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My Belated build thread

S3AMJ May 20, 2018

  1. S3AMJ

    S3AMJ OEM+

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    Well it’s turned up, just need to give it a good clean, remove any corrosion and sand it up ready for painting. I will look at fitting another outlet to aid with breathing too.

    [​IMG]
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    It was pretty dirty, I have put it through the dishwasher a couple times.

    [​IMG]
    Here is the part number for anyone else interested in getting hold of one. Becoming rare as hens teeth.


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  3. S3AMJ

    S3AMJ OEM+

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    In other news..... I’ve been using my car to get to work occasionally being a key worker, with today being pretty hot 25-28c I was keeping an eye on my inlet temps to see how efficient everything was running.

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    One (1) degree below ambient temps suggests things are pretty good!

    [​IMG]
    This shows how effective my water/meth set up is, putting my foot down for 2-3 seconds and drops down by 10 degree! It has been known to go lower than that.

    Oh, the temp on my ColorMFA above the Voltage is my ambient temperature for those wondering.


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  4. spiker

    spiker trying to growl less these days

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    I guess you do your own plumbing at home too ;)
     
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  5. S3AMJ

    S3AMJ OEM+

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    I’ve worked in construction for around 15 years after leaving the army picked up a few things over time. I wouldn’t say they were hidden talents though mate!


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  6. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    Plumbing/pipefitting is easy, it’s what I do for living so must be ha auto electrics is a different story still not got my
    Mfsw working , what you do in construction?
     
    Last edited: Jun 2, 2020
  7. S3AMJ

    S3AMJ OEM+

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    Yeah pipework is fairly simple to be honest, just remember “measure twice, cut once!” Haha.

    I’ve done everything from bricklaying, carpentry, tiling, plumbing, roofing, etc.

    Things I hate with a passion, plastering and painting.

    I’m actually qualified as a maritime security officer as well as an air conditioning installer. So talk about variety is the spice of life!

    Now I’m head of estates for a private hospital that we own including over 160 properties in London.


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  8. S3AMJ

    S3AMJ OEM+

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    Met up with Bruce and his Brother Alfie today to get my direct port injection all installed. Really pleased with the outcome.

    Just need to try and get it booked in with Bill and all mapped in.

    [​IMG]
    [​IMG]


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  9. <tuffty/>

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

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    What an awesome manifold

    <tuffty/>
     
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  10. S3AMJ

    S3AMJ OEM+

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    One of a kind.... literally! Bought it off some nice guy ha. Bruce was very impressed, Alfie his brother was like “ah fs” a pretty manifold now I’ve got to be extra careful.


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  11. Bluepower

    Bluepower Registered User

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    Awesome!
    Just drilled and tapped the runners for the WMI nozzles? sealed with teflon tape?
     
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  13. S3AMJ

    S3AMJ OEM+

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    Exactly that mate, drilled and tapped, Teflon tape and done.


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  14. hydro s3

    hydro s3 S3 amk

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    Looking well mate. Its coming on really well. Sort that oil cap though that would annoy me if it was mine lol.
     
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  15. S3AMJ

    S3AMJ OEM+

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    Haha don’t worry mate I’m gonna ditch it I think. All it needs is the metal bits underneath to be pinched and it’ll fit straight, just not got round to it stands to proud as well for my liking, so gonna go with a standard S3 one.


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  16. S3AMJ

    S3AMJ OEM+

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    Today I reduced the height of my AGN rocker cover where the coilpacks sit and increased the diameter of the holes to allow the coilpacks to fit in snug. I then gave it a light sanding removing all the cast irregularities and degreased. Ready for getting powder coated this week.

    [​IMG]
    [​IMG]


    I also changed my air filter with a massive K&N filter which has a 6” neck! I’ve fitted a 3.5” to 6” velocity stack. I will be making a custom 90mm TIP as a lot of my stuff that used to go into the TIP will be removed.

    [​IMG]

    All to maximise the efficiency ready for getting it remapped with the direct port meth injection. I’m also getting Badger5 to drill and tap an injector into the K04-380 hybrid turbo’s compression housing at the neck to aid with keeping temps down.

    I’m going to make a proper aluminium heat shield as well next weekend for the charge pipe.


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  17. hydro s3

    hydro s3 S3 amk

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    That's interesting putting a nozzle on the turbo housing. Have you been told by how much that will help temps?
     
  18. S3AMJ

    S3AMJ OEM+

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    Not sure how much difference it’ll make mate. It can only be better, if you think about it, that’s going to be the point where the air temp is at its highest temperature when it’s being compressed. We are talking temps of like 120+ degrees @ 25psi.

    So by the time it gets through the intercooler, it could be around say 50-60 degrees on a hot day like we’ve had lately.

    That could be 38-40 degrees by the time it’s in your inlet manifold!

