Time for a build thread....big turbo

S3Alex · May 11, 2015

COSTA_P said:
There is a way of putting RS6 rear discs on which I think are 335mm. If you're running something like a 360-370mm up front would even the system out stop it squirming around under harsh braking.

I do remember DaveB telling me something similar,but it required a fair bit of work and custom carriers etc.

Forge's kit looks like they've done all of the necessary work,so I will have a look soon enough.

S3Alex · May 15, 2015

So...the Cool-Tube etc has worked well,and kept my car from trying to incinerate it's wiring,and it's running well.

The only thing that gave me a fright this week was a god-awful squeal from the front left brake in all this torrential rain....I think the disc is rubbing against either calipers or pads in those conditions,but it sounded terrible.
That's another job for the upcoming service time.

When it's dry,no problems at all,and the thing is honestly scary fast at times.

TorqueTerrorist · May 17, 2015

S3Alex said:
That's so true.....it's like marmite.

I've had a real boneshaker before(the Escort,which had a rose-jointed fully adustable Proflex-clone setup),and I'd say this car has also got a very hard setup.
It does have some compliance,and rides bumps pretty well,without crashing into everything,but it is overall very hard,and wouldn't be judged as comfortable by most.

It's my daily driver,like all of my quicker cars have been....I honestly enjoy them far too much to simply want them as weekend cars.

My hat goes off to anyone having a monster for a daily...

Legend!!

Btw, thanks for your advice on pump and IC. Defo going for pump.

S3Alex · May 17, 2015

TorqueTerrorist said:
My hat goes off to anyone having a monster for a daily...

Legend!!

Btw, thanks for your advice on pump and IC. Defo going for pump.

Thank you!

All of the modified cars I've had,from a Sapphire Cosworth at 440bhp on a GpA engine,through a GpN Escort Cosworth with ALS and water injection,to this thing,have all had to be daily drivers for various reasons.

Partly I'm too mean to buy a runaround,and mostly I can't resist the fun of driving the modded car.

The pump and Stg2+ software do make the S3 a much better car,with good torque and power,and I know I've said it about a million times here,but it's the best overall value without going to a hybrid or big turbo,plus all of the bits you need for Stg2+ are also needed for any further steps.

TorqueTerrorist · May 17, 2015

S3Alex said:
Thank you!

All of the modified cars I've had,from a Sapphire Cosworth at 440bhp on a GpA engine,through a GpN Escort Cosworth with ALS and water injection,to this thing,have all had to be daily drivers for various reasons.

Partly I'm too mean to buy a runaround,and mostly I can't resist the fun of driving the modded car.

The pump and Stg2+ software do make the S3 a much better car,with good torque and power,and I know I've said it about a million times here,but it's the best overall value without going to a hybrid or big turbo,plus all of the bits you need for Stg2+ are also needed for any further steps.

Amen to that brother. I'll be happy with the stage 2+. It's bargain performance.

COSTA_P · May 19, 2015

S3Alex said:
I do remember DaveB telling me something similar,but it required a fair bit of work and custom carriers etc.

Forge's kit looks like they've done all of the necessary work,so I will have a look soon enough.

http://store.034motorsport.com/rear-brake-rotor-upgrade-kit-8j-audi-ttrs-335mm.html

Thats what i found, guessing the TTRS rear caliper is the same as the s3 one both using a standard 310 disc.

S3Alex · May 20, 2015

So...the list now includes...

Rear brakes
New LP fuel pump and swirl pot
90mm exhaust

Kind of tempted by the bluetooth adapter and iPad software for the Syvecs,but already have the Toucan.....

Allman45 · May 20, 2015

S3Alex said:
So...the list now includes...

Rear brakes
New LP fuel pump and swirl pot
90mm exhaust

Kind of tempted by the bluetooth adapter and iPad software for the Syvecs,but already have the Toucan.....

What does the swirl pot do?

S3Alex · May 21, 2015

Allman45 said:
What does the swirl pot do?

One of the issues is the pump picking up air as well as fuel on hard cornering as fuel slops around in the tank.

A swirl pot swirls the fuel from the pump and de-airs it before it's sent to the fuel rail.

S3Alex · Jun 5, 2015

Forge 4 pot rear brake kit on order.

