

a few more goods have landed from TPS too so will get some pics tonight of those too

 

[Prawn]

Very jealous of this, that cage inside the TT just looks amazing!

 

[Airs]

Very jealous of this, that cage inside the TT just looks amazing!

Cheers Prawn it was a nightmare to fit, first time doing 1 and can honestly say i don't think i would again lol welds arnt the neatest but its structural lol

 

[Airs]

Well ladies and gents here goes another update

whilst I've been waiting for my engineers to get this snapped head stud out i decided to get my new wheels out of the shed and give them a coupe of coats of wax and heres how the first 1 looks



and with the flash on they look like this (just ignore the trainers, i may of been polishing them in the house where it was warm lol )



also got a call of the dude fabricating my tubular manifold to say it was ready





once i stripped it all off the old engine we noticed their was still some metal filings inside of the manifold so we cleaned it all out with spray degreaser and cleaner, then go bait stupid, but got some cool pics lol



cam was all re-bolted down, injectors fitted into the head, injector loom fitted, and surface all cleaned for rocker cover



Flywheel, clutch plate and pressure plate all fitted, for it being a custom billet flywheel, their is still some ****** weight in it!!



engine all timed up, belt covers re-fitted, new water pump,



Gearbox all fitted and re-painted (quickly)



and then the exciting bits started t happen





big inlet fitted





still some finishing to do on the inlet to make it look more asthetically pleasing,

one question for some of the more knowledgeable people, when i have mounted the turbo up to the manifold on the engine, when you stand at the rear where the turbo is, the turbo sits slightly on the wonk and the core is not perfectly vertical :S does this make any difference to it?? its not massively out but it is out, any help would be awesome thanks

 

[<tuffty/>]

Nice work dude... great to see an actual TDi tuning project... bit thin on the ground in this section and something I personally have no experience of...

<tuffty/>

 

[Airs]

Nice work dude... great to see an actual TDi tuning project... bit thin on the ground in this section and something I personally have no experience of...

<tuffty/>

Thanks <tuffty/> yeah not a lot of people really going this deep into it tbh, i have cam across a few stumbling blocks along the way finding some bits and using things from different engines accros the board, wether it be petrol or diesel lol

can't wait to get it all up and running, especially with this bad weather we are meant to be getting 4x4 for the win

 

[Rice]

Just looked through this all, pretty fricking cool! Cant be many diesel 8n's around .

 

[Airs]

Just looked through this all, pretty fricking cool! Cant be many diesel 8n's around .

hey matey thanks for looking, as far as im currently aware, their is 1 2wd 8n in the uk and 1 quattro in the states

so pretty rare lol

 

[bigray]

proper love this