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Its turning intoo a track car ....

scotty_24 Jul 19, 2016

  1. scotty_24

    scotty_24 Well-Known Member

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    Been busy!

    Jardo (@16Klappe ) has refurbed by headlights for me. The levelers are broken, so manual adjustment for me and leaving the auto levellers unplugged.

    They look amazing!

    Got them fitted last night, has a fight with my front bumper. How people get these to sit right with a Welly cooler is beyond me!
    The lights look awesome, I need the headlight aim set but couldnt wait to drive it last night so headed out for a play!

    I love this car :D

    36229374_10161338877060354_6264169694811389952_n.jpg 36310244_10161338536960354_6728977416431075328_n.jpg S35.jpg
     
    SamHendry likes this.
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  3. scotty_24

    scotty_24 Well-Known Member

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    Guide : How to fit A3 headlight to S3 8L so headlights can be adjusted manually


    So.
    After Jardo refurbed the headlights for me, we found the manual adjusters weren't working.

    To recap:
    Headlight level sensors on the front wishbone and rear tie bar annihilated by curbs on track, headlights now point to the floor.
    The solution? A3 Headlights converted to Xenon with manual adjusters:
    Why A3 headlights? Theyre cheap knock offs brand new, and I happened to come across a set used for £25.

    The A3 knock off headlights use a H1 halogen dipped bulb.
    The S3 uses a D2S Xenon with ballasts. First problem encountered!

    2.jpg

    The H1 uses a one blade connection, the HID kit needs live and earth.

    3.jpg


    Easily sorted!

    Red - Blue
    Brown - Black !

    4.jpg


    Heat shrinked the connections, just didnt get photos.

    I was now left with this :

    5.jpg

    The HID Ballast needed mounted and the headlight rear cover drilled so the HID wiring could pass through.

    6.jpg

    There you go, easy. Little bit of silicone to make it water tight.

    7.jpg


    Next up was to remove the old ballast and mount it in the OEM position.
    8.jpg

    And mount the bracket back in its place

    10.jpg



    Then fit the light, connect all connections!

    11.jpg


    Thats one side done!

    12.jpg


    And the moment we have all been waiting for.... Headlight manual adjustment sorted. See the drivers side pointing at the floor still?

    13.jpg


    Repeat process both sides.


    Job done


    Fully working HID Xenons, in cheap A3 lights that look just like S3 ones with the all important manual adjustment for the MOT tester!

    14.jpg .




    Massive thanks to Jardo for the help, and @<tuffty/> for the help with the wiring !

    Hope this helps someone who has knackered headlights and needs a cheap fix.

    Cost me £25 lights (can be founf on ebay for £130) and £12 for a H1 HID kit.
    And a night on the drive, with losts of swearing :D
     
    hydro s3, RS4B5, SamHendry and 2 others like this.
  4. Rainbird

    Rainbird Well-Known Member

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    Proper job, nicely done chaps.
     
    scotty_24 likes this.
  5. xDaNx

    xDaNx Member

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    When JNL ported your chinafold did he port the head side of it and gasket match it? Just had mine off and one of the runners overlaps the port on the head by alot, if that makes sense.
     
  6. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator

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    Check it fits properly on the head too... most of the ones I have seen need the top of the flange to be ground so it sits on the head properly

    <tuffty/>
     
  7. xDaNx

    xDaNx Member

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    Yeh I checked that when i originally got it, seems to be loads of clearance.
     
  8. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    not just porting, but "port matching"..... both on head side and turbo size.
    for example, our gen2 which is part of the k04-380 kit, is cnc ported on exactly the gasket port centres, to gasket diameter (42mm vs 33mm of port) and blended into the runners. no step then. At turbo end its ported to 47mm diameter to a template, which is used by aet and us (machine shop) so again, no steps and full bore ported. I have'nt seen any ported chinafolds which are as worked as what we have found is needed to be done to get the max out of them. - *think backpressure*

    enjoy
     
    hydro s3 likes this.
  9. scotty_24

    scotty_24 Well-Known Member

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    Yes
    The runners were ported to match the exhaust ports on the head, the collector is ported and opened up to 47mm. As Bill has said, JNL porting is never going to be bang on as JNL didn't have my head to match up with, but at the time I had it ported he was the only one porting these and my Pro4 had cracked and I wanted the car back on the road, so JNL porting was the only option.

