Cheap AGU ebay build thread

[antwan64og]

1998 A3 1.8T for £450 off ebay with an undiagnosed misfire.
Took a punt and bought it, one ICM and new Spark plugs later she was running great.

Decided to do this all on the cheap. The plan with this was to make a reliable cheap car with about 250hp eventually by using a slightly bigger turbo and planning to run moderate boost to not stress everything.

Transmission
After a bit of abuse the clutch started to slip so had fitted a Sachs VR6 clutch and pattern G60/ABF flywheel on the driveway by Lee from Oemautospares.
Changed clutch slave and starter motor at the same time.





Turbo
Bought a broken Ko3s off ebay
Ordered a balanced CHRA with a ko3s compressor wheel and a ko4 turbine.
Currently trying to buy a cheap Ko4 001 for the exhaust housing on ebay but may have to pay to get the Ko3s housing machined 5mm bigger for the ko4 turbine.
Bought an Rspec MBC to run in parallel and Boost gauge.

Since I’m a cheapskate I’m be using extension springs to stiffen the actuator, I’m not paying £150 for a forge one.



Bought a ported ko3 manifold from Oemautospares that I’ll stick on at the same time as the turbo.

Brakes
Reconditioned callipers and 312mm carriers with blank discs, Brembo pads and braided hose up front all bought from and fitted by oemautospares.



Just waiting for 256mm reconditioned rear brakes and braided hoses. May upgrade these to 300mm with the adapters.

Suspension
Stock suspension is nice and smooth so no need to replace it yet,
But ultimately plan to fit Bilstein B4 Sport Shocks with Apex springs.
Got a red TDI dogbone bush to fit.


General
Jetex Panel filter

Tuning

I have an AGU bin file for VR6 MAF, Ko4 turbo and 440cc injectors and I have an MPPS cable so will flash a spare immo off ECU I have and try this tune once everything is ready.

Bought an ECU connector from the states planning is to make a PNP megasquirt harness at some point but might just stick the car on a trailer and send it to Rtech depending how busy they are.

Need to Order
Toyosports FMIC with 2.5” piping
EMS-Pro ECU
Down pipe
Buy an 2.5” exhaust or get one welded up
Rear ARB
80mm Ko3s TIP

*Will add pictures later, photobucket is not playing ball today

 

[Mrharris2]

Can't complain at £500 looking good man how much was the clutch and flywheel as I'm after than and how's it feel/respond?. my build is the same as yours agu k03s. Good work

 

[Prawn]

you complete pikey *******

 

[Prawn]

I love it!

Really like the approach. i'm all for doing things properly, and that includes bodging. if you actively set out to get power as cheaply as humanly possible, and accept and know the risks of doing so, then hats off to you!

it's when people bodge things and fit utter tat in the belief that it's top notch that gets me.

Good luck mate, i hope you get to your 250bhp goal Interesting approach on the semi hybrid spec turbo, should be plenty for your needs

 

[antwan64og]

Clutch, flywheel and proper VW hardened bolts was about £230, them its just the fitting.

It feels a million times better, the clutch is light but more positive.
My dual mass flywheel was ruined anyway, previous owner had the clutch changed but left the old flywheel in. It only last 15000 miles.

 

[antwan64og]

you complete pikey *******

Haha, I'm stubborn when it comes to stuff.
Sometimes instead of paying someone to do stuff I'll do my research and buy all the stuff and spend 3x as much doing it myself.

Hey I figured aslong as it VSR balanced and has got the proper seals the turbo should last. You never know what you're buying anyway. Since I'll be using a ported manifold it may help longetivity too.

I've got an RF900 streetfighter I need to sell to fund getting rods done......

 

[Prawn]

Sounds good mate, I look forward to seeing the outcome

 

[Mrharris2]

Well that's it at the end of the day you feel good about doing it no matter the outcome haha. And sounds good on the clutch ill have to order mine ASAP and get it in before the remap

 

[Lee oem]

I was googling about the AGU motor and this came up

I told you don't sell the bike, I want to see how it stacks up to my Turbo E30 once she's done.

There's a 256mm rear caliper kit with your name on it.....

 

[antwan64og]

Yeah i keep thinking it looks stupid with just the fronts in red

 

[antwan64og]

Plans changed, turns out I bought a ko3-026 which is a ko3 with an uprated actuator to produce 180hp so I scrapped that idea and bought:
Broken ko4-023
Billet ko4 compressor wheel to mate to the new CHRA I have
Ko4 manifold
TT225 downpipe
Ko3 3" downpipe
Ko3 10mm mild steel flange

The plan is to make a ko4 to ko3 adapter like the frankenturbo one, i'm not paying £200 for a ko4 downpipe.

