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Relentless 3" Downpipe, decat and Powerflow System Fitted! Lots of Pics!!!

Benjiman46 Jul 31, 2012

  1. Benjiman46

    Benjiman46 R-Tech Terrorist

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    First of all, I would like to say a MASSIVE thank you to all the guys at Top Gear Performance who carried out all this work and put up with me taking loads of pictures :D

    The first thing to do then is remove the old, heavy, restrictive exhaust...


    [​IMG]


    [​IMG]


    Then, instead of dropping the subframe, and seeing as my flexi was already knackered and needed replacing, we decided to butcher the old downpipe to remove it, chopping it just above the part where it splits in two.

    [​IMG]


    [​IMG]


    Look how restrictive this part is :S

    [​IMG]


    The next step was to make access to the top of the turbo/downpipe area.

    Remove the charge pipe.

    [​IMG]

    Then you will have a bit more room to reach the downpipe to turbo nuts.

    [​IMG]

    Removing the top one is easy enough

    [​IMG]

    But the next one required this special tool we threw together...

    [​IMG]

    The last one should then be on the bottom and clearly visible (makes sense to leave the easiest till last)

    [​IMG]

    Downpipe removed! (After about 5 hours)

    [​IMG]

    Look at the comparison between old and new... Unleash that turbo!

    [​IMG]

    Fitting the new downpipe was a lot easier and took only an hour to do, but we had to chop the hanger off the new downpipe to allow us to fit it (as we didn't drop the subframe) Don't worry, it gets welded back on later...

    [​IMG]

    All fitted and nicey nice :) Not much room at all though!

    [​IMG]

    We used new loc-nuts as the old ones were nyloc nuts (very stupid idea on a turbo) hence why it took so long to remove them, the nylon had melted into the threads.

    [​IMG]

    Now to fit the de-cat and the rest of the system!!! I was very excited at this point :D

    [​IMG]


    [​IMG]


    [​IMG]

    The first part of my system was bent into shape and offered up to the car...

    [​IMG]

    These were the boxes I chose (Didn't want it too loud)

    [​IMG]

    First box tacked in place

    [​IMG]

    Second pipe bent into shape and tacked in place

    [​IMG]

    The final stages of bending for the back box

    [​IMG]

    Back box offered up and tacked

    [​IMG]

    To make the 180 degree bend, two 90 degree bends were TIG welded together to make a nice pretty finish (and optimum flow) Then the t
    ailpipe offered up and tacked in place...

    [​IMG]

    Constant checks were made to see if it was level and to ensure the exhaust didn't hang too low and f
    inally the whole thing was removed and precisely welded to ensure perfect sealing...

    [​IMG]


    The exhaust was then put back on the car, level checked, then all the hangars that were needed to utilise the existing rubbers were welded into place and it was finished!!!

    [​IMG]

    Later that day once the car was thoroughly warm, I thought I'd make a short video to demonstrate the sound... Beautiful :)

    Audi S3 3" Downpipe, Decat and Powerflow Exhaust - YouTube

    Thanks for viewing and I hope it was educational or informative to a few people on here planning on doing this :) Big shout out to Top Gear Performance in Doncaster Top Gear Performance Doncaster

    Ben
     
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  3. Nogmeister

    Nogmeister Registered User

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    How much did it all cost ya mate?
     
  4. aragorn

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    What size is the exhaust? 2.5"?

    Shame they havent used a proper mandrel bender :(

    You need to do a video of the car on the move, rather than just revving while stationary. Stationary revving always sounds a bit limp and ghey as theres no load on the engine.
     
  5. Benjiman46

    Benjiman46 R-Tech Terrorist

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    Hiya mate, for fitting the downpipe and decat, and making and fitting the custom exhaust it was £508, I bought the downpipe as well as a manifold from relentless for $450 (£296) so add a percentage of that to the £508 for the total cost :)

    It is 2.5" yeah, They use a different type of pipe bender, but I'm not sure what it's called... Just as good and plenty enough flow for my needs :)

    and I'll be getting some drive-by videos done soon to show the sound properly, I only got the exhaust done last week :)

    Ben
     
  6. JtotheD

    JtotheD Registered User

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    exactly the same set up i have mate. i have a sports cat tho. i'm impressed with mine. how you finding yours?
     
  7. s3clarke

    s3clarke Money grabbing s3!

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    looks good ben :)
     
  8. Benjiman46

    Benjiman46 R-Tech Terrorist

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    Nice one :) It's awesome pal, pops and bangs alot without the cat though lol But I don't mind that ;)
     
  9. Benjiman46

    Benjiman46 R-Tech Terrorist

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    Ahh cheers dude :)
     
  10. Dan-Jnr

    Dan-Jnr Registered User

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    Looks like a tasty exhaust system.
     