    Ive had no issues, I do realize that a Badger5 ported one would have been better but Bill doesn't port them on demand as they are too much of a headache for the money they make.

    As Tuffty says, meke sure the turbo mounting face and head mounting face are flat, mine was checked with a straight edge and was machined flat.

    Mines not port matched, its just ported. It works, I get out on track and enjoy my car :D
     
    andrew_wright likes this.
  10. xDaNx

    xDaNx Member

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    Ah ok, having just took mine off again I can see where it's not matched with the black soot rings, opened it up the best I can to match the gasket with the tools I have but I can definitely see why Bill doesn't want to port and sell these anymore lol.

    Just need to take the manifold and turbo to be machined now, fed up of messing around with gaskets.
     
  11. scotty_24

    scotty_24 Well-Known Member

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    Sack the gasket off, best thing I ever did. One less thing to worry about.
     
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  13. scotty_24

    scotty_24 Well-Known Member

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    s35.jpg s34.jpg s33.jpg s32.jpg s3.jpg


    So Jardo came over last night and machine polished the car!
    We also gave the interior a good going over as it was smelling musty after living in my garage for a year while saving for the house. Its only recently I am using the car more and more.

    Looking good, photos don't do it justice. Facebook upload of photos in a hurry have killed quality too.

    Coilovers, wheels and spacers needed!

    Hopeful to book another trackday when I'm back from holiday this month. Looking like an October day somewhere possibly Knockhill or the old faithful local Croft.


    On that note, my dual pod pillar gauge holder is doing my tits in and gets in my way on track as well as driving.
    I'm gonna sack it off and run one of these below :
    pod.jpg

    The thought is to run boost and oil temperature as I currently do, as well as oil pressure.

    Ideally I'd like an AFR gauge, but at the moment got bigger fish to fry than spunking £250 on a wideband AFR gauge with Lambda sensor.

    That's it for now, planning a run out in the car on Sunday :D
     
  14. hendo#1

    hendo#1 Active Member

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    I have the exact same 3 pod in my car.

    I’ll be taking it out at some point soon to return the car to standard.

    It has a Stack oil pressure gauge, Stack AFR gauge and Stack boost gauge in it.

    Drop me a PM if they could be any use to you. There is over £600 worth of gauges, I’d sell the lot as a package complete with the 3 pod holder for £200.
     
    Tj 0785 and scotty_24 like this.
  15. scotty_24

    scotty_24 Well-Known Member

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    Give me a shout when you are in a position to sell them, and I'll see whats what!
     
  16. scotty_24

    scotty_24 Well-Known Member

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    So.. With the guidance of @Prawn I have bought a few bargains.

    I currently have Boost and Oil temperature on A pillar.

    Bought this :
    [​IMG]


    And found a matching oil pressure gauge on ebay cheap :
    gauge.jpg

    And bought this to T off the pressure gauge:
    [​IMG]

    The oil temp gauge is ran off the blank on the oil filter housing.

    Cant wait to get all the gauges refitted in their new home.

    Next up will be a liquid gauge in the drivers side air vent, or a AFR gauge when funds allow.

    Ive tried to do this as cheap as possible as I just got engaged and baby on the way :D
    [​IMG]

    There goes my 3076 BT build ! ha ha ha

    She will be staying hybrid for the meantime.

    Does anyone know what readings I should see on my new oil pressure gauge?
    Cold idle, warm idle and under throttle?
     
    hydro s3 and <tuffty/> like this.
  17. hendo#1

    hendo#1 Active Member

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    I didnt pay much attention to mine, but I know on a cold fast idle it was 90+psi.

    Warm idle around 30psi.
     
  18. Rainbird

    Rainbird Well-Known Member

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    Congrats on all counts dude :icon thumright:
     
  19. hydro s3

    hydro s3 S3 amk

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    Congratulations chum
     
  20. scotty_24

    scotty_24 Well-Known Member

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    Cheers lads.

    Gauges going in next week :D I will report back
     

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