Also just for bragging rights Brembo's juniors will sit over stock 312mm discs with Boxsters carriers,
I'm not using 323mm discs because I want to keep 16" wheels and cheap 16" performsnce tyres, lol.

I just need longer carrier bolts and M12 spacers to line the caliper up perfectly
Also the wheels needs 25mm spacers but thats easy to sort.

Test fitting yesterday

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[antwan64og]

I tend to change my mind like a woman.

Sold the Brembo calipers on a whim and decided to use stock ATE calipers.

Yesterday installed the red Tdi dogbone mount along with an s3 lower brace and a TT strut brace. The strut brace required angle grinding, Prawn will like the pic later, lol.

The car handles totally different, feels really tight, I wasnt expecting a difference but it feels good.

After having the ko4 together on the table I decided again in a whim not to use it

Bought myself a ko3 hybride VSR balanced that has been shown to put out 290whp

Supersize tip, maf and s2000 filter

I just need to fit the turbo, ported manifold, downpipe, injectors, fuel pump, intake assembly and figure out how to flash the ecu with mpps

 

[Mrharris2]

Looking good but yes you do change your mind a lot Indecisive is good means your thinking about it lol

 

[Prawn]

hahahaha, where's the pic for me?

You do keep changing your mind a lot, but it's all good fun!

Will you fit this one? or will you change your mind again

Good work, keep it up!

 

[antwan64og]

Prawn! This is my pikey strut brace.
An s3 brace is like £50-60 and fits perfectly.
A TT brace is £20 and needs a little trim....

Just to clarify it wasnt supposed to look like this. My mate got a bit happy with the cutting disc and cut it all the way through.
The TT brace had a bolt hole where the A3 bonnet strut goes.

But it makes a big difference anyway!

And yes I plan to fit this turbo.
I just need to be assed to desolder the the immo chip on a spare ecu, it won't program on the board. I don't want to try flashing and brick the ecu without having a spare on standby.
Since I sold the bike this is my only transport.

I've got a Sytec ITP331 fuel pump to go in the tank and blag 440cc green tops from japan, lol.

 

[Mrharris2]

Ah man that cut looks evil lol I got a tt brace for mine off a chap on here for free I also had to make that cut what a ball ache...

 

[S3 Hilife]

I like it mate, it just goes to show you dont need fat stacks of cash to get the job done, It looks like you should get some really good results.

Its a shame the Streetfighter had to go tho.

Steve

 

[antwan64og]

Your cut is well nicer than mine, Iol.

I do miss the bike but I've got a 3 month old baby girl so it was a fair trade really

 

[Mrharris2]

It's not that much better lol it's a hard angle to cut. Just paint it black and hope for the best that's my view lol and linish it first to make it smooth

 

[JimS3]

Ah man that cut looks evil lol I got a tt brace for mine off a chap on here for free I also had to make that cut what a ball ache... View attachment 41409

Tidy job there, glad my old garage door stop is getting some use!

 

[Mrharris2]

I couldn't remember your name jim else I was going to tag you haha. Your garage door stop is doing a better job for me I think lol I've literally only drove my car 2 miles with it on and I've lowered it by 25mm and it handles noticably different which I Wudnt of thought seeing as they over steer. Thought stiffening the rear would help more. New to all this suspension arb and strut stuff. Sorry for the hi jack and babbling on lads

 

[antwan64og]

Forgot to mention I fitted Avon ZZ3 upfront and Toyo R-1's at the back a few weeks ago.

The Toyo's grip nice but are wuite soft walled so in my wisdom I picked them for the lighter back end and stiffer walled ZZ3 for the front for some more longetivity.

I actually changed the first tyre dry with tyre bars and a lump hammer with no washing up liquid. That was a sweaty ball ache, so did the other 3 on the pneumatic machine over the road.

Transporting precious cargo, the tyres obviously

 

[antwan64og]

I don't know if it will help but the stock inlet large port inlet manifold is nowhere near the gasket so gasket matched it.

This was halfway through doing it

 

[Mrharris2]

Did you notice anything after doing the inlet manifold mate?

 

[antwan64og]

Did you notice anything after doing the inlet manifold mate?

Its not fitted yet, was gonna do it at the same time as the intercooler.

Spent time recently bodging the
girlfriends focus back to health. The valve cover gasket kept blowing out and ******* oil down the block. A quick google told me to check for a collasped pcv hose. Problem now bodged with random silicon tubing and exhaust gasket silicon on the new valve cover gasket

 

[antwan64og]

Got these in the post, 15 mandrel 3" stainless bends.

Planning to do
2 x 90 bends for the mid pipe
2 x 45 bends for the over axle section

Also had 2.5m of 3" stainless tubing delivered

Also go this coming in the post, i'll measue the inlet when in arrives to figure out the adapter needed.



