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My minor modding thread

<tuffty/> Jul 29, 2009

  1. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    4C09701C-D320-41DC-9B4C-BDF61C223D7D.png Another daft question but on the drawing hose 17 goes to number 19 is that on the block, I should of fitted all these before I fitted the headlights and front end back on I’m struggling to for access but wanted it in to try and get things wired up
     
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  3. <tuffty/>

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

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    Take the front off mate... its dead easy

    <tuffty/>
     
  4. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    upload_2020-6-20_22-27-0.gif I knew it hopefully the rain. Holds Off tomorrow cheers tuffty
     
  5. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    Was there a reason why you used the 1.8t throttle body over the r32 one ? Or is a case of it would be cleaner look as the vr tb is water cooled
     
  6. <tuffty/>

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

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    It's not a 1.8t TB dude... 1.8t is 60mm...this is 70mm from a V6... R32 is 75mm..

    I used the 70mm for a couple of reasons... First was I made over 600hp using it on the 20v engine... Secondly it fits better in the available space...

    You have to hack it about a bit to get it to clear the fans... And that's with the V6 slim fan pack too which of course is a must have

    <tuffty/>
     
  7. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    My bad didn’t realise the v6 and and r32 were different just presumed it was the 1.8t when you adjusted the inlet fixings, yeah I have the slim fans fitted and it’s tight just wondering if the r32 one I got will fit as obviously it’s not meant to be fitted there with standard inlet, not looking forward to
    Trying to Pipe the fmic it’s already tight for room
     
  8. <tuffty/>

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

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    That's why I did mine the way I did it... Gives me all the room

    <tuffty/>
     
  9. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    45rA Guy
    Yeah I should pay attention to the little details and make life easier for myself ha
     
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  10. <tuffty/>

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

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    Little update.... things are moving quite slowly... I haven't really done much to the car other than drag her *** out once in a while for a drive... and to charge the battery lol

    Anyhoo... I now have the parts ready for the next 'phase'...
    IMG_20200824_161436.jpg

    ACL big end bearings... already had the ARP rod bolts but in there for effect... also the weld on fitting for the oil drain in the sump...

    I have a cap to use for now as I want to finish the engine side of the mods in this phase ready to then get the remaining parts ready for the turbo fitting...

    Turbo is at AET having the hot side removed as try as I might I have been unable to free it and so rather it was dealt with someone more setup for it... hopefully it will just pop off easily and the turbo survive and still be usable...

    I have some aircon pipes coming too so will get that sorted as well...

    Once I know where I stand with the turbo I will start collecting the remaining bits to do the fitting... bends etc for the downpipe and wastegate, stainless tube and fittings for the coolant lines, oil feed and drain lines...

    I also need to sort out an oil cooling solution... the oil temps have been exceeding 100deg in the warmer weather... this may change once the aircon is working again and slow speed fans are always on but I have been meaning to sort something for a while now so this will be done in due course...

    In fairness... I don't actually miss the power of my 20v... I do however wish I had a bit more just to get over the flatness after the initial pickup... the 3.2 certainly feels more lively at lower rpm so with the turbo picking up the slack she should be pretty damn drivable...

    Feeling a bit more motivated to crack on with her now... be nice to make some progress at least :)

    <tuffty/>
     
  11. S3AMJ

    S3AMJ OEM+

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    Looking forward to this mate, it’s been a king time coming. Hope AET can sort out your turbo, like you mentioned it’s in good hands.

    Have you got room anywhere for an oil cooler? I was in traffic yesterday for an hour stand still business down near Stonehenge and my temps were creeping up, I’ll be pinching the 13 row oil cooler off my A3.


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  13. <tuffty/>

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

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    Yeah I have room... prob put it up top of the FMIC like we normally do tbh...

    Just need to sort out the sandwich plate setup etc

    <tuffty/>
     
  14. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    I have no doubt that you will be up and running before mine and that it will look like it came out the factory with knowing how you like your oem+
     
  15. S3AMJ

    S3AMJ OEM+

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    I was watching some of youtuber decimal tenths strokaaa motaaaa stuff he sourced his sandwich plate from somewhere and made some notable comments about what to look for and he got it cheap. I don’t honestly remember though.


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  16. <tuffty/>

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

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    OEM + will be tricky to pull of tbh... I have have plans for a clean and co-ordinated look though

    <tuffty/>
     
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  17. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    I’m sure it will look tidy, where as I’m sure mine won’t have been looking at a few to get an idea of how to make it look tidy, that Darren francis on Facebook engine bay is fantastic, makes me want to take mine out and start again ha
     
  18. S3AMJ

    S3AMJ OEM+

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    I’ve wanted to do a wire tuck and hide some things, hats off to those have take the time to do it! I’m sure yours will look good TJ..... after all, it’ll have a 3.2 turbo in the engine bay. Only a handful can say they’ve done that.


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  19. <tuffty/>

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

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    Darren has done a few of these tbh... he was behind Eddies conversion too...

    I drew a little inspiration from it in terms of direction as tbh there isn't much info out there which is why hopefully my thread and subsequently yours will help others with this type of conversion

    <tuffty/>
     
  20. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    Yeah,yours will be the do’s and mine the dont’s :blink:
     
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  21. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    So I started to tackle the wiring and have a few questions there was two plugs and a ground wire that headed to where the throttle body was originally one is for the throttle body I can’t make out what the other one and ground wire are for 757D06FC-500B-4C10-BFA7-6E9AEC0C1120.jpeg

    After the injector wires there’s a plug( not sure if it’s for oil level sensor in sump?) and a knock sensor where should these being going to? Does it have 3 knock sensors? As I have a two already at front of the block by the oil housing
    51145AD5-5D7C-4796-B8CF-E75A032095F9.jpeg
     

    Attached Files:

    Last edited: Sep 3, 2020
  22. <tuffty/>

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

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    Assuming that the 6 pin plug is the TB the 2 pin next to it is the PCV valve on the inlet mani

    There are only two knock sensors... one on the front of the block between cyl 4/6 and one round the back by cyl 1/3... other wire is the sump sensor...

