Tom's S3 Progress report

[Tom93]

Figured seens although im on the forum i might aswell share with everyone what im upto! Basically ive had this car for 6 months now and its been a working progress since the beginning. Im going to post up pictures and bits to catch everyone upto the present day, then i can add to this page as time goes on, hopefully So here we go!

Bought it and it looked like this, rough paint, rough wheels, rough engine and so on.





What became immediately apparent was the car was missfiring, so a quick google brought me here and a new loom for the coil packs was ordered...



Problem almost solved..



2.0tfsi coils, problem gone.

So small mod...


****** headlights plague vag cars!




Thats better.

So then i decided i was going to keep this car for a while and i wanted to get it looking a bit better, so wheels and coilovers was next!



A few coats of Poorboys Wheel Sealant later...


So i got some spacers ordered and then fitted it all in a weekend... Which gave me this...


Ideal! So then i moved onto polishing to try and get the paint looking better...






Wish i could keep it looking that clean!

Now somewhere among all this, the car has also had a new steering rack, suspension bushes, 3"dp and a non res Miltek cat back. And assorted silicone hoses in the bay. And other things i cant remember at the minute but i will later!

Future plans from now (22/09/2015) are V4 manifold, hybrid turbo/turbo porting, mapping hopefully at badger5 and then water meth... Sadly no engine build, just cant afford to

 

[S3AMJ]

Hey good progress so far!

Can I just point out, unless your going to change the rods...... I wouldn't bother with hybrid, v4 manifold and so on.

Those mods will take the car beyond its internal capabilities and you'll end up with a mess to sort out.

 

[Tom93]

So other day i got some new QD (quick detailer) Its called Finishing Touch and its made by OCD Finish. And it leaves the best finish of any QD i've used to date Take a look...



But in other news i have started working on the engine, i had an exhaust blow ive been unable to cure even after a downpipe, so i thought either blown gasket or cracked mani, so i didnt take any chances, bought a V4 and gather parts for full service/all fluids all gaskets new nuts bolts etc and today i made a start. But i had to finish leaving it like this...



Left unable to remove the turbo which was my goal for the day, if i went from drive in to turbo on the floor in this afternoon i was going to be happy. But ive just got home and realised theres a bracket for the oil supply pipe i didnt know about and thats all that stopped me completeing my goal, if i knew thaat i would of won Atleast i know what im going for tomorrow now. Tomorrows plan is v4 fitted and get the turbo to the machine shop for porting.

 

[Greg-S3]

What a joy these are to get the turbo off! When I did mine I had to drill 2 of the E14 bolts that go through the manifold and hold the turbo! Then... I had a 14mm bolt that went through the bracket on the back! Horrid job first time round!

 

[SamHendry]

What a joy these are to get the turbo off! When I did mine I had to drill 2 of the E14 bolts that go through the manifold and hold the turbo! Then... I had a 14mm bolt that went through the bracket on the back! Horrid job first time round!

Did you soak the bolts in fluid overnight?

 

[Greg-S3]

Did you soak the bolts in fluid overnight?

Soaked them, heated them up the works! No joy at all mate!

 

[Tom93]

I nearly sheared one, had my 18v impact on them, 2 came out but one had to resort to the breaker bar

 

[Tom93]

Soo today, well half a day really, im enjoying thorough lie ins! I acheived this much...



Basically i got the turbo and manifold off. Ideal. Ready to start early tomorrow and get the pro4 on and ready for the blower once its been ported

 

[Tom93]

Cant beleive this is as far as i got and then forgot to update, loads happened since.

Fitted the pro4, started the car, blowing like a bitch. Removed pro4 and returned it and fitted the standard one.

Whilst the car was apart i wanted to refresh the turbo aswell, looked around online, couldnt afford a real hybrid so bought a pretend one...

Straight fit into the OE comp housing but 11blade billet gtx style wheel, Seems to have done me no favours so i wouldnt recommend it. Having planned to fit the pro4, i had already ported my hotside to match the "super gasket".

Anyway drove around on actuator pressure for ages, then went up to see Bill at Badger5.