Fitted the s2000 filter yesterday to the stock MAF, it definately makes the car pull nicer through the rev range.

Just need a sunny weekend to have a crack at making a 3" ghetto exhaust, lol. I'm going to try straight through with no mid silencer first, if its too noisy/droney Cheapest solution will involve 2 x 3"-4" steel cones and 620mm of 4" tubing.
I'm figuring to just drill a sh!t load of holes in the 3" straight section and weld a 4" tube around it with a cone either end. That costs £25 in parts opposed to £120 for a stainless silencer. My estimates that it will drone between approx 2000-2500rpm calculate to about a 620mm resonator needed.

Also Planning to weld the stock CAT into the 3" downpipe so exhaust is road legal.

Thats the plan anyway.... My welding is woeful but as long as it doesn't leak it will be fine.

 

[Jay A3]

Ghetto exhaust love it! Haha

 

[antwan64og]

The 80-70mm silicon adapter wouldnt fit over the air filter even after I heated it up in boiling water. I had s piece of 80mm silicon lying around so fixed it in the usual ghetto fashion

 

[Jay A3]

Sure it was an 80 internal measurement? Or you put it on the right way?? Lol

 

[azzzah]

Hi mate where did you get the stainless bends and how much did you pay? If you don't min me asking

 

[antwan64og]

Yeah its definately 80mm internal silicon adapter, the s2000 filter is actually 82mm externally and the silicon wouldnt stretch over it. This is why the s2000 filter slides over the 80mm maf perfectly.

Ideally you'd get a 70-86mm adapter and jubilee clip it down.

 

[antwan64og]

Hi mate where did you get the stainless bends and how much did you pay? If you don't min me asking

Bought a box off ebay of
* 5 x 45 degree bends
* 5 x 60 degree bends
* 3 x 70 degree bends
* 2 x 90 degree bends

They will do for my friends exhaust to.

There is another box on ebay now from same the seller.

Considering mandrel bends are £10-£15 each it works out a bargain if you use them all.

 

[jaykay8L]

Inspirational stuff on this thread. Love it!

 

[azzzah]

Bought a box off ebay of
* 5 x 45 degree bends
* 5 x 60 degree bends
* 3 x 70 degree bends
* 2 x 90 degree bends

They will do for my friends exhaust to.

There is another box on ebay now from same the seller.

Considering mandrel bends are £10-£15 each it works out a bargain if you use them all.

Thanks mate ill take a look!!

 

[Essexman]

Nice thread, mine was up for 500 on ebay, haggled to 400 haha, had dodgy flywheel, soon sorted that & wanted to do the similar plan to you, Had it for a year now, been so busy with other stuff, but wheels/ coilovers/ zorst & remap next month

 

[00monkeyboy00]

Love this, I brought mine for £475. Already converted to gas, got a few miles on the clock mind!

 

[antwan64og]

Mini update

Finally changed vacuum hoses and got a cheap set of direnza boost hoses off the bay.
Also fitted a 2nd hand 210n diverter valve since It was sounding like a rally car on lift off with the s2000 filter.

Also got a heat shield to hold the filter in place and spent 45 munutes fighting with the silicone 80mm adapter to get it over the filter.

I know I should of held out but didnt want to blow £230 on a wellycooler just yet so fitted a thicker cheapo SMIC as a stop gap.

I don't know if it was the vacuum hoses, the new boost pipes or the diverter valve but fuel MPG improved dramatically!
A return journey to work was using a quarter of a tank, now it uses just over an 8th of a tank.

I hate winter, got a big pile of stuff to fit......
Turbo
Decat
Ported manifold
sFS supersize tip
Vr6 maf
Fuel pump
Injectors
Flash ecu

 

[TheRunningMan]

Looking good. I'd be interested to hear if you notice any difference with the intercooler. It's something i've thought about as don't really want the hassle of fitting a front mount and want to keep the car as standard looking as possible. I guess it's a fairly big compromise over a front mount.

 

[Essexman]

Even if no difference its got to be worth doing anyway, more finns?, not batterd like standard, less usage than standard, A 'maintenence upgrade' and its Shiinnnyyy !

 

[antwan64og]

Looking good. I'd be interested to hear if you notice any difference with the intercooler. It's something i've thought about as don't really want the hassle of fitting a front mount and want to keep the car as standard looking as possible. I guess it's a fairly big compromise over a front mount.

I wish I had logged IAT's before and after to compare.
If my IAT's do shoot up when the new turbo is on I can always take a grinder to the front bumper, cut a hole for a 6 inch velocity stack and have ducting going to the SMIC. Thats the £20 option.

The £230 option is still the wellycooler.

Depends how much I have spare at the time and how high IAT's go.

Treated myself to a inlet manifold spacer gasket, so I'll fit that soon and see how the IAT's are.