Audi S3 GT3582R stroker Build (previously GT3071r)

[Feel]

Phil LOL, it was only last week I finally fitted my Feel Charge pipe only been on the shelf for 7 years and I have to say its great...... I gained 3g/sec in airmass flow.
The stock chargepipe silencer is super restrictive.

lol. I could've made a fortune if only you'd posted that yeas ago

 

[tufftybloke]

Awesome work. Really awesome.

Just one thing - the stock charge pipe has a little spigot/stub underneath that sits in one of the grooves on the bracket. I'm 95% positive that leaving this off some custom charge pipes I did a while back is what helped them to blow the silicon off the charge pipe, because the whole charge pipe moves north west in the mountings.

Sorry if it's a bit late, just thought I'd mention it.

Edit: Mind you, the ends of ours weren't swaged, but I would still think about it.

Your edit pretty much says it all dude lol...

Have made quite a few of these for customer cars including Bill's Lupo with no issue... the Lupo doesn't even run brackets...

Bead roll/swaged ends (or the lack of them in your case) will pretty much result in pipes popping off... never had a pipe come off once bead rolled and no need to use any other type of clip than the JCS hi-grips for the boost levels run on road setups...

I know the spigot you mean... I removed this on my modded OE pipe on the GT30 setup ages ago... the top pipe is pretty much solidly held in place by the brackets...

Biggest issue I will have tbh is if I have compromised the welds integrity by flushing them... Bill got good penetration when he did it but there is always a chance it could have a weak spot where I have got a little happy with the grinder...

<tuffty/>

 

[Pimped up vario]

The welds should be alright if you have chamfered the edges of the material.

 

[Lew]

Jealous is an understatement lol

 

[tufftybloke]

Small update... a few parts turned up this week...

...made a start on the back box...

...and roughly mocked up some tail pipe options in photoshop... these use tactically cut 3" stainless bends..

Slash cut and cutting to follow the bumper profile may be a bit more of a challenge...

hope to get a bit more done tomorrow... ideally the oil drain mocked up ready for welding and coolant lines... need to get this lot done so the welding of the manifold can be finished and I can get it off for ceramic coating...

Still waiting on a few other parts but hoping to have the engine in for the end of the month so I can get the DP and exhaust etc finished ready for first start!!...

<tuffty/>

 

[tufftybloke]

Little more done today...

Coolant lines...

Oil feed...

Oil drain...

There are of course a couple of gaps to fill lol... these will be filled with PTFE lined flexi's...

Now that the lines are essentially done the mani can go off for the final welding and then off to be ceramic coated..

Getting there

<tuffty/>

 

[rae1001]

Glad to see its getting closer, not long now untill your behind the wheel again!

 

[tufftybloke]

Day off to day to go a do some more... the build is at the loads of silly little jobs stage...

First job, tailpipe... had a go using two 90deg 1.5D bends...

...put the back box in place to get a better idea of where things were likely to end up...

Next I knocked up one of the hangers...

Bit more to do but parts of the box needs final welding now before I can do the rest and the DP needs fabricating before I can see what else needs doing to mate the back box to the centre section

Last job of the day... using a section from one of the tailpipe offcuts I made a bracket for the coolant lines...

Just need to make a little clamping bar to hold them in place and job done...

Getting there

<tuffty/>

 

[Chambers_CUPRA]

Awesome job

 

[tufftybloke]

Thanks all for your kind words

soooo... I slash cut the pipes... look a bit better I think..

...outside tailpipe slightly set back to follow curve of bumper

....done...

<tuffty/>

 

[Pimped up vario]

That is very well done. Tasty and beautifully precise.

 

[tufftybloke]

That is very well done. Tasty and beautifully precise.

Thanks dude

Little more today...

I had already replaced the exhaust lifters as there was a little bit of odd wear on the cyl 4 ones... when I rebuilt the head I had an inlet lifter drop its centre when I took it from the box... put it together hoping it would be fine then read about the issues Scullies had with a missfire having found a similar lifter issue... this of course bothered me so bought a new set of inlet lifters too

So stripped off the manifolds and cam cover (needed to anyway as the manifold goes off this week to be finished)

Good job I decided to do this as when I lifted out the 11th lifter the centre kinda stayed there :/

The culprit for whatever reason is a little clip that had come off and stayed inside the bucket... clearly no good would come of this...

Nice new ones ready to go back in...

...as I was in the mood for working on heads I stripped another one that was lying about and fitted super tech valve train to it

Loaded my wheels and tyres into the racing Golf ready for a trip to the powder coaters tomorrow...

<tuffty/>

 

[tufftybloke]

Another day off to get stuff done... loaded the Racing Golf up with my wheels to take to City Powder Coaters...

At £20 a wheel plus £5 to fit and balance the tyres I couldn't really be bothered to pursue painting them as it would end up costing me more in paint to get the finish I want... went for the plain silver rather than the sparkly silver as the sparkly effect was very sparkly and a little ott for me

Bumped into JoJo (a fellow ASN member and S3 owner) at Maccy D's too (crap selfie pic alert!)

