Grahams81-Leon 4wd, Big Turbo - Back in the saddle :-)

[grahams81]

What turbo are u going to run gt30 or gt35 perhaps

Thinking of either a gtx3071r or a 3076, i think a gt35 would be a bit too laggy.
Gonna go twin scroll to try and get it spooling as quick as possible.

 

[seatcupramad23]

Nice sensible solution really looking 4ward to completion of this build

 

[Applemobile]

Thinking of either a gtx3071r or a 3076, i think a gt35 would be a bit too laggy.
Gonna go twin scroll to try and get it spooling as quick as possible.

The GT series is a bit oldschool these days IMO, not looked at the precision 6262 or similar?

 

[grahams81]

I was thinking of the new GTX range - here's some bomf offof the 034 website -

Introducing the new Garret GTX line of turbos! After setting the standard in turbocharging in the early 2000's, Garrett has stepped up its line of GT turbos back to state-of-the-art status. Have your peak flow and spool it too! GTX wheels are the latest aerodynamic engineering from Garrett Honeywell, essentially what it gets you is the same power as the next biggest turbo but wtih the same surge and spool characteristics. In other words, the GTX3071 spools the same as the GT3071R but flows what the GT3076R does. More power, no compromise.

The above does sounds good to me...

I know the precision turbos seem all the rage at the moment especially with the guys over the pond.
Integrated engineering have been using a 5857 whilst testing there camshafts and have good numbers from them, but that perticular turbo looks to be a bit too large for my needs, i think a CEA 5557 is probably more suited to what i am looking for.

Anyone have any experience with the precision turbo's and are the ceramic centre bearings really worth the extra $550 ???

 

[calvinvw]

I was thinking of the new GTX range - here's some bomf offof the 034 website -

Introducing the new Garret GTX line of turbos! After setting the standard in turbocharging in the early 2000's, Garrett has stepped up its line of GT turbos back to state-of-the-art status. Have your peak flow and spool it too! GTX wheels are the latest aerodynamic engineering from Garrett Honeywell, essentially what it gets you is the same power as the next biggest turbo but wtih the same surge and spool characteristics. In other words, the GTX3071 spools the same as the GT3071R but flows what the GT3076R does. More power, no compromise.

The above does sounds good to me...

I know the precision turbos seem all the rage at the moment especially with the guys over the pond.
Integrated engineering have been using a 5857 whilst testing there camshafts and have good numbers from them, but that perticular turbo looks to be a bit too large for my needs, i think a CEA 5557 is probably more suited to what i am looking for.

Anyone have any experience with the precision turbo's and are the ceramic centre bearings really worth the extra $550 ???

There maybe old school turbos but precision have a problem with oil seals atleast garrett are tried an tested i believe in sticking with what works anything new other people can try an test last thing you want is it spitting veines through to your engine. Good luck with build.

 

[Applemobile]

Garretts still regularly poor oil down peoples inlets, and garrett rebuild prices are very high!

 

[styling]

how. will you manage. Haldex?

Sent from my HTC HD2 using Tapatalk

 

[grahams81]

how. will you manage. Haldex?

I'm planning on running a standalone Haldex controller like this one - http://www.exclusive-tuningparts.de/shop/product_info.php?products_id=25

Not going to be buying it for a while, i've still got loads to buy for the car ££££££££ -

Engine ----

Turbo - Garrett GTX3071 This will be needed soon to build the Manifold.
Exhaust Manifold Flange for DIY Manifold, already got most of the pipework.
Tial Wastegate,
Fuel Injectors, Fuel Pressure Regulator, Upgraded Pump,
Mapping Session,
Forge or Samco Coolant Hoses,
R32 Throttle Body,
Forge Race Intercooler,
Various Braided Pipes For Breather System / Catch Can.
Possibly IE Street Camshafts (funds depending)

Drivetrain & Chassis -

Lightweight Flywheel & Clutch - thinking Spec stage 3+ or stage 4,
Quattro Gear & Transfer Box - Bidding on one ebay.
Drivers Side Front Drive shaft,
TT / LCR Hubs, ARB, got LCR wishbones already,
Haldex Controller,
Standard TT Rear Brake Calipers for Quattro Rear Beam,
4 Pot Front Brake Calipers - Not sure what to get, haven't even thunk about it yet,
Coilovers,

Body & Interior -

Full Rollcage,
Various Gauges,
LCR Bodykit,
Respray,

Thinking with the amount of stuff to buy its gonna be a year before its on the road
But it will be worth it.

Todays progress-

I put the cambelt round the lower pulley and put the new lower cambelt cover on and then the lower auxillary pulley -

I then cleaned all the inlet cam followers up, and cleaned the cams up ready for installation -

I decided to use the original VVT chain tensioner for the engine (checked it over and no signs of wear) so just cleaned it up oiled it and put the new seal / half moon in using a bit of the silicone and put the cams in with the new Cam Chain.

Timed it up with 16 rollers between the marks on the cams, the cutouts on the cams are very slightly out to the arrows on the bearing caps but i think its just cos the cam chain tensioner isn't full of oil - its certainly not one tooth out on the sprockets...

Used the Redline Assembly Lube on the bearing faces.
Torqued up the camshaft bearing caps to 10NM.