Looks nice,but more importantly a lot more brake and caliper area than before,so it can be fitted shortly,and then we'll see.

Sayam · Jun 5, 2015

The distinct lack of videos after the last round of mods has been noted

S3Alex · Jun 5, 2015

Sayam said:
The distinct lack of videos after the last round of mods has been noted

Too busy holding onto the steering wheel thank you !

Sayam · Jun 5, 2015

Haha, knew you'd have a good reply for me!

Seriously though, I do hope you invest/have invested in a GoPro at some point

S3Alex · Jun 5, 2015

Sayam said:
Haha, knew you'd have a good reply for me!

Seriously though, I do hope you invest/have invested in a GoPro at some point

I will eventually....or at least sort the iphone holder out to do the same.
One day.....I promise.

It's not as good as being there though.

TorqueTerrorist · Jun 5, 2015

TorqueTerrorist said:
Amen to that brother. I'll be happy with the stage 2+. It's bargain performance.

I didn't go for the pump in the end. Couldn't stretch this side of holiday...the missus has been trained by her mother to instil into her partner a sensible approach to life...

At least I'll have something to look forward to. I need to uprate the I/C anyway. Totally hooked, and I'll be blaming you when I'm bolting the bigger turbo on! Lol

S3Alex · Jun 5, 2015

You'll have to include the people that got me started. Lol.
Enjoy it...every bit for each stage is needed for the next so nothing is wasted.

TorqueTerrorist · Jun 5, 2015

Tell you what Alex, AmD speak very highly of you, and I find your conduct and advice on here exemplary.

Thanks again for your advice.

S3Alex · Jun 5, 2015

Thank you very much.
That's really kind of you.
AMD and I go back to the start of this car's modified life over 7yrs.

I can't fault anything they've done and the work is always to the best standard and the fact it hasn't broken down over that time is a reflection of that.

This is sounding like a mutual congratulation society but I can't recommend them highly enough.

It's always a pleasure to drop in even for a chat.

Sayam · Jun 5, 2015

S3Alex said:
I will eventually....or at least sort the iphone holder out to do the same.
One day.....I promise.

It's not as good as being there though.

Thanks...I'm sure I'll get a go in it someday too

TorqueTerrorist · Jun 6, 2015

S3Alex said:
Thank you very much.
That's really kind of you.
AMD and I go back to the start of this car's modified life over 7yrs.

I can't fault anything they've done and the work is always to the best standard and the fact it hasn't broken down over that time is a reflection of that.

This is sounding like a mutual congratulation society but I can't recommend them highly enough.

It's always a pleasure to drop in even for a chat.

They are very refreshing compared to what I was used to years ago on the tuning scene, and recently come to think of it. I had my car booked in with another business. I had to speak to three different people just to get somewhere close to an answer to a few questions. They were short, impatient...

AmD however have staff who are extremely knowledgable, polite, patient. That's just on the phone. Then when I arrived I was taken good care of. I won't be using anyone else now. A friend of mine has a new RS4, now he's going to be using them.

Rant over.

Love what you've done to your car man. Haha

S3Alex · Jun 6, 2015

Definitely.

I've said it before back in the bowels of this thread,but I've been to a few well known Cosworth tuners back in the day,and the first was all over all of the car mags of the time.
Nice guys,couldn't fault that,but the build quality was poor.....16V head being rebuilt on a piece of cardboard,ON THE FLOOR,an exhaust that had pieces cut out of it to fit around the gearbox,plus a load of blown welds etc etc.

The second,a rather more business-like operation,looked at the exhaust and said it looked as if the guy who welded it was drunk when he did it.
The man running that operation was a rallycross and BTCC competitor,and knew how to build an engine that would race and not explode.

I prefer tuners that run race operations,as some of that philosophy ends up in the road cars.

TorqueTerrorist · Jun 6, 2015

S3Alex said:
Definitely.

I've said it before back in the bowels of this thread,but I've been to a few well known Cosworth tuners back in the day,and the first was all over all of the car mags of the time.
Nice guys,couldn't fault that,but the build quality was poor.....16V head being rebuilt on a piece of cardboard,ON THE FLOOR,an exhaust that had pieces cut out of it to fit around the gearbox,plus a load of blown welds etc etc.

