ShaneBe's S3 Build

[ShaneBe]

Hi guys im new around here and thought I would post a build up with my progress with my new Audi S3.

I have always previously had Honda's and thought i would bite the bullet and start a S3 project.

Previous 1 of 2 EK9's:

Heres what I picked up this weekend;

Plans are;

Milltek Turbo back or if there is anything with better airflow etc please tell me as always looking for information and the best parts.

Ohlins coilovers or nitron

Intake been looking at revo as i have seen alot of members running this, not sure which intake to really go for

Stage 1 map.

A few track days are planned to see how the S3 does and Germany ring trip sorted for July.

I'll keep this post updated

 

[ch1z64]

Check out a BCS turbo back expensive but custom build excellent workmanship and i her the lads are awesome too.
Many a good cai revo , itg . To name 2.
Check the build section where you will get a lot off good advice from the old ones

 

[ShaneBe]

Check out a BCS turbo back expensive but custom build excellent workmanship and i her the lads are awesome too.
Many a good cai revo , itg . To name 2.
Check the build section where you will get a lot off good advice from the old ones

i'll check them out thanks mate!

yeah i posted this in the wrong section

 

[prt57]

Yes, BCS exhaust and a Revo intake. Make sure the Revo is the latest version with the stronger mounting point onto the engine.
Best custom tuner is RTech at Nuneaton.

 

[ShaneBe]

Thank you mate I'll 100% look into a BCS exhaust, do you know rough price figures for a turbo back? And dB wise?

 

[S3Alex]

I've had a Milltek exhaust on mine a while back,and now a custom BCS system,and can totally recommend the BCS for build quality and gas flow etc.
The service from Nige and his team is also excellent.

I've got one of the original ITG intakes on the car,with a few custom mods to the inlet ping,but overall the ITG is still doing it's job well,even if it looks a bit ugly.

The other really good intake is the Revo.

Suspension.....you'd need to consider the whole thing,from ARB's,bushes and then coilovers,and whilst both your choices are excellent,you could also take a look at some of Bilsteins shocks which will give you a bit more road-friendliness.

I had a kW CLubsport system on mine which in the end was just not as useful on our potholed roads as I would have liked,and on the recommendation of Storm Developments,moved to a Bilstein kit which has made the car a lot more usable.

Best custom tuner.....
That's a good one....pick the best forum rated tuner within a driveable distance and use them....R-Tech,and Unicorn both get good reputations here for work with the stock ECU,and I can recommend both Storm Developments and AMDTuning as well.

 

[paddy]

I see AMD do a Cobra exhaust full resonated turbo back with sports cat for £1150, thats a huge saving over BCS, i will probably bite the bullet and go up to BCS but its a fair old trip for me.....

 

[S3Alex]

I see AMD do a Cobra exhaust full resonated turbo back with sports cat for £1150, thats a huge saving over BCS, i will probably bite the bullet and go up to BCS but its a fair old trip for me.....

It is a fair old trip.....AMD fitted my original exhaust,and the replacement rear box when the first one blew a weld or two(which to be fair to Milltek,they replaced out of the warranty period),but I had my car trailered up to BCS.

I used Shiply to find a couple of people who could transport a car reliably and cheaply ... Www.shiply.com

 

[paddy]

Must be cheaper to get an exhaust sent down here than send the car up there

 

[S3Alex]

Must be cheaper to get an exhaust sent down here than send the car up there

For sure but it was a custom build as well.

 

[paddy]

Oooh sounds like the ticket, i am just trying to decide if i want a turbo back with a sports cat or the same but powervalve.
The website is pretty crap, the FAQ has not been working for months, doesnt inspire confidence TBH. I mean your web site is your shop window.....

 

[ShaneBe]

just a quick photo of the rear!

full service this weekend.

and ADO8's will be ordered this evening

 

[ch1z64]

Oooh sounds like the ticket, i am just trying to decide if i want a turbo back with a sports cat or the same but powervalve.
The website is pretty ****, the FAQ has not been working for months, doesnt inspire confidence TBH. I mean your web site is your shop window.....

