1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

My minor modding thread

<tuffty/> Jul 29, 2009

  1. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Well one is missing the balls and the cage so not surprising they look different :)

    General wear looks ok, nothing obvious but difficult to tell as its in pieces so can't check it easily

    Drive train is essentially std and designed for around half the power I run so as with all things modded while it will handle power increases to a degree longevity window decreases substantially so who knows... the car has 130k miles on her on these parts so something was bound to go at some point

    <tuffty/>
     
  2. Avatar

    Google AdSense Advertisement


  3. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Been a car fixing kinda day... well... mostly at least... the fuel leak on the A2 is getting worse so started on that seeing its the daily only to find the gasket I had ordered for the tandem pump was wrong... disappointing

    This left me essentially with no working car... so stuck the S3 on the ramp instead as all the parts for that had turned up too...
    [​IMG]

    [​IMG]

    CV joint ready for greasing up...
    [​IMG]

    ...and fitted
    [​IMG]

    New rear doughnut fitted...
    [​IMG]

    All going well so far... I had also bought some replacement number plate lights as the old ones were broken...
    [​IMG]

    Only problem was to fit the I needed to remove the boot trim strip and I honestly could not be ar5ed with that so cleaned up the existing holders and just fitted the lenses instead... will sort the full job out at a later date..
    [​IMG]

    Finished the day off helping Bill bleed the clutch on his Leon which was being particularly difficult...

    Was nice to drive the S3 again after nearly two months off the road...

    Will be at Bill's tomorrow to finish the A2 off as driving the S3 to work in this weather just fills me with dread lol

    <tuffty/>
     
    limbo118118, JOSEA3T and S3Alex like this.
  4. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Change the pads and rotors today... I have been using 330mm rotors and Ferodo DS1.11's... love the pads and the confidence they give but hate the fall out on the wheels as its more than just dust... the stuff sticks like nothing I have ever seen before and makes cleaning my wheels mostly impossible without actual scrubbing and quite frankly I can't be bothered with that...

    The other issue I have is the std size pad for my AP's needs a 60mm deep rotor and most are setup for 50mm deep pads... I can use pads designated to be rears though as these seems to be the right depth but its limiting the choice of pad I can use and the rears inherently seem to have less material depth meaning they don't last as long...

    Our resident brakespert @Prawn suggested I tried some Mitex M1155's... boy did I struggle to get a part number though... my AP Racing CP6600 calipers (TVR branded) are the same pad pattern as the Mk4 Ibiza Cupras with the AP caliper option... this is my goto car when searching for pads but couldn't find a part number for that car... then I discovered the Clio V6 uses AP's with the same pad pattern so managed to finally track down a set of fronts... Part number was MDB2207M1155 (MDB2207 is the normal pad type)...

    Left me with a bit of a problem... the rotors...

    As luck would have it, Bill recently went to a fully floating setup and 'retired' his old set which are the same bells as I have but a 335mm x28mm rotor with 60mm pad depth... while they were not really going to be much use on a race car they would serve me for a while and at least meant I could try the rotors out to see if they would work with the pad size without committing to the billion or so quid they would cost to buy only to find they didn't work so big thanks to Bill as always for having my back...

    So started by undoing the caliper mount bolts... was a little worried about them as they hadn't been undone since I fitted them some 7 years ago and bolts in alloy stuff in that environment tends not to end well when you undo stuff...
    [​IMG]

    Thankfully they both came out easily!...