Scary day, thought i broke the car before i got there but luckily it was just a turbo bolt had worked its way out, quickly refitted, sorted a boost leak and cable tied some pipes up out the way and we were putting down some power... Not alot, but some.
http://vid817.photobucket.com/album...4-DAC8-4341-80C2-05629A9690A3_zpsmbrwcqxe.mp4


Anyway i spoke to Bill about my previous concerns about the map and decided not to do a before power run. Bill read the map off the car and had a little chuckle about it. I think he said the egt protection was just off, the boost control was also just off, he said it would just boost all the boosts until it exploded. And there was something about it going lean instead of rich or vice versa, when it was supposed to be safer it actually done the opposite. All in all, **** map.

So Bill mapped it and it literally didnt like boosting and the IAT's were through the roof. Also it wasnt making much power. Calculated that we had airflow but it wasnt getting turned into power, it is a 130k motor thats probably been ragged to **** half its life so i put it down to that.

Anyway, left Badger5 with instruction to get an intercooler that actually cooled and an uprated actuator. Oh and a peak power figure of 248bhp.

So thats exactly what i done...

Toyosports Type B size=big.

Got that fitted up and the inlet temps dropped alot. 24degree max, over a full throttle 4th or 5th gear run.

And then bought an actuator from BBT...


Its downstairs i just cant be bothered to take a picture of it.

But i havent fitted it because it will need a map tweak after... and its all ££££.

Anyway, going to try and photograph more and keep this updated... But for nowheres a picture i snapped at asda at 5am the other morning...

 

[Tom93]

Also at some point during all the above i bought a B5 TIP with heatsheild and got that all fitted up.


Bill kindly tweaked it for me when i was up there as i hadnt shortened it enough and it was beginning to kink.

 

[IPG]

Soo today, well half a day really, im enjoying thorough lie ins! I acheived this much...



Basically i got the turbo and manifold off. Ideal. Ready to start early tomorrow and get the pro4 on and ready for the blower once its been ported

how difficult is it to do this in situ? does it make it easier lowering/raising the engine at all?

 

[Tom93]

Pain in the *******. If you take out the drivers side shaft you can get a few from there but i done most of mine pretty much lieing across the slam panel/rocker cover and reaching my arm around. I didnt raise or lower the engine, just left it as is on its mounts.

Some people find it easy fitting the pro4, i definately didnt.

 

[Tom93]

So D-Day today, sort of... Compression test time... Results are below, not sure what to make of them, hopefully someone will be able to tell me what should and shouldnt be...



The arrow on cylinder #4 meant the pressure was dropping as i was reading it, probably something to do with the gauge.

 

[badger5]

low compressions presuming gauge is accurate to mine
Healthy motors are 190psi

 

[Tom93]

Soooo yeah. Found out my cambelt is 4 years overdue. And my engine is tired soooo refresh time.

 

[Tom93]

So after i read the workshop manual online and studied a few other threads i bit the bullet and jumped in. Took me about 2 hours to go from running to head on the floor. Not quite the 20mins the lad at badger5 reckoned he could do, but nonetheless progress im happy with.

I then removed the turbo, and just got the pistons and rods out as i lost the light. But thats ideal i could get indoors, strip them down and clean them ready to go again... I have an ultrasonic cleaner so everything that fits has gone in there lol!



Used a brass wire wheel on the drill to clean all the gunk off them and then put them in the cleaner again, came up quite nice really.

Leaving the rods in there little sealed packets for a minute, i had to take one out just to admire it but im leaving them in there until im ready to fit them.

But yeah just got back from the machine shop having dropped off my manifold and turbo for skimming so i can run no gasket. And i left the head there aswell, its being stripped, cleaned, faced, all valves/guides/seats checked and/or repaired, valves lapped then reassembled with all new seals. Could just put it back on as is, but its done 130k and even the guy in the machine shop said these are plagued with valve guide trouble, so i might aswell sort it whilst its off. Also gasket matched the inlet ports (every little helps).

So now begins the painting/cleaning of any parts i still have here.

Oh and heres my big metal toilet brush



Thats it for now!

 

[Rainbird]

Looking good dude. Those pistons have come up really well, will be tackling a set myself at the weekend but with no ultrasonic there'll be slightly more manual labour involved!