The Golf was faultless on the journey (some 130 odd miles round trip)... not too shabby for a 22 yr old little 1.3

Back at Bills around midday and cracked on with pulling the mock up engine/box from the car...

After my initial selfie fail with JoJo, I gave it another go with the lesser quattro'd Mark...

Then Mr Wellings of Wellycooler fame popped in...

Slightly failed selfie in empty engine bay pic...

...and thats it until the weekend... more stuff on order and a couple more days off next week to pick up wheels and see if I can get a little closer to getting the engine in the car...

...and I finished off fitting the supertech valves to the customers head too ;P

<tuffty/>

 

[swedey21]

Keep up the good/anal work...not in a gay way like..

 

[tufftybloke]

More of the little jobs done this weekend..

The threads in the engine mount (the crappy one that gets in the way of cam belt changes) were pretty much non existent... in fairness its been off a few times and the threads don't seem to last more than a couple of belt changes before showing signs of failing...

So bought a helicoil kit and set about sorting it...

Drilled out the holes

Tapped then with the supplied tap...

...and screwed in a couple of helicoils (they were 16.5mmm deep so used two for better thread contact on bolt)

Next I removed my gearbox from the the build engine for cleaning...

Gave it a good going over with a water based detergent, stiff brush and a scotch brite pad then power washed it...

Finished off with a wire brush... not 'clean' but paintable at least...

Unfortunately I spotted a small issue... there were a couple of small cracks on the oil filler boss

I think this could be due to the filler plugs being metal rather than the later ones which are plastic and there has been some sort of reaction or expansion that has caused this damage to occur... just as well I am planning on rebuilding another box then really... I have a low mileage (40k) 02m FWD box from a Leon that I will use the internals of to build a quatty box...

Bill has a broken 02M quatty box (selector fork and a dodgy syncro)... Hoping this might be available as a donor for the build...

That won't be for a little while yet though as I want the car up and running first...

I also decided to replace all the engine mount bolts as they are supposed to be a one use affair but I am still on the originals so all things considered they are being retired...

Mounts waiting to be blasted for painting

Last job of the day is to change the inboard CV boot... I didn't remove the shaft tis time as to be fair I wasn't struggling for access...

Cleaned the joint of grease (that stuff gets everywhere!!!) and refitted with new grease and the new boot...

Greased up the back of the joint and fitted the new cap...

So thats it for now... a few more little jobs and a bit more fabrication left to do... still waiting on a few parts... manifold is having the last bits welded up so should be back soon then I can see if I have any money left to ceramic coat it lol... have ordered a replacement OE heat shield which I am hoping will arrive soon as it was on back order...

Might get a bit of paint on the box tomorrow morning as I have other stuff to do in the afternoon... Tuesday I am off to pick up the wheels from the powder coaters... hopefully they will have come out ok but tbh the damage on one rim might not be easy to sort..

No matter... I am keeping an eye out for another set of RSTT's with a mind to get them perfect..

<tuffty/>

 

[Pimped up vario]

That's a shame about the box. The two different types of metal will have different coefficients of thermal expansion so one can place stress upon the other as it expands at a different rate. Aluminium casts can be a pig to weld. It's a shame it can't be fixed. A small indent in the surface from a drill should stop the crack propagating and if the webbing on the other side permits then you could put a band around it to stop the metal breaking anymore.

 

[tufftybloke]

That's a shame about the box. The two different types of metal will have different coefficients of thermal expansion so one can place stress upon the other as it expands at a different rate. Aluminium casts can be a pig to weld. It's a shame it can't be fixed. A small indent in the surface from a drill should stop the crack propagating and if the webbing on the other side permits then you could put a band around it to stop the metal breaking anymore.

It is a shame but I always planned to rebuild the box anyway as the diff bearings whine a little and I want to mod the selectors before they do the typical 02m thing of breaking...

This way at least I can get a box done while still having the car on the road... it looks like the cracks been there a while... not sure if its leaking as yet as the box was dirty anyway...

Will see how it goes but I'm not massively bothered by it at the moment... unless it starts to leak all over my painted bits of course lol...

<tuffty/>

 

[tufftybloke]

Went and got the wheels today...

Compared to a rather knackered set of OE finished RSTT's

Considering the price (£20 per wheel plus £10 if they have to remove/refit a tyre) the finish is very good... there were a few issues though...

They had powder coated the mounting face of the wheel... this can be a problem do to heat softening the powder coat and allowing the wheel to move a little which can lead to wheel wobble at best or if enough can effectively release the torque of the bolts which then come loose.... plan will be to sand the coating off at a later date...

There are also a few little imperfections here and there...

I treated them to some poorboys of course...

I was about to fit them and discovered a small issue...

They had fitted the tyres incorrectly... rather than pairing them per axle, they paired them side to side!!... ffs!...

You may also notice that two of the tyres are pretty much had it... they are legal enough to get the car on the road and the engine run in... once thats done I will be replacing the old 452's and will get the others swapped so they are paired on a axle...

As a comparison I took a few pics of the sparkle silver... