3.0TDi build update, straight through exhaust with 3.0" downpipe and home made rear section. Video i

bentwenty

Registered User
Evening all, it's been a little while since I've posted on here, so I'll start with a few pics of how it's looking now. I don't have much left to do with the exterior, I'm happy with how it is looking now.
e430eed9c14c886c76153cf211994f3b.jpg

3b07ff87bfa1c1bf7c612c1ead40a2f0.jpg

96d505f71f84ec9b6f26a2847f5ce579.jpg

5f4497ce7da9a5461bcb5e0e798be11f.jpg

I got the wheels (19x8.5, reps I believe) very cheap as they were in very poor condition. I had them shot blasted and powder coated by my favourite powder coating place for £100 for all 4 (unbelievable, I know), who have done an amazing job!
454aa0eaa401deced0968d263957dfe6.jpg

A set of brand new Falkens were a must, they are the best I can afford to put on, and seem to perform very well. I'm running ZIE914s in 235/35/19.
Next were eibach 40mm springs, they have actually dropped it by 52mm at the back, but it rides very comfortably, just about clears speed bumps and nothing rubs, so I'm happy.
Now on to the main event, the exhaust! One of the big attractions of the 3.0TDi for me was the fact that it's a V6.
But being a luxury executive saloon, Audi has carefully engineered the exhaust in an attempt to hide the fact that it has an engine at all, let alone a 3.0 V6!
I had other plans, namely a 3" decat downpipe from darkside, and a home made back box delete!
Here is the downpipe, it came to just over £360 delivered, its beautifully made!
a2d1801904e1becc208e56017ba5643c.jpg
415234a98ab0ecad683958f201e6b670.jpg
91f19c3a282a031e51fcdcfa3531e2f4.jpg

Removing the old exhaust was a PIG! I was hoping to keep the original cats intact to sell as they are worth a fair bit, but that didn't happen! Even after cutting them with a grinder (with no guard or handle attached so it would fit in the tunnel...), I still had to support the gearbox on a block of wood and a jack and remove the NS gearbox mount!
9aa939afda67033f839b91b4c15aa68c.jpg
5a9524dcef793d0b8f7bb7b86158c3f1.jpg

Fitting the new one was pretty straight forward, I had to make a special spanner to be able to tighten the back turbo flange nut, but other than that it was pretty simple.
For the backbox delete, I started with a 1m length of 2" stainless, 2x 30deg 2" bends and a 0.5m length of 3.5" stainless.
I mirror polished the ends of the 3.5" as I was using it for the tips.
4fdf2c8ae5d7617983276ca7f21a0d90.jpg

I then cut it exactly in half, and then cut out two annulus from 1.5mm plate, with an OD of 3.5" and an ID of 2" to serve as adapters for the tips.
I then welded them on with stainless wire. I haven't been welding very long, so my welds look terrible, so they have all been ground back. They are pretty sturdy though.
95207f6a962f22a28285e37560c15f2b.jpg

With two of those made I cut off the old back boxes with a grinder, it was then a case of lining up the 30deg bends and welding them on to the 2" stainless, here is one of my welds, about the only good thing I can say about it is I didn't burn a hole though, and it probably won't fall off... More practice needed!
e9179e279dd133019c1277a41f3e0eda.jpg

After a bit more fab work, two of this popped out
5d2198857236a7d619e87fec93d7ab7e.jpg

At this point it was a bit late in the day, and I made my first of two minor balls ups, I forgot about the fact that the car was on stands at the back, and not the front, and I welded the tips on level to the ground. So when I put the car down, both were pointing down by about 20deg!
The second balls up was not quite getting them both the same length, but I had plans to fix that. Here's how it looked.
c44df4d53802156ef95c976cfb00d6e5.jpg

And most importantly, here's how it sounds!
Overall I love the sound! Very loud and throaty on power, but pretty quiet and respectable off power. It does have a pretty nasty drone/rasp at about 2200RPM, if you are accelerating slowly, the tiptronic box loves to shift about there, so it's pretty annoying/embarrassing as it takes away from the more refined nature of the car. I plan to fix this by building a side pipe resonator, and trimming it to length so it either disappears or is at a much higher RPM. But I need to do some more research before I jump into that!
I want happy with the tips, they looked a bit 'fast and furious' just hanging out the back, so I spent a good 2h with a couple of different grinding wheels. I have profiled them to the bumper, and I'm much happier with them!
21af14137270e923b71ec7209c7084de.jpg
69d4115ea2842cc52dce90405888c365.jpg
5f2fbb22c9bee2137c11a8b47579158b.jpg

I hope you found that at least a little bit interesting, any questions fire away!
Ben
 

adamss24

Registered User
Ben, it looks good, especially from someone that done it first time ! Well done !
 

bentwenty

Registered User
Ben, it looks good, especially from someone that done it first time ! Well done !