Shot with the Camshaft Drive pulley & Belt on -

I put the new cambelt covers on but it appears im gonna have to trim the middle one to make room for the engine mounting bracket -

Next up i put the AGU large port Inlet Manifold on and bolted the standard throttle body on, im not gonna use it but just wanted it on to stop any crap getting into the engine -

I put the new dipstick tube on but i had to bend it to get it in - think i need to order a AGU one as i think there bent more to give more clearance.

The only job left is painting the Camcover red but i think it's gonna look a bit naff so might have it powder coated along with the engine mount bracket.

So that's pretty much it with the engine for now

Yesterday i got delivered loads of the schedule 10 1.5" 316 pipe bends for making the turbo manifold, the collector is on its way from the US. I've gotta order a Manifold flange from 034 Motorsports & the Turbo so i can get the Manifold underway.

Gonna start on the Audi S3 shell tomorrow and strip it and cut most the crap off it i dont need.

 

[calvinvw]

...

 

[calvinvw]

Timed it up with 16 rollers between the marks on the cams, the cutouts on the cams are very slightly out to the arrows on the bearing caps but i think its just cos the cam chain tensioner isn't full of oil - its certainly not one tooth out on the sprockets...

Nice build sure is getting there, i had the same problem i removed the cams like twice now an is still in the same location they are slightly off i couldnt understand why it was like that, on the pictures from VW of assemblying cams the arrows are spot on it made me scratch my head for a few days.

 

[Scott-o]

Awesome built mate! Looking forward to seeing it run, youll have to get yourself down to the local club rolling road days when its done.

Also join vagcars.co.uk if you would like and get a spare minute, its a north east vag community forum, always good meets etc

 

[grahams81]

Nice build sure is getting there, i had the same problem i removed the cams like twice now an is still in the same location they are slightly off i couldnt understand why it was like that, on the pictures from VW of assemblying cams the arrows are spot on it made me scratch my head for a few days.

Yeh i was a bit unsure myself mate, and i must admit i did have the cams in and out 3 times while i changed sprocket positions etc but it turned out i had it right first time.
Still all good practice tho.

 

[grahams81]

Awesome built mate! Looking forward to seeing it run, youll have to get yourself down to the local club rolling road days when its done.

Also join vagcars.co.uk if you would like and get a spare minute, its a north east vag community forum, always good meets etc

Yeh i would like to get out a bit when its running, hopefully bump into you. I must admit i'm fancying a couple of track days round croft when its ready but to be honest it won't be this summer, far too much to do still and the fact i work away from home every week doesn't help...only get weekends to play in the garage

 

[grahams81]

Well had a good day on the car, i've been working on the 4wd conversion as the engine is now finished.
My new 6 Speed 4x4 gearbox arrived today, won on ebay for £200. The guy i bought the back axle did agree to sell me his but he wouldn't return my messages so went back to good ol ebay.
Here's a piccy of it laying next to the Fwd gearbox -

On its own -

Well i also stripped the Audi S3 shell down, removed all the seats, loom and all the other crap. Half way there -

Turned it over (its amazing light when its stripped down) and removed the petrol tank -

Here's a couple of shots of the under side -

I managed to get the Leon partially stripped, got the carpets and trim out, bumper off. I've only got 2 axle stands so tried to get some off a mate but he was working so i've just got the front of the car in the air at the moment -

Couple of Pics of the inside of the leon -

One of my bengals apparently loves my leon always sleeps on the dash when i've got the doors open while im grafting on it - here he is -

 

[grahams81]

While i was waiting for the axle stands i decided to start drilling out the spot welds on the S3 shell, i was just gonna plasma cut it out so tried using it and its a bit messy & firey so thought i would drill the spot welds as it would be good practice for removing the leon parts -

Shots of the drilled out welds -

So at the end of play today i've finished drilling the spot welds out on the boot floor, panel above petrol tank and inner wheel arches.
Just got to flip it over tomorrow and drill out the spot welds on the frame rails and remove all the bits i don't need.

Can't believe how knackering it is drilling out spot welds and scraping of seam sealer... better get a good nights kip and have another full day at it tomorrow.
So long for now,
Graham.

 

[m0rk]

Do you think you'll need an IVA to get it back on the road?

 

[Ronin225]

Very interested to see how difficult this turns out to be, i ma end up seeing if feasible on my LCR
Will be watch lots so keep up good work

 

[grahams81]

Do you think you'll need an IVA to get it back on the road?

Not too sure mork, i've been looking on the goverment websites and a IVA test may be relevant as it has been modified, but there seems to be a bit of a grey area as to what constitutes too much modification and therefore an IVA test.
I would presume if the MOT tester is unhappy with it then maybe a IVA test will be required.

I am not planning on just cutting straight lines and welding in the s3 back end, i will be seperating the joints in the chassis legs and then reattaching the s3 ones. The joints will then be seam welded and may have plates welded over the areas (just depending on how happy i am with the look of the job)

Along with a nice full roll cage im sure it will be nice and stiff (safe)

 

[m0rk]

I think if you use the OE weld points, and plate if required - if you coat it in seam sealer you'll most likely be OK.

Before you cut the Leon, weld in a strut between the arches to stop them collapsing. Definitely if you're using Axle stands as the car will want to sag

 

[James.Judd.1]

Very impressed! I'll be keeping an eye on your build