I have a 3 stone type honing tool in the garage but was considering getting hold of a FlexHone instead. Don't really fancy paying that much for something I'll use once if the current tool will do the job much the same though. Be interested to hear how you get on with it (and if anyone else has any opinions/experiences)
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xHa48ABUrOsFnDGg8qCvu7cR5uOsfLgpDa9HYJPAGk5EtoKg7RTmMuhK1tq0enzaHhzHbTscG1zHA5LjeFdZyjSySmQ1aSDLVkZG1kQ/tJhzNcI5uHBZEpwMDWChNGMaN24AcgF7S2CWI4uydRwpQZ9mxtcLMq7quPNxXa7LG6aQv2N7rPujxv6nujzVzvDfb3um7WjXdmyLZXxPrXF65+Q4LSXpbqufIcxu/QdT+qkmkkpigwsYcIoDhBNAa1PPZ9VErNIJJG4dZsdHUOwyE0jYeWKrjyaeC1y+MT694IDG3W7zag/v5GjtHfIwtjHNz14FuN4bhxBlHlvvuJAji+Z5FeVVk2qZoG2rWDbvdnUuPNziT8y5s4MMeI985n969uQ/y4neso4LPlWPbCAcOLEGVq733El0knzPLj0ova57LilYHDIf1mWvLKKM+oJ+JYkUYc6h7o1n/A3d5mjfNbG9Hmz2Y1ymtRq6nhFNnQNNPn5LXH6lR6/ry7WV8m0bGji0HLLiT/ABLMEP2eAAnXaC3rPKAZnfLGWxj43cFg3XAZJxliENHke9IThij83mvkvW+LSC/CHVbEC3F7xqS+T5nlx6UVRjWRoxYiMTYR2jm++QaMj6ueWhd7eSDgJq5lcbh4pXHFI7pjJA5NCybG3s4w87RScj/uOBbZo/JuKU9GrCsNkM8rYwe+cz93aT6VQS7Qq7KAPIzlOPpGw6o83Z+SnC1ty2YNaXAUDqBg4MaKAfqtktIIiICIiAiIgIiICgmmFleJcbhqv1W5jOmZ/MKdrynsrH0xsa6mzEAaeqVYjOgtnykfxIaPIVP5hStdIoGsFGtDRwaAB9F3UiCIioIiIOKLhsYGwUquyIOKLCtNzxPrqhpNaloAriaW1POhOfMrORBDLRobKxwLX9pE0hxYe+cOYbXYQTTPKgqtXf7zDK2N+KgaDjIID3vOJ7uuMnpQBWOukkTXCjgHA7QRUHyKz+V1ENF7q7QB7hquIea72trgb0Jq70WVpRoZ9sIc2UsewOAJ2axrmBt3qSQwNYKNFBy9P5ei9FUQGHR20WOCQtaZJgC8FgJxyHUbTfqMxGnFw4KKWKPtJOzka5gZV8wcCCImCrhnnrUDR8Suiix7Vd8cneaCcs9+RBGfCoBpyTBV99SmoYcnVMkoG6WQDU6MYGM8itvoXdWKshFO0OBvJje+7zyaFnX17OGSvdLFK6ORzsTg7Wa4nbsoR9VJLou4QxhvugNHQb/M1PmEgz2tAFBuXKIqCIiAiIgIiICIiAiIgIiICIiAiIgIiICIiAiIgIiICIiAiIgIiICIiAiIgIiICIiAiIgIiICIiAiIgIiICIiAiIgIiICIiAiIgIiICIiD/9k=

 

[Tom93]

I dont have a honing tool and the americans rave about them so figured id just buy one, now that its here and i had to pay £12 customs charge aswell its probably cost me more than i really should have paid for a honing tool. But if it does a really nice job then ill be happy. Would of thought i can recoup most of my costs if i sell it on ebay anyway. Plenty of prople rebuilding engines out there and the flex hone does a small range of cylinder bores so not limited to 20vt motors.