    Think I got the use out of the old pads :)
    [​IMG]

    So you know what I was wobbling on about earlier regarding the pad depth issue... here is the comparison of the pad depth between a 'rear' pad and the correct 'front' pad...
    [​IMG]

    Not much in it you may think but its enough that on a rotor designed for a 50mm pad it will over hang at the rear and wear oddly (plus it did cause unwanted pad knockoff on more than one occasion)... a pic of the larger pad on the old rotor... this is with the top edge of the pad flush with the outer edge of the rotor...
    [​IMG]

    ...compared to the 335mm rotor...
    [​IMG]

    Much better... this did present a new issue which I anticipated anyway hence removing the caliper from the bracket...
    [​IMG]

    Larger rotor now hits the caliper... so I made some spacer plates up from 2mm thick ali...
    [​IMG]

    ...and all is well again...
    [​IMG]

    All back together :)
    [​IMG]

    Now for the nearside.... this didn't go quite as well...
    [​IMG]

    B*gger!... 12.9 hardness bolt just sheared off!!... in fairness I was surprised only one did this but not surprised it was the side that spends its life in the puddles by the side of the road...

    Never mind... drilled it...
    [​IMG]

    ...helicoiled it...
    [​IMG]

    ...all back together :D
    [​IMG]

    Initial thoughts are that they seem to have a nice bit of bite but I am still bedding them in and bearing in mind that they are previously used rotors so need to sort themselves out...

    Hopefully they work as well as the DS1.11's but don't make my wheels un-cleanable (I don't mind a bit of dust)

    <tuffty/>
     
    Prawn, S3 Hilife, jojo and 1 other person like this.
  5. Prawn

    Prawn My other car is a MINI!!!!

    11,846
    4,022
    113
    Good stuff PT!

    I hope my pad suggestion serves you well!
     
    <tuffty/> likes this.
  6. hydro s3

    hydro s3 S3 amk Team Ming Blue Audi S3

    632
    153
    43
    Just read this whole thread. Excellent amount of detail put in by you and Bill. Gave me plenty of ideas and its definitely a go to thread to find out how to do things.
     
    <tuffty/> likes this.
  7. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Thanks... :)

    I have to go through it again soon to replace all the image links thanks to Photobucket lol

    Some more updates soon... some remedial work to do :)

    [​IMG]

    <tuffty/>
     
  8. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Bought a few bits off Shaun who was breaking his car (sadly :cry: )

    One such part was the new front grille... seems this is the only way to get hold of a replacement facelift S3 grille badge these days as the original is now obsolete..

    Mine is looking a little faded..
    [​IMG]

    New one looks a little better...
    [​IMG]

    ...but obviously the chrome surround had to go... so removed it from the grille...
    [​IMG]

    Keyed the chrome using 400grit wet n dry then gave it a couple of coats of etch primer... felt good to be painting stuff again lol...
    [​IMG]

    And finally a couple of coats of matt black...
    [​IMG]

    Will let that dry fully before refitting and give the rest of the grille a quick clean...

    I then moved onto my wheels which I gave up with ages ago due to the fallout from the DS1.11's... have tried various fallout and wheel cleaner products but on advice from Fran of FM Detailing fame I gave Bilt Hamber Korrosol a go...
    [​IMG]

    As you can see there is a lot of fallout baked on to the wheels...
    [​IMG]

    Did an initial soak leaving it to dwell for 5 mins or so...
    [​IMG]

    ...sorta touched them...
    [​IMG]

    So did a couple more applications agitating with a scrubbing brush... a bit more came off this time...
    [​IMG]

    Has potential but clearly I need to put a little more effort in to get them clean so at some point they will need to come off and have a good day spent on them to get them sorted...

    The todo list is starting to grow again lol...

    I also acquired Shauns door and rear qtr blades plus front and rear bumper panels as he had them all painted... my passenger side door blade is starting to lift away do to corrosion so no doubt there will be some horror uncovered when I remove them... not ready to deal with that as yet :)

    <tuffty/>
     
    voorhees, Goubo1 and jojo like this.
  9. Simon/s3

    Simon/s3 Member

    32
    0
    6
    Hi tuffty,
    I'm currently working on a stack pillar mount like the one you've done, great job by the way.
    Could you tell me where you brought the vacuum pipe in from the engine bay to the cab and how you got it up to the pillar?
    Thanks

    Sent from my E6853 using Tapatalk
     
  10. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Vacuum pipe was bought from A N Other seller on eBay... standard off the shelf stuff...