    Ground wire went to a bolt for the SAI/coolant flange out back iirc... I just moved it to another bolt when I relocated the TB wiring...

    <tuffty/>
     
  23. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    ah right I was thinking this was a knock sensor Near the clucth end of the block but I guess it’s not
    28A62AC8-FB9F-49D9-BD86-04A2F9E61E92.jpeg

    Anyway rained off for the minute but having a bit of trouble with the injectors doesn’t seem to sit right F86056D5-DE4C-4231-AF3E-E3F3950F61D8.jpeg
     
  24. <tuffty/>

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

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    1st pic is the crank sensor...

    Injector body looks too short mate tbh... mine are Bosch PN: 0280158123
    Screenshot 2020-09-03 at 13.45.23.png

    <tuffty/>
     
  25. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    Yeah I thought so , Ive spoke to rushworth and will send them back , as always thanks for the help been putting the wiring off for two long found a shattered connector on the 3.2 loom local Audi want £20 for it could buy a full loom for that lol
     
  26. <tuffty/>

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

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    The plug will have a part number on it... search ebay as most of the VAG plugs are available cheaply on there

    <tuffty/>
     
  27. MPH

    MPH Registered User

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    What plug do you after mate as I've got a few spare ones knocking about

    Sent from Syknet Global Defence Network
     
  28. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    Ordered it with parts request received it today thank for the offer
     
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  29. <tuffty/>

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

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    This week turned out to be pretty decent...

    I have been struggling to get the hotside off my GT35 and with Covid I have not really been to Bills much at all this year to sort it all out...

    In the end I got Alex to send it off to AET to see if they would have more success... this week it returned...

    Ta Da!!
    Screenshot 2020-09-26 at 14.58.52.jpg

    There was an issue with carbon apparently... it was suggested it was the seal but the turbo never smoked at all and the cost for the work was most of the way to the cost of a replacement CHRA brand new so I just asked for it to be returned as is and if it becomes an issue later then I'll deal with it then...

    Cleaned up the CHRA... actually looks mint tbh... and the bearings are fine too...
    Screenshot 2020-09-26 at 14.57.17.jpg

    Screenshot 2020-09-26 at 14.57.36.jpg

    And gave the hotside a blast too
    Screenshot 2020-09-26 at 14.57.57.jpg

    Happy days... feeling a little more motivated to crack on... maybe next week lol...

    Few more things to sort obvs but this was a big hurdle to get over to allow me to even fit the thing at all :D

    <tuffty/>
     
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  30. S3AMJ

    S3AMJ OEM+

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    That’s a result mate! Glad to see it wasn’t a major issue. So are you saying...... it might be all bolted up next week?

    Looking forward to seeing how you get on.


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  31. <tuffty/>

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

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    lol... comedian :)

    <tuffty/>
     
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  32. S3AMJ

    S3AMJ OEM+

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    Sorry couldn’t resist! But joking aside mate, good news.... I’m actually as excited as you are! I’m hoping to be up in a couple weeks, be good to catch up with you then.


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  34. b2

    b2 Registered User

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    Hey Tufty you going to use the standard 6 speed quattro gearbox? I heard the turbo r32 boys like to use a modified 02M with diesel final drive to make most of the extra power. The reason I am asking as I am interested in this gearbox setup for my stage 2 1.8t too.
     
  35. <tuffty/>

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

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    I am using a standard 4-motion box... the ratios are alleged to be a little taller than the R32 apparently but not really looked into it too much

    I had considered the derv ratios but tbh given I had 620hp out of the 20v on a std S3 gearbox and got on with that ok I think a VR6 running 450/500hp will be ok on std ratios...

    I suspect the main reason the VR guys run the derv ratios is for better top end speed/lower cruise ratios... my 20v redline was 7.8k but I have no intention of revving the VR that high so you will lose 10/15mph per gear...

    I plan to leave the manual standard as it will make it easier/cheaper to replace if needs be... the only other thing I may do at some point is fit a DQ500 as IECU will be supporting DSG properly in the next firmware update

    <tuffty/>
     
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  36. <tuffty/>

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

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    Not much to update on as no work has really been done but...

    Stumbled across this item in my research for oil and water line suggestions for the VR... apparently its what HPA use...
    Screenshot 2020-10-31 at 17.20.11.png

    Essentially you use the cam chain tensioner to bolt this to the head... (and copper sealing washers)... you can then take the oil feed off this for the turbo and is obviously already filtered... I have got one now so might try this rather than off the back of the t-piece and having to use a separate inline filter...

    The other little development is this...
    Screenshot 2020-10-31 at 14.12.33.png
    This is a cutting jig for making a 6 into 1 merge collector.... I'll leave it at that for now as this is still being decided on but this would make life a bit easier for turbo fitment, wastegate fitment and everything in between...

    <tuffty/>
     
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  37. Tj 0785

    Tj 0785 Registered User Bronze Supporter Silver Supporter VCDS Map User

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    Looks like a nice solution better than fitting a sandwich plate to tap off from
     
  38. TrueSoft

    TrueSoft Registered User

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    Just a BIG thumbs up from me.
    Its been great reading for last 3 months.
    Great insight and a massive learning curve.
    I love my 2003 S3 and have been inspired to do more to my car.
     
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  39. <tuffty/>

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

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    Thanks dude :)

    <tuffty/>
     

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