 

[Tom93]

Painted valve cover, wrinkle black


**** picture but it does look nice in person.

 

[<tuffty/>]

I'd clean off the paint where the rubber seal of the oil cap sits else it will blow oil past from not sealing properly

<tuffty/>

 

[Tom93]

Heads back, looks nearly new, apparently all the guides were shot exhaust worse than inlet. But its looking beautiful. Put the turbo back on today and got the last piston in and sump on. Ready for head tomorrow

 

[Tom93]

Havent updated this for a while.

Its running, done 1000miles, just got my mot so 12 clear months on that. And im booked in at badger5 for a map tweak, got uprated actuator and forged rods since my last visit. Exactly a week today Tuesday 12th

 

[Dave Broomfield]

keeps us updated please as I'm looking to have this done to mine

 

[vanilla_ice]

Also at some point during all the above i bought a B5 TIP with heatsheild and got that all fitted up.


Bill kindly tweaked it for me when i was up there as i hadnt shortened it enough and it was beginning to kink.

Good work.

Is this the Badger5 recommended orientation of the Jetex filter? Metal support wire on top as opposed to below?

 

[Tom93]

Good work.

Is this the Badger5 recommended orientation of the Jetex filter? Metal support wire on top as opposed to below?

Doesnt matter really thats just the way it ended up last time i put it on.

 

[Tom93]

Took a picture.

 

[badger5]

Good work.

Is this the Badger5 recommended orientation of the Jetex filter? Metal support wire on top as opposed to below?

makes no difference at all functionally.

 

[vanilla_ice]

makes no difference at all functionally.

Thanks Bill. How about from a support perspective?

 

[Tom93]

Thanks Bill. How about from a support perspective?

No, the filter is supported by clamp/fit of the neck onto the MAF.

 

[badger5]

Thanks Bill. How about from a support perspective?

there is no support. its a filter. it clamps onto maf - /end /simples

 

[rushton]

Take it you reused the standard pistons?

How did you clearance the sump?

 

[Tom93]

Yep brass wire wheel on the drill to clean the pistons up.

In what way do you mean clearance the sump?

 

[Tom93]

So today was D day. Made 280bhp, all choked up then, wouldnt take any more boost wah.

 

[badger5]

glass half empty kinda guy are'nt you. -

Not +40bhp on Novembers previous build... taking a positive for you

turbo chra from ebay, chinafold diy ported by you (not enough), 11 blade chra same size as stock k04.. flows 280bhp of air for 1.2bar same as a stock k04 does. Miracles were never going to happen from this spec on a realistic dyno.

chin up.

 

[Tom93]

Actually thats a good point, IAT's are way down with a proper intercooler and the actuator is giving me more boost. And the engine is making much better power now its been refreshed so well done on that part. It is in the right direction so i should be more of an optimist haha!

 

[badger5]

Actually thats a good point, IAT's are way down with a proper intercooler and the actuator is giving me more boost. And the engine is making much better power now its been refreshed so well done on that part. It is in the right direction so i should be more of an optimist haha!

thats more like it dude.
AITs spot on, all good, more torque more power, no leaks... and rodded so future potential is all there

 

[SamHendry]

Tom nice results! As above now you have got forged rods, you must be tempted to go down the hybrid route!

Do you think WMI would have improved your figures?

Btw is chinafold another term for a relentless mani?

 

[Tom93]

Have a read above and you'll see i have a "hybrid" already. We're using that term loosely though lol!

I did mention it to Bill but he seems to think backpressure is the main issue at the moment, and adding water meth would increase the exhaust gas volume (more in, more out) and that would just make it worse. Sadly to fix the issue would mean removing the manifold and turbo and reworking the collector, which in my opinion isnt worth it to put this turbo back on, its proved its no better than a standard K04 so imo pointless to put back on, obviously in the pursuit of power.

So ill be saving for a hybrid then get the manifold machine and reworked and OK'd with Bill before refitting with a proper hybrid. Then maybe water meth aswell....

Chinafold is a whole nother manifold, have a google, theres an absolute tonne to read online about them.

 

[SamHendry]

280 is still plenty to have a serious play! With a forged engine and fresh head you really have a great foundation to build on. What injectors are you using Tom?

 

[badger5]

bosch 550's as his std ones maxed out @ 270bhp on the day