    I routed it into the scuttle then through the black cover (on a facelift or white on pre-facelift) on the drivers side to get it into the cabin area

    <tuffty/>
     
  11. Simon/s3

    Simon/s3 Member

    32
    0
    6
    Thanks I think I know where you mean the black box under wiper mechanism?
    Where will it come out in the cab will I need to remove dash or anything to find the end?

    Sent from my E6853 using Tapatalk
     
  12. Avatar

    Google AdSense Advertisement


  13. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    That's the one... You will need to remove the lower part of the dash to get your hands up there

    <tuffty/>
     
  14. Simon/s3

    Simon/s3 Member

    32
    0
    6
    OK nice one, how do you pop the light switch out BTW?
    Thanks for you help

    Sent from my E6853 using Tapatalk
     
  15. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    I never bothered... you have to twist it in some way or other (a few people have posted on this before) but all I did was unplug it once I dropped the lower dash

    <tuffty/>
     
  16. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Little update... for a while now I have been wanting to sort the fuelling out on my car... I was running 750cc injectors @4bar which equates to around 865 ish cc...

    Logging the duty and lambda correction suggested they were pretty much maxed out giving me no head room if I needed it so... today Bill kindly gave me a slot on the dyno and I fitted a set of 1000cc injectors swapping the the FPR from 4bar to 3bar...

    20180121_111956.jpg

    Things went well... injectors behaved nicely with very low IDC but... it was evident that something was amiss..
    tufftyfuelling001.jpg

    Despite adding fuel in the map the ECU was still trying to add fuel... AFR was fine but it suggested fuel just wasn't getting through quickly enough... Bill had seen this before on other builds and the fix was to fit a billet rail (larger) and larger fuel line from the inline pump to the fuel rail...

    To be honest I knew I was close to the limit with standard lines and always planned to upgrade but.. seems this may force my hand a bit :)

    Before I do anything though I need to check the fuel pressure though... its entirely plausible that either one of my pumps could be weak... I am still on the original (17yr old) intank pump and the DA inline has been in some 8 years now so who knows... we didn't have time today to hook up the pressure gauge so will either rig up a pressure sender and connect it to the FIS Control (will do that anyway) or grab a run on the dyno at some point to test it...

    Power wise I was down a little peak power but gained a little midrange torque but this is easily within the normal operating range of a highly tuned car and I on the road its still fast as f*ck!

    Took a video of the 22psi run..


    ...and a graph...
    tufftyfuelling002.jpg

    Once I have sorted the fuel rail etc out then I might look at any tweaks to the map but tbh I can't imagine there is much more power there without compromising reliability and drivability and I am not a number chaser... my car is fast enough... :)

    <tuffty/>
     
    IanPG, hydro s3 and S3 Hilife like this.
  17. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    ...oh and of course took a couple of actual pictures too...

    [​IMG]

    [​IMG]

    <tuffty/>
     
  18. Erikn89nl

    Erikn89nl Well-Known Member

    933
    383
    63
    Oh good, I was getting worried this excellent photography blog was getting off-topic :p

    Good to see OEM+++ (how many pluses are you on now?) is getting further upgrades :)
     
  19. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    only the two ;)

    [​IMG]

    <tuffty/>
     
    Erikn89nl likes this.
  20. Alex C

    Alex C Well-Known Member VCDS Map User Audi S3

    3,364
    390
    83
    OEM#
     
  21. Prawn

    Prawn My other car is a MINI!!!!

    11,846
    4,022
    113
    Still the best car on the forum by a mile :hearteyes:

    Good stuff PT

    :racer:
     
    GeorgieS3 and <tuffty/> like this.
  22. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    For completeness I grabbed the dyno plots from Bills today...