Go for the tb with sprotscat it is the biz Paddy

 

[samuelh_888]

ADO8's will be ordered this evening

Yokohama's?

Take a look at Michelin PS4 for the S3.

 

[ShaneBe]

Yokohama's?

Take a look at Michelin PS4 for the S3.

yeah man yokohama's.

oh really i'll check them out!

 

[ShaneBe]

small update;

I have listened to you swines and have just purchased a BCS turbo back. (i will get pictures when it arrives)

will be looking for a revo intake (seen these seem to give the best results)

as im looking into a stage 2+ remap now, what fuel pumps do you guys recommend? previsouly with all my hondas i have used Walbro but dont think this is a good choice for the S3's as i've been reading!

what fuel pump would you guys recommend for stage 2+ remap?

 

[samuelh_888]

I’ve fitted a Loba HPFP. There is a couple of options - Loba (£640), APR (£700+) or Autotech internal (£350’ish. Maybe a little more).

If you get your 2+ at RTech I believe they’ll fit the Autotech internals into your existing hpfp as part of the service.

What ever you go for, make sure you do the cam follower and seal too.

 

[ShaneBe]

I’ve fitted a Loba HPFP. There is a couple of options - Loba (£640), APR (£700+) or Autotech internal (£350’ish. Maybe a little more).

If you get your 2+ at RTech I believe they’ll fit the Autotech internals into your existing hpfp as part of the service.

What ever you go for, make sure you do the cam follower and seal too.

is that how much they are? walbro was always like £130

yeah i was looking at going RTech!

good shout i'll look into that aswell

 

[S.]

You need hpfp for stage 2+ and as far as i know walbro doesn't make one.
VIS motorsport hpfp might be a bit cheaper than other options.

 

[samuelh_888]

VIS motorsport hpfp might be a bit cheaper than other options.

Yes, VIS Motorsport - I knew there was another but couldn’t remember the name. They’re about €300 and get positive reviews on the VW forum.

 

[S3Alex]

is that how much they are? walbro was always like £130

yeah i was looking at going RTech!

good shout i'll look into that aswell

Unfortunately everything on these cars costs.....the pump here is a high pressure direct injection pump rather than the type you're talking about,and is costly.

Mine has had an Autotech for around 90k miles(!) and providing they're installed very carefully,they are reliable.

 

[paddy]

I bought a Lobo this morning from VRS Northampton for £620 inc vat and delivery with new follower included.

 

[Kaine19]

Look at rs4 fuel return valve. Your spark plugs also. Before mapping, have a check on your pcv valve, diviter valve, oil pick up pipe, fuel filter. And as above your cam follower. Would recommend the inlet and injector clean. Rtech do this also.

 

[tcardio]

I always like build threads but maur pics please

 

[paddy]

He only started the build thread on Monday and he has posted a couple of pictures !!! researched tyres and bought a full turbo back exhaust !!...........

 

[tcardio]

yeap...you know our addiction. Build threads are the best evar!

 

[prt57]

small update;

I have listened to you swines and have just purchased a BCS turbo back. (i will get pictures when it arrives)

will be looking for a revo intake (seen these seem to give the best results)

as im looking into a stage 2+ remap now, what fuel pumps do you guys recommend? previsouly with all my hondas i have used Walbro but dont think this is a good choice for the S3's as i've been reading!

what fuel pump would you guys recommend for stage 2+ remap?

Great news about the BCS. Did you go for the Powervalve or non Powervalve? I might have one of these too, how long is the wait at the moment?

We have 2 cars with the Loba pump and have had no problems at all. I have heard about a few problems with the Autotech internals installed into older pumps if the seals are not replaced too.
I believe that RTech replace the seals when they install the internals.
What mileage is your car on? Our TTS has done 40K miles before its recent walnut blast and injector clean at RTech. The inlet calves were quite badly coked up and the walnut blasting brought them back to perfect. The injector clean brought them back to perfect pressure and spray pattern. A dodgy injector can be the cause of piston failure if you are getting a weak mixture on one cylinder. The plastic filter baskets that can collapse in the injectors are replaced with metal ones.
Whilst the inlet manifold is off the RS4 fuel valve can be fitted easily at the same time.