Thank you very much! I really appreciate that!
 

bentwenty

Registered User
Good job, having a go yourself it's more satisfying and you save some money. The V6 TDI sounds great, side branch resonators do a go job of reducing the resonance / drone that you can get with a straight through system without killing the noise too much.

Thanks very much!
Yes absolutely, I always enjoy learning a new skill, once I have my own house I plan on building a 'proper' track car, so investing in a good quality mig welder and learning to weld will certainly pay off.
In the short term the whole exhaust has cost me about £700, which is about what I was quoted for a full system. But that included the welder, and gas, and tips and gloves and a mask etc...
Thanks for the advice on the resonators, that confirms what I have seen so far with my own research. From an engineering point of view, it makes perfect sense; the droning is a product of the resonant frequency of the exhaust. The most significant factor that affects that frequency is the volume of the exhaust, so by changing the volume I am change the frequency.
That part of the project is on hold for the moment though while I fix my injector problem.
My sump is slowly filling with diesel, I have white smoke on hot idle, and my fuel economy is very poor, so I know I have the well known 3.0TDi injector failure!
I'm looking at getting a set of used (low milage) later revision injectors as that is most likely what I can afford.
 

adamss24

Registered User
Ben, I would get new injectors if I was you unless you find some later type ones with low mileage. Last set I got was 1300 for 6 brand new Bosch injectors from my local diesel shop. He made no money on them but I always give them work so they put it on the next bill ! Keep modding and be safe !
 

niedzial1983

Registered User
Evening all, it's been a little while since I've posted on here, so I'll start with a few pics of how it's looking now. I don't have much left to do with the exterior, I'm happy with how it is looking now.
e430eed9c14c886c76153cf211994f3b.jpg

3b07ff87bfa1c1bf7c612c1ead40a2f0.jpg

96d505f71f84ec9b6f26a2847f5ce579.jpg

5f4497ce7da9a5461bcb5e0e798be11f.jpg

I got the wheels (19x8.5, reps I believe) very cheap as they were in very poor condition. I had them shot blasted and powder coated by my favourite powder coating place for £100 for all 4 (unbelievable, I know), who have done an amazing job!
454aa0eaa401deced0968d263957dfe6.jpg

A set of brand new Falkens were a must, they are the best I can afford to put on, and seem to perform very well. I'm running ZIE914s in 235/35/19.
Next were eibach 40mm springs, they have actually dropped it by 52mm at the back, but it rides very comfortably, just about clears speed bumps and nothing rubs, so I'm happy.
Now on to the main event, the exhaust! One of the big attractions of the 3.0TDi for me was the fact that it's a V6.
But being a luxury executive saloon, Audi has carefully engineered the exhaust in an attempt to hide the fact that it has an engine at all, let alone a 3.0 V6!
I had other plans, namely a 3" decat downpipe from darkside, and a home made back box delete!
Here is the downpipe, it came to just over £360 delivered, its beautifully made!
a2d1801904e1becc208e56017ba5643c.jpg
415234a98ab0ecad683958f201e6b670.jpg
91f19c3a282a031e51fcdcfa3531e2f4.jpg

Removing the old exhaust was a PIG! I was hoping to keep the original cats intact to sell as they are worth a fair bit, but that didn't happen! Even after cutting them with a grinder (with no guard or handle attached so it would fit in the tunnel...), I still had to support the gearbox on a block of wood and a jack and remove the NS gearbox mount!
9aa939afda67033f839b91b4c15aa68c.jpg
5a9524dcef793d0b8f7bb7b86158c3f1.jpg

Fitting the new one was pretty straight forward, I had to make a special spanner to be able to tighten the back turbo flange nut, but other than that it was pretty simple.
For the backbox delete, I started with a 1m length of 2" stainless, 2x 30deg 2" bends and a 0.5m length of 3.5" stainless.
I mirror polished the ends of the 3.5" as I was using it for the tips.
4fdf2c8ae5d7617983276ca7f21a0d90.jpg

I then cut it exactly in half, and then cut out two annulus from 1.5mm plate, with an OD of 3.5" and an ID of 2" to serve as adapters for the tips.
I then welded them on with stainless wire. I haven't been welding very long, so my welds look terrible, so they have all been ground back. They are pretty sturdy though.
95207f6a962f22a28285e37560c15f2b.jpg

With two of those made I cut off the old back boxes with a grinder, it was then a case of lining up the 30deg bends and welding them on to the 2" stainless, here is one of my welds, about the only good thing I can say about it is I didn't burn a hole though, and it probably won't fall off... More practice needed!
e9179e279dd133019c1277a41f3e0eda.jpg