    Previous full boost map run, current full boost map run and the fast road map run
    [​IMG]

    [​IMG]

    <tuffty/>
     
    andrew_wright and antwan64og like this.
  23. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    So with the New Year, new enthusiasm thing going on with the car I finally took to plunge on something I had been sitting on for most of last year..

    [​IMG]



    So.... you may have worked out that I am now running a standalone ECU... :)

    The Ignitron ECU is a focused ME7.5 replacement... its more or less plug and play hardware wise and so far has been a fairly painless experience to setup... its as OE++ as a standalone can get which is right up my street...

    I am going down the VE tuning route and have binned the MAF sensor... this meant I needed to fit a MAP sensor into the inlet so it could see both vacuum and boost so I used a 4bar Bosch sensor which is a standard VAG part...
    [​IMG]

    Its kinda 'thrown' in there for now to get the car running but the inlet will come off at some point and it fitted properly with a boss welded in..

    The ECU fits in the OE bracket too
    [​IMG]

    Ran the USB cable through to the car so I can easily connect my laptop if I need to (the ECU has an autolog feature which means I don't need the laptop connected until I want to download it for viewing!)
    [​IMG]

    Car started fine on first turn of the key... I am basically at the fuel tuning stage so no boost or other things just yet... just drive and adapt...
    [​IMG]

    The engine feels a little flat at the moment as timing is at a very conservative level until fuelling is done but overall the MAF less experience with this setup just shows how tetchy a MAF can be when at this level of tune... might explain why Audi decided to go MAF less on the latest RS3 engine...

    Starting to fall in love with the car again after a period of meh ness... I have a fuel rail on the way to address the potential starvation issue and will be doing a bit more work on things like baffeling the catch can and generally tidying things up... I may even revisit the camber plates and see if I can fit a more substantial spherical bearing in them now that the H&R's have removed the crashy ride (a contributing factor to the bearings popping before)

    So... bit of driving to do to get the fuelling adaptions sorted and then the actual tuning can begin... really looking forward to it...

    While I doubt that I will get any more top end power I will gain in drivability and the fact I can tweak as I go... ME7 tuning is quite involved and I don't have the time to spend on it... it also ideally needs emulating on the dyno for a few sessions to get it where it needs to be and trying to get Bills time on the dyno is just a difficult as he is so busy...

    This way I can get most of the leg work done then the dyno session can be to do the more interesting stuff... once there I can 'live' with it for a while and make small adjustments as required from logging and tuning on the go..

    Beyond that the ECU has 'toys' too... ;)
    27992870_10156240903904874_6313503085758689414_o.jpg

    Rather excited about this next chapter of the S3's modded life :)

    <tuffty/>
     
    ToughlilT, craigt1985, IanPG and 7 others like this.
  24. Rainbird

    Rainbird Active Member

    338
    195
    43
    Sounds like a cracking piece of kit. Good to hear you've got the bug back too :thumbs up:
     
    <tuffty/> likes this.
  25. Prawn

    Prawn My other car is a MINI!!!!

    11,846
    4,022
    113
    Looks like a really fantastic piece of kit PT!

    Really Impressed with how easily its been installed and up and running so soon!

    Can't wait to see how you get on tuning it
     
    <tuffty/> likes this.
  26. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Logging capabilities on it are cool... you can log using the software on a connected laptop or set it to auto log... it will then write a log based on variables you define to its internal memory that can be downloaded as and when... you can just set it and forget about it...

    If you have an issue at anytime you can easily just download the log and see what was going on at the time...
    log-sensors.PNG log-ignition.PNG log-injection.PNG
    All very cool stuff...

    <tuffty/>
     
    S3 Hilife, Alex C and andrew_wright like this.
  27. Stuart B

    Stuart B Well-Known Member

    2,584
    520
    113
    exciting times ahead :)
     
    <tuffty/> likes this.
  28. IanPG

    IanPG Well-Known Member Silver Supporter Team Nogaro Blue Audi S3

    1,510
    632
    113
    here's an ECU that's not been mentioned anywhere before?!?!

    any more info on it @<tuffty/> ?
     