The second,a rather more business-like operation,looked at the exhaust and said it looked as if the guy who welded it was drunk when he did it.
The man running that operation was a rallycross and BTCC competitor,and knew how to build an engine that would race and not explode.

I prefer tuners that run race operations,as some of that philosophy ends up in the road cars.

Oh god, I have some not so fond memories of one guy building my bottom end in the corner of a sh*tty workshop.

I remember Steve Scott at A1 rally sport used to race and build some good, strong road going Cosworths. A few mates had engines built by them.

I used to dream of Julian Godfrey building my own Escort Cosworth.

I never did get an Escort Cosworth in the end. By the time I could afford one they were all out of reach. Plus I killed so many RS Turbo engines/ gearboxes, turbos, it put me off Fords.

Good old Audis are holding up well though. Although I blew a box in my last 8P S3, oh and snapped the prop. I've since grown up, and look after this one. Already bored of the stage 2 though. *** lol

Ron burgundy · Jun 7, 2015

S3Alex said:
Hi,good to see you back.

It's running a daily 550bhp,and was running over 600bhp on Storm's dyno.

It was turned down a bit,as the exhaust(a sort of hybrid Milltek) is running out of flow,and needs to be replaced to safely run full power for extended periods,so that's been booked.

The brakes are again a sort of hybrid,as a lot of the current kits weren't around when I started all this,so it has VWRacing 6 pot calipers,and APRacing rotors on the front,and ZeroSixty rear discs,with Mintex 1155 pads all round.

It's pretty decent,and doens't fade easily,but I did see on another thread that Forge now make a good sized rear brake system for the S3.

Hey

Nice bit of power you have now, you must love flying around in it.
I will let my pal know what you're using .
Do you think Lamborghini brakes are overkill? I've now seen Ferrari 458 brakes being used but I don't know whether it's more for just the looks or whether you really have to spend that much for serious braking !

Thanks

S3Alex · Jun 8, 2015

No not overkill but not necessarily any better than a 6pot AP Racing setup.

I think given the choice all over again(more of which later this week I think) that's the one I'd take.

S3Alex · Jun 8, 2015

So hoping(as must Steve at AMD) that this rear brake kit just bolts on.

Nothing else on this car has,so I'm not sure why this should be....

It's gone on the list of things to do,beside finally having to treat the intake piping to some Reflecta-Gold,as the underbonnet temps are much more noticeable now,and a pile of minor things.

The front brakes are looking a bit suspect right now,as something has been grinding away a bit under heavy braking,and it's turned out to be one of the calipers getting machined a bit by the disc.

Everything leads to the next....

PippinR · Jun 10, 2015

Hi Alex
I have had a quick skim through your thread. I will be reading it in more detail later but looks amazing so far. I am interested in your Toucan display. In the winter I am going to be installing a Vipec ECU in my 3000GT and the Toucan works with that too. Do you have any feedback of how it performs? Until I saw the Toucan worked with it I was planning on using a tablet moulded into a fibreglass shell in the dash with software to do similar things to the toucan but also to run music into a sound system (as it would be mounted where the head unit usually is). It would have less functionality that the Toucan though such as switching maps from it etc. wouldnt be possible. Do you think the toucan is worth the money considering I would have to keep a head unit as well which I think will look messy?

S3Alex · Jun 10, 2015

Hi.....I think for the Syvecs,it's an essential addition.

It gives you access to a lot of things that otherwise you'd need an ethernet connection for,like the TC settings,ALS and so on,plus the maps,which you can do with a switch,but this is so much easier.

The other useful thing on the Syvecs is the Toucan gives you all of the error codes,and the ability to reset things like a lean trip(as we have a few fuel pickup issues).

I don't know the Viper ECU at all,but if it's in any way similar,the Toucan will be useful.
Mine is mounted in a dash vent holder that comes with the device.

Perhaps the only thing for me that might be even better is the bluetooth adaptor for it,which means I could run the Syvecs as an iPhone app.

Krony · Jun 10, 2015

Got them brakes in yet mate ?

S3Alex · Jun 10, 2015

Krony said:
Got them brakes in yet mate ?

Soon.