    So I guess the general idea is, cool it down at the source, increasing the air density, if it’s gets to 20-30 degrees after the intercooler, then it’s going to be way way below ambient temps by the time it gets into your inlet manifold.

    Then the direct port injection will increase octane levels and reduce knock allowing more timing.

    I’ll be running 6 nozzles in total...... potentially a 7th if it would benefit from it at all.

    1. One in the turbo compressor housing after the turbine.
    2. One post intercooler.
    3. One in each runner (4 direct port)

    7th nozzle would be placed where I originally had my secondary nozzle which dramatically decrease air temps in the inlet manifold.

    But I’ve been told by the guru’s that I shouldn’t need that one.


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  19. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    Where did you get that filter from it fills the space left by the battery relocation nicely
     
  20. S3AMJ

    S3AMJ OEM+

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    Got it direct from K&N mate. It’s a RU-5064.

    Be aware that it’s got a 152mm neck! Which is 6 inches. I’ve bought a 90mm-152mm velocity stack (Bellmouth)

    It’s a bit of a monster air filter, completely overkill for my current build, but like you said fills the space perfectly and I can still get the battery cover over it, etc.


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  21. S3AMJ

    S3AMJ OEM+

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    Finally fitted my AGN rocker cover today.
    [​IMG]
    [​IMG]
    [​IMG]
    Once I fitted the rocker cover I mocked up for the heat shield I needed to make, even with my turbo, manifold and downpipe been ceramic coated it still radiates masses of heat.[​IMG]
    I’ve ordered a black TFSI coilpack harness cover which I fit to finish it off.
    [​IMG]
    [​IMG]
    [​IMG]
    Ran out of time this weekend to get the new 90mm TIP pipe cut up ready for welding. Once that’s all done I’ll get it powder coated the same as all the other bits.


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  22. S3AMJ

    S3AMJ OEM+

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    Didn’t get time to do everything I wanted to do today.
    [​IMG]
    Made some 30mm sleeves out of some 38mm O.D aluminium pipe. This was to add some additional support for the coilpacks and to finish off a cleaner look as well.
    [​IMG]
    Also fitted my TFSI coilpack harness cover, which looks much much better, had to unravel the old insulation tape from the harness, checked for any breaks as this is quite common, then taped it all back up making it more tighter to fit inside the cover.
    [​IMG]
    [​IMG]
    Had a little time left over to swap out my fuel rail pipes, they looked pretty cracked. So bought some nice 6AN rubber fuel pipe with stainless steel braided sleeve. Also bolted up a couple pipe separators to keep it together.
    [​IMG]
    I will be changing the jubilee clips I’ve used as they aren’t really suitable. They pinch the pipe oddly where the worm gear is, which can easily cause a leak.


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    Last edited: Jul 11, 2020
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  23. hydro s3

    hydro s3 S3 amk

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    Looks really smart mate
     
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  24. S3AMJ

    S3AMJ OEM+

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    Cheers buddy. Getting there finally getting the car mapped in for the new direct port next week. Might try and get launch control and flat shift set up too.


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  25. hydro s3

    hydro s3 S3 amk

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    Are you getting the other meth nozzle into the turbo aswell while it's there?
     
  26. S3AMJ

    S3AMJ OEM+

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    Hell yeah I am good job I’ve fitted a larger tank! It’s gonna be rinsing through the stuff. I’m intrigued to see what potential gains I’d get with the additional well placed nozzles. Bruce the meth guru said on my kind of set up, anything up to 30bhp! We’ll see what happens.


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  27. spiker

    spiker trying to growl less these days

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    Just - WOW - looks fantastic - great work
     
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  28. S3AMJ

    S3AMJ OEM+

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    Cheers buddy. I’ll get some more pictures up later on in the week. May even attempt a video of the car on Badger5’s new Dyno


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  29. Asim1

    Asim1 Registered User

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    Cant wait for the video
     
  30. S3AMJ

    S3AMJ OEM+

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    Wellllll...... my car being the problem child that it always has been. Didn’t go as completely to plan as we had expected.
    [​IMG]
    Arrived at Badger5 to undergo a few changes prior to mapping in the DirectPort meth injection. One of which was to change out my TIP as I wasn’t plumbing anything into it other than the DV.

    The pipework I had brought 90mm was proving difficult to fit because of the angles, etc.

    But Bill and the boys being awesome, had some odds and ends laying around to make a 4” TIP for me. Welded up a nice bracket to hold it all in place and machined up and welded a 4” section onto the back of my velocity stack which was only 3.5” to mate up with the new pipework. Nathan did an awesome job, you wouldn’t tell that any fab work.

    Also the guys drilled and taped a CM1 nozzle into the turbo compressor housing at the neck.