  29. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
  30. Prawn

    Prawn My other car is a MINI!!!!

    11,846
    4,022
    113
    Wouldn't this be better with a MAF? :whistle2:
     
  31. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Pillock! ;)

    <tuffty/>
     
    Prawn likes this.
  32. badger5

    badger5 www.badger5.co.uk Site Sponsor

    9,759
    2,143
    113
    cos all oe's use them..... apart from those that don't :p
     
    Prawn likes this.
  33. Avatar

    Google AdSense Advertisement


  34. Pedrosousa

    Pedrosousa Member

    178
    3
    18
    Do you still have fis control working?

    Enviado do meu SM-G950F através do Tapatalk
     
  35. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Not at the moment... need to send the spec to Stefan and see if there is a way to display it over CAN as the iecu is CAN only and has no k-line comms

    <tuffty/>
     
  36. Pedrosousa

    Pedrosousa Member

    178
    3
    18
    Integrated haldex controller would also be a great mod

    Enviado do meu SM-G950F através do Tapatalk
     
  37. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    Its on the todo list apparently

    <tuffty/>
     
  38. Erikn89nl

    Erikn89nl Well-Known Member

    933
    383
    63
    Along with cruise control! :D
     
    <tuffty/> likes this.
  39. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    So... I posted in the FIS forum (http://fis-control.de/punBB/viewtopic.php?id=315) and sadly it seems that the IECU won't be able to communicate with FIS....

    I did get FIS up and running again though as the default loaded preset was block 1 of the ECU... this would essentially make FIS **** out from not being able to connect so the fix was to set external sensors as the default...

    Upshot is I can configure the FIS presets for external sensors so I can add a wideband controller, fuel pressure etc in addition to oil pressure and temp that I already have... that would give me enough data to keep me happy for the immediate potential issues...

    The ECU however will allow external sensors to be connected to its redundant connections...
    analogue-input.jpg

    analogue-input2.jpg

    ...which is quite nice...

    As much as I hate to lose FIS and its usefulness by connecting the sensors to the ECU it means they can be logged in context of everything else and the logging system on this ECU is awesome...

    In any case... I need glasses for reading and computer work but my distance is bob on... means I can't really see the DIS very well without glasses and can't drive with them on... might be time to move that on especially as I take my netbook that has VCDS and the Ignitron software on it in the car when I go out in her so I can live without FIS at the end of the day if needs must...

    Adding a sensor to an input adds a menu item that gives you a table to scale... really nice feature that :)
    oilpressure.jpg

    So far I have been working on coldstart.... or more specifically cranking... its little things like this that makes or breaks how the car feels overall...
    In the file below you can see a bit of a blip in revs on cranking when the engine catches... this gave a rather stumbly start
    cranking-coldstart-07.JPG

    ...bit of tweaking and the transition is smoother and now starts rather nicely
    cranking-coldstart-08.JPG

    Revs rise a little too high now but thats a tweak on the TPS side of things...

    Nerdvana :)

    <tuffty/>
     
  40. Erikn89nl

    Erikn89nl Well-Known Member

    933
    383
    63
    Indeed... soon as they sort out cruise control, I'm joining the queue for one of these!
     
  41. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

    22,417
    4,486
    113
    You will of course need to convert your loom and go DBW of course but if you pop over to the UK Prawn will knock that out and map it in a weekend LOL ;)

    <tuffty/>
     
    Rainbird and Alex C like this.
  42. Erikn89nl

    Erikn89nl Well-Known Member

    933
    383
    63
    Good thing I'm already doing all that, minus the Prawn
     
    <tuffty/> likes this.
  43. beeitch

    beeitch Member

    68
    1
    8
    Keep up the good work!
     

Share This Page