 

[ShaneBe]

You need hpfp for stage 2+ and as far as i know walbro doesn't make one.
VIS motorsport hpfp might be a bit cheaper than other options.

thanks man i'll have to take a look at these.

I bought a Lobo this morning from VRS Northampton for £620 inc vat and delivery with new follower included.

That seems like a pretty good deal! and they are only down the road from me.

Look at rs4 fuel return valve. Your spark plugs also. Before mapping, have a check on your pcv valve, diviter valve, oil pick up pipe, fuel filter. And as above your cam follower. Would recommend the inlet and injector clean. Rtech do this also.

I have been reading about the rs4 fuel return valves, do you think this is the best route to go then?!
Of course, due to this being used on track these things will be checked on the regular!

Im going to be speaking to Rtech soon with regards to the remap.

I always like build threads but maur pics please

I will have more photos soon .

Great news about the BCS. Did you go for the Powervalve or non Powervalve? I might have one of these too, how long is the wait at the moment?

We have 2 cars with the Loba pump and have had no problems at all. I have heard about a few problems with the Autotech internals installed into older pumps if the seals are not replaced too.
I believe that RTech replace the seals when they install the internals.
What mileage is your car on? Our TTS has done 40K miles before its recent walnut blast and injector clean at RTech. The inlet calves were quite badly coked up and the walnut blasting brought them back to perfect. The injector clean brought them back to perfect pressure and spray pattern. A dodgy injector can be the cause of piston failure if you are getting a weak mixture on one cylinder. The plastic filter baskets that can collapse in the injectors are replaced with metal ones.
Whilst the inlet manifold is off the RS4 fuel valve can be fitted easily at the same time.

From reading you're not the first person to say about problems with autotech!

My car is quite high mileage around 115k mark

If you don't mind me asking what prices was Rtech quoting for this ?!

 

[prt57]

I think the RTech walnut clean and injector clean was £325 on its own. At 115K miles the valves will be really clogged if they have not been done before.
However, they do packages including a remap plus cleaning etc at discount prices. Best to give them a call to see what they can do for you.

 

[ShaneBe]

I think the RTech walnut clean and injector clean was £325 on its own. At 115K miles the valves will be really clogged if they have not been done before.
However, they do packages including a remap plus cleaning etc at discount prices. Best to give them a call to see what they can do for you.

Good shout mate!
Didn't even think of doing this, so this will be added to the list!

 

[ShaneBe]

Have been looking at suspension options most of the day.

Would coilovers would people recommend?
I have been looking at bilstein and kw.
Has anyone used either of these if so how are they?

Or if you have any others please give me some feedback to help make up my mind

 

[paddy]

I would be wary of walnut blasting unless you are having problems ? For a start you dont know that it hasnt already been done and if you are not experiencing problems it could be just another waste of money.

 

[prt57]

I would be wary of walnut blasting unless you are having problems ? For a start you dont know that it hasnt already been done and if you are not experiencing problems it could be just another waste of money.

My son’s TTS was running fine at RTech stage 2+ so he had the walnut clean and injector service as preventative maintenance. We had read that an injector that is running weak on a tuned engine can cause high cylinder temperatures and then piston ring land damage.
As it turned out, one of the injectors did have slightly lower pressure that was identified and sorted out.
The car was more sprightly after the walnut clean and injector service.

 

[Kaine19]

One of my injectors was down before mapping. I need to get back and re-check it really before the above happens. I hadnt noticed the injector was down so am guessing if its back now i wont notice either

 

[ShaneBe]

I know i've been quiet for these past couple of week, i've been waiting for the weather to pick back up to fit the BCS.

Fingers crossed tomorrow will be nice like today.

After alot of reading and looking the plan is a stage 2+ remap.

Been looking and trying to find the best intercooler to run with this set up what would everyone recommend? will be used to daily + track

 

[prt57]

It depends on your budget and also how extreme you want the intercooler modification you want to happen.