  11. s3gazz

    s3gazz Registered User

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    look great and sounds great mate does the downpipe touch the subframe once u cut the hanger off
     
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  13. Benjiman46

    Benjiman46 R-Tech Terrorist

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    Well it did, but it got welded back on when the rest of the hangars were made up so now it doesn't. I've noticed it vibrates when turning and accelerating, which probably means it's touching the subframe every now and again.. Nothing a red dog bone mount can't fix ;)
     
  14. s3gazz

    s3gazz Registered User

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    em thought it might mine does now but is the v1 thinks its pipewerx for me
     
  15. Benjiman46

    Benjiman46 R-Tech Terrorist

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    I'd go for the V2 relentless mate if it was my money, if you get them direct from the USA and they're very cheap.

    Just ordered a red dog bone mount poly bush off the 'bay :)
     
  16. s3clarke

    s3clarke Money grabbing s3!

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  17. s3gazz

    s3gazz Registered User

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    thanks mate iv already got the red dog bone mount on just sick of the vibrating noise.

    what v mani u running im after the v3 when its out
     
  18. [Dave B]

    [Dave B] Daddy

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    Thanks for the pics, helps to give me an idea of what I'm getting myself into when I get around to fitting my Pipewerx downpipe/cat and miltek system...looks like I should have the grinder/dremel handy!
     
  19. carl-1968

    carl-1968 A4 sold, lots of bits available, ask for details

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    Looks sweet, I had a 3" custom made for mine and it sounds superb, even though its a Diesel lol
     
  20. jamie408

    jamie408 Registered User

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    quick question. having not fitted a cat does the EML not light up????
     
  21. superkarl

    superkarl MAN OF STEEL

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    it will do eventually, mine came on after a week. doesnt cause problems though and can be coded out
     
  22. S3 Rav

    S3 Rav Registered User

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    Your near side tyre is the wrong way around.
     
  23. jamie408

    jamie408 Registered User

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    coded out using VCDS??
     
  24. superkarl

    superkarl MAN OF STEEL

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    no in a remap. any decent tuner could do it
     
  25. jamie408

    jamie408 Registered User

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    thanks mate
     
  26. Ryan_W

    Ryan_W Registered User

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    No it's not mate. Vredstein Ultrac Sessanta tyres are made that way.

    [​IMG]
     
  27. Benjiman46

    Benjiman46 R-Tech Terrorist

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  28. Benjiman46

    Benjiman46 R-Tech Terrorist

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    On an APY engine (what I have), it doesn't have a post cat Lambda sensor, so it won't ever come on, on the AMK and BAM engines, it will though because they both have post cat lambda sensors.
     
  29. Benjiman46

    Benjiman46 R-Tech Terrorist

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    And plus 1 on Ryan's post, very good diagram too, thanks :)
     
  30. jamie408

    jamie408 Registered User

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    ok kool in the process of geting a 52 plate s3 so what engine is that?? BAM??
     
  31. Benjiman46

    Benjiman46 R-Tech Terrorist

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    Yeah will be BAM, it should have a bit of a facelift.. Slightly different back lights and tiny bit different interior and badges.. OH... and 225bhp as standard ;)
     
  32. jamie408

    jamie408 Registered User

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    happy days. its got white leather and 225bhp 4x4 and a cat back system 100.000 miles payin £3k for it the door cards look real nice i think with black and white leather
     
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  34. marknjayne

    marknjayne Registered User

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    fantastic buddy...im over at exhausts uk on friday having a 3" downpipe and 200 cell cat itted to my tt225...getting it ready for big power
     
  35. jamie408

    jamie408 Registered User

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    yeh im wanting get a downpipe too
     
  36. Danny22

    Danny22 Registered User

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    Sounds very nice.....Where did you get your plates from mate??
     
  37. s33nyboy12

    s33nyboy12 Registered User

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    Sorry for hijacking .......... £3k is a bargain! Bit too cheap I think, I'd get it checked by someone who knows s3, borrow a vcds and scan it. Fsh? Hpi clear?

    Use buying guide on here in stickies , cheers, Sean
     
    Zman6000 likes this.
  38. jamie408

    jamie408 Registered User

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    hehe its not what u no its who u no tbh mate. its got FSH shed loads of receipts. body work is perfect and no fault codes. thats what you get when people fail to pay for a car mate. it is hpi clear aswell
     
  39. Benjiman46

    Benjiman46 R-Tech Terrorist

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    Got them from Dub Meister mate, they make them in Germany from genuine German plate materials and ship them over.

    Ben
     
  40. s3clarke

    s3clarke Money grabbing s3!

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    cheers bud, seems decent priced if its good
     
  41. Benjiman46

    Benjiman46 R-Tech Terrorist

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    Yeah apparently they stop the engine rocking and make gear changes faster and smoother... But also increase engine vibration inside the car. Hense why I went for the red one for the diesel A3 and not the yellow one for the S3. They're awful for vibration apparently!
     
  42. Dan S3

    Dan S3 Registered User

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    I was told either dog bone mount will wear in after few hundred miles and the vibration becomes a non issue
     
  43. Jambo26

    Jambo26 Registered User

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    Could you do a video for sound purposes please would like to hear yours please

    Jamie
     

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