Krony · Jun 10, 2015

Looking at the front 356mm kit initially after i do arbs and the anti lift kit so am interested in some feedback

S3Alex · Jun 10, 2015

Krony said:
Looking at the front 356mm kit initially after i do arbs and the anti lift kit so am interested in some feedback

I would look at the AP kit for fronts.

ALK is only worthwhile after coilovers and ARBs.

PippinR · Jun 11, 2015

Thanks for the feedback Alex. The vipec is based on Link ECU's. Made by a guy that used to work for Link I believe and he got fed up of trying to make improvements and having his ideas shot down so he went on his own (or that's how the story goes anyway). The feature I really like is that you can password protect maps. So you can have a map with zero fuel so it can't be stolen without the password and a map with a low rev limit for those damn valet's who like to rev the hell out of your car while you're not there. I came back to a guy who was supposed to be cleaning my Silvia and he was sat there bouncing it off the limiter.......

S3Alex · Jun 11, 2015

Very similar in some ways to Syvecs then.
Maps can be protected.
Also things like ALS multistage TC and loads of other stuff.

I really DONT like people playing with my car.....I'd have blown a fuse.

The advantages of the Syvecs include direct injector support,and the ability to run both direct and port injectors simultaneously,which was a must-have for the setup on my car.
That meant I could go back to using the S3 injectors up to 400bhp,and bring in the others above that,so we could keep the better spray pattern from the S3 injectors as well.
That meant no more smoke-screens under load...!

S3Alex · Jun 15, 2015

Rear kit seems to be in....

Bad news is the front calipers are shot,so I need the new front set I was worried about.

Good job I'm working hard.

S3Alex · Jun 16, 2015

AP are quoting a 6-8 week lead time for their kit curently,which is like it always is.

AMD are working on trying to shave that down a bit but right now the car is going nowhere,as you can't drive it without knowing it's going to stop...LOL.

I always thought I was a bit hard on brakes,but Ben's comment made me smile...he said I must hammer them as there's a huge lip on rotors.
Oh well....must remember not to slow down.....

S3Alex · Jun 19, 2015

Car back today.....good in one sense.

Still need the replacement brake kit,but no joy on that,with a 2 month lead time on the brakes,and the calipers,and the bells....

S3Alex · Jun 19, 2015

And a few pictures to tell the rest of this...

Forge are currently the only company I know making an off the shelf rear brake kit,complete and ready to go,for the S3.

You get a 330mm rotor,and 4 pot caliper system,with hydraulic handbrake.

After the smoking MAF episode,I heatshielded some of the wiring,and Steve at AMD finished the job....

Before....

And after....

And a squidgy breather filter to replace the original which the bonnet was crunching....

Sayam · Jun 19, 2015

Lovely stuff mate, thank you for the pictures.

One question I've always wondered - on so many cars I see big discs (those with a large diameter) and massive callipers, but the ratio of brake disc surface to hub is tiny, so you end up with a massive disc thats really thin..what's the point?

Perhaps a picture can illustrate, compare picture one with two

Can you see how you have what looks like two inches of brake disc surface, whereas in the first picture there's nothing there.

Also, how come no one has put more than one caliper on a disc yet? Would the disc break?

S3Alex · Jun 19, 2015

As far as I know it's got a lot to do with surface area,heat dissipation,friction and a lot of other stuff I know nothing about....LOL

Also diameter has a big influence on the force you can exert.

You really need DaveB for this rather than me.

Hope my APs roll up soon.

Car is going exceptionally well right now ... The way the boost builds is amazing.

BTW dual caliper systems have been tried and used but if a single caliper system can be as effective in race situations there is no need for the complexity of dual systems,and if a single caliper system can dissipate enough energy to overcome the tyre's adhesion,then again,a dual caliper system would have no benefit.

S3Alex · Jun 19, 2015

I always forget something.....

Previously I said that on it's return from Storm,Andy had commented on the handling being a bit weird and generally not right.

I eventually worked out that having run R888s on it,and then swapped over to the Michelin PSS's in winter,we hadn't taken the softer sidewalls of the PSS into account,and the compression damping was WAY off.
So,a month ago we increased the front and rear damping by a notch,and now by 2 steps at the front and one at the rear,but leaving the rebound damping as before.

Car rides bumps better,corners flatter,and faster,so it's getting there.

Time for a build thread....big turbo

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