After a bit more fab work, two of this popped out
5d2198857236a7d619e87fec93d7ab7e.jpg

At this point it was a bit late in the day, and I made my first of two minor balls ups, I forgot about the fact that the car was on stands at the back, and not the front, and I welded the tips on level to the ground. So when I put the car down, both were pointing down by about 20deg!
The second balls up was not quite getting them both the same length, but I had plans to fix that. Here's how it looked.
c44df4d53802156ef95c976cfb00d6e5.jpg

And most importantly, here's how it sounds!
Overall I love the sound! Very loud and throaty on power, but pretty quiet and respectable off power. It does have a pretty nasty drone/rasp at about 2200RPM, if you are accelerating slowly, the tiptronic box loves to shift about there, so it's pretty annoying/embarrassing as it takes away from the more refined nature of the car. I plan to fix this by building a side pipe resonator, and trimming it to length so it either disappears or is at a much higher RPM. But I need to do some more research before I jump into that!
I want happy with the tips, they looked a bit 'fast and furious' just hanging out the back, so I spent a good 2h with a couple of different grinding wheels. I have profiled them to the bumper, and I'm much happier with them!
21af14137270e923b71ec7209c7084de.jpg
69d4115ea2842cc52dce90405888c365.jpg
5f2fbb22c9bee2137c11a8b47579158b.jpg

I hope you found that at least a little bit interesting, any questions fire away!
Ben
Mate where did you do the wheels for £100??? im there Monday morning !!!

2006 Audi A6 3.0TDI quattro sline le mans | Daytona Grey Pearl
 

bentwenty

Registered User
Mate where did you do the wheels for £100??? im there Monday morning !!!

2006 Audi A6 3.0TDI quattro sline le mans | Daytona Grey Pearl

City power coaters in Birmingham. They have a website with their details on it. They are £20/corner for 18" and below, £25/corner for 19" and above.
They don't answer the phone, you will be ringing them for a couple of days before you get anything, and they don't respond to emails at all.
But they know their stuff if you go in person. They turned mine around in a week and did an excellent job!
There was some pretty heavy kerbing which they ground out after shot blasting.
Choosing colours with them is challenging, you are best to bring your wheels to them and they will show you examples.
 

bentwenty

Registered User
Ben, I would get new injectors if I was you unless you find some later type ones with low mileage. Last set I got was 1300 for 6 brand new Bosch injectors from my local diesel shop. He made no money on them but I always give them work so they put it on the next bill ! Keep modding and be safe !

I'm going to get the best I can afford. I have found 6x genuine brand new 059 130 277 BD with 3 years warranty for £1100. I know that's an excellent price, but it's a little more than I can spend at the moment as I'm squirrelling away as much as I can for a house.
I'll shop around a little more before I buy anything.
Thanks for the advice!
 

niedzial1983

Registered User
City power coaters in Birmingham. They have a website with their details on it. They are £20/corner for 18" and below, £25/corner for 19" and above.
They don't answer the phone, you will be ringing them for a couple of days before you get anything, and they don't respond to emails at all.
But they know their stuff if you go in person. They turned mine around in a week and did an excellent job!
There was some pretty heavy kerbing which they ground out after shot blasting.
Choosing colours with them is challenging, you are best to bring your wheels to them and they will show you examples.
Thanks a bit to far for me :(



2006 Audi A6 3.0TDI quattro sline le mans | Daytona Grey Pearl
 

MarkWizard

Active Member
VCDS Map User
Like the grill mate. Did it come with the quattro badge and where did you get it from?

Thanks
 

bentwenty

Registered User
Like the grill mate. Did it come with the quattro badge and where did you get it from?

Thanks
Thank you mate! Yes the badge was an extra £20 with the grill. The grill came from Mark Brodie at Brotek Performance.
 

bentwenty

Registered User
RE: Injectors for those interested,
After a couple of days leg work going backward and forwards with different breakers, I have sourced and bought a set of 6 059 130 277 AH used for £430 incl. postage. They are not the latest revision, but they are one of the later revisions (fitted to 2009 cars) that people seem to be fitting with no issues in replacement of the first revision 059 130 277 S which have just failed in mine.
They have come from a car with 61k miles, FASH and a fully running engine. I will try and source a seal kit for them, and then fit and code them next week when I'm back from a week away!
Ben
 

rmctri

Registered User
Hi, great post.. I was wondering how you got on with the side pipe resonators please? I've just had the mufflers removed and replaced with straight pipe and 4" tips but i'm seeing the same drone as you around the 2000rpm mark. Not what I wanted. Thanks
 
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