    [​IMG]
    [​IMG]
    With it all wired into the Ignitron ECU. So we had full control of what it was doing. We could easily move it to come in when we wanted.

    However........ it did absolutely nothing! Not a bean, Lambda wasn’t showing any additional fuel being there so we couldn’t adjust anything. We ran out of dyno time, but we will be revisiting it and getting a better understanding why it’s not playing ball.

    I’m going to run different levels of meth 80/20 ratio’s and do some logging, see what’s occurring.

    Determined to get to the bottom of it and get a better understanding of what makes it more efficient. Nice little project.

    Hopefully shedding some light and assisting others in a similar situation.


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  31. hydro s3

    hydro s3 S3 amk

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    Aw bummer mate. What are yous thinking could it could be something like a electrical fault? What meth ratio where you running before.
     
  32. S3AMJ

    S3AMJ OEM+

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    No nothing like that mate, I was running a 50/50 mix. Other cars that have run a similar setup have seen changes in the fuel trim immediately. Mine...... nothing! So something isn’t quite right. We tried adding 1+ deg of timing and the car wanted to pull back. So it shows that the original map was on point were Bill left off.

    All the nozzles are spraying as far as we could tell. So the next thing to test is the ratios... 80/20 meth/water and also 20/80 meth/water. See how it effects the car, weather we increase the octane more by adding more meth or adding more water.

    The car was overboosting for some reason, weather that’s because the water/meth was increasing pressure I dunno.


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    Last edited: Jul 18, 2020
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  34. hydro s3

    hydro s3 S3 amk

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    Hope you get sorting easy enough.
    The nozzle you got put in the turbo housing where did you get it from or what size cc was it?
    With the ignition ECU you use will it help anyway to find out your meth trouble
     
  35. S3AMJ

    S3AMJ OEM+

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    Just requires time and trialing out different stuff I think. I mean I’m not chasing numbers..... just when you fit something that supposed to allow more safer tune-ability, maximising the efficiency of your engine/turbo but does jack sh1t. Then something clearly isn’t right. When we turned off the directport and volute (turbo) injector, nothing happened either.

    I got the nozzle from Bruce Morris, CoolingMist who is the guru in this sort of stuff. I’ve been in talks with him and he said it should deffo be doing something, suggested the same as I’ve mentioned and potentially changing nozzle sizing.

    The size of the nozzle is a CM1 which is 85cc @ 200psi.

    I think my pump is currently running @ 190psi. So say that injector is probably more like 80cc.

    The Ignitron allows us to have full control of the meth, in terms of when it comes in, dials out, set up for failsafes so I can run dependant on it. Things like that, I do have a pressure sensor fitted so it shows there is pressure there. Part of the failsafe.

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    Last edited: Jul 18, 2020
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  36. S3AMJ

    S3AMJ OEM+

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    Ok...... completely out of the blue. I am now the proud owner of another car! This A3 was owned by a Neil Newman a couple years ago, who had put a lot of time and effort into including a lot of money!

    I couldn’t pass up the opportunity on buying this car because it was built by none other than our awesome tuning team Badger5.

    [​IMG]

    [​IMG]
    [​IMG]

    My next build was to go stroker and a big turbo...... This is exactly that!

    2008 Stroker with a GT3071 Billet comp. it’s only covered 3000 miles since it was built back in 2016.

    My plans are to drop this engine into my S3, swap the front brakes over as this has some nice 8 pot K-Sport calipers on 356mm grooved discs.

    [​IMG]

    Then possibly sell the rest..... and the list is extensive!

    Emerald K6 ECU
    Vibratechnics Engine and Gearbox mount
    02J 5 speed Wavetrac LSD
    02J 5 speed reconditioned gearbox
    Stack Boost Gauge
    AEM AFR Gauge and controller

    That’s just off the top of my head.

    I would also sell my current engine and K04-380 hybrid setup, cupra r brembo’s, etc.

    Watch this space...............


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  37. Asim1

    Asim1 Registered User

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    Lucky guy
     
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  38. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    Put me Down for the LCr brembos that looks like a true sleeper what bhp is it running
     
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  39. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    @danny_dj3 turbo setup for you if you decide to stick with it
     
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  40. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    5 speed is it a fwd how it handle putting the power down
     
  41. S3AMJ

    S3AMJ OEM+

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    Haha you’ve got first dibs I’ll obviously post everything for sale in the right section when they do become available. It’s currently around 416bhp. Far more potential it was just the injectors that were maxed out being 550cc.


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  42. S3AMJ

    S3AMJ OEM+

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    Yeah FWD mate, shame because if it was Quattro I would have used the Wavetrac LSD in my gearbox when it gets built.


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  43. danny_dj3

    danny_dj3 Registered User

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    hmm......got me thinking now. im defo interested in gauges.
     

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