I have a Wagner intercooler on my S3. You only have to do minor modifications to screw hole brackets with little files to get everything to fit. The Wagner is massive and excellent quality. Very little pressure drop across the core, even better than oem. Consider replacing the air con radiator at the same time as everything has to come off again in the future if it corrodes. ECP sell a Hella replacement and if you stipulate it must be black you will get an identical one to the original. Amazingly, they also sell a silver coloured one with the identical part number but the whole construction is different too!

The more extreme intercooler isxalled a Wellycooler. This is just a large universal intercooler that is made to fit with custom brackets and custom pipework. This sits in front of the air con radiator and you lose the oem crash barrier/core support. Some people leave the oem intercooler in place as it is part of the water radiator and air con rad support pack. Whereas you can buy brackets to represent the oem intercooler which allows you to remove it leaving the brackets supporting both radiators on both sides. The bodge job is to get an old oem intercooler with maybe a damaged core from a breakers yard. Cut out the core and just use the end tanks as the supports.
If your car is prefacelift and you have the Alloy end tank intercooler it will be worth £150 - £200 to the GTI boys.
The welly cooler installation will be cheaper than the Wagner and will cool even more efficiently than the Wagner but you have to have your car chopped about.
For me, I wanted the OEM type of fit and appearance of the Wagner.

As another OEM style, you may want to consider the Airtec stage 2. Cheaper and a bar and plate design compared to the Wagner’s tube and fin.
You will now drive yourself crazy researching whether bar and plate or tube and fin is best!!!!

 

[paddy]

I suppose the question is then as you have fitted a Wagner and that seems to be the popular choice here..........has it made a difference
Were you experiencing drop of in performance at track days or hot weather ? did you have a plastic end OEM that was causing trouble ?

 

[prt57]

In cooler weather an uprated intercooler is not essential but remember the Wagner suffers from less pressure drop than the OEM version so there is less restriction for the air being pushed into the intake by the turbo. My car had the Alloy end tanks so had the better version tobegin with.
Standing in traffic would produce heat soak with the oem and it did not seem as nippy on really warm days. I have yet to experience a warm day as I only installed the Wagner at Christmas!
If you follow RTech Facebook you will see reference to the car only having standard intercooler when the figures are produced from the dyno.

 

[paddy]

Looks like something i will need then thanks

 

[ShaneBe]

It depends on your budget and also how extreme you want the intercooler modification you want to happen.

I have a Wagner intercooler on my S3. You only have to do minor modifications to screw hole brackets with little files to get everything to fit. The Wagner is massive and excellent quality. Very little pressure drop across the core, even better than oem. Consider replacing the air con radiator at the same time as everything has to come off again in the future if it corrodes. ECP sell a Hella replacement and if you stipulate it must be black you will get an identical one to the original. Amazingly, they also sell a silver coloured one with the identical part number but the whole construction is different too!

The more extreme intercooler isxalled a Wellycooler. This is just a large universal intercooler that is made to fit with custom brackets and custom pipework. This sits in front of the air con radiator and you lose the oem crash barrier/core support. Some people leave the oem intercooler in place as it is part of the water radiator and air con rad support pack. Whereas you can buy brackets to represent the oem intercooler which allows you to remove it leaving the brackets supporting both radiators on both sides. The bodge job is to get an old oem intercooler with maybe a damaged core from a breakers yard. Cut out the core and just use the end tanks as the supports.
If your car is prefacelift and you have the Alloy end tank intercooler it will be worth £150 - £200 to the GTI boys.
The welly cooler installation will be cheaper than the Wagner and will cool even more efficiently than the Wagner but you have to have your car chopped about.
For me, I wanted the OEM type of fit and appearance of the Wagner.

As another OEM style, you may want to consider the Airtec stage 2. Cheaper and a bar and plate design compared to the Wagner’s tube and fin.
You will now drive yourself crazy researching whether bar and plate or tube and fin is best!!!!

thank you so much for all this info helps alot!
Do you have any pictures of your intercooler? and fitting it was it fairly straight forward?

have you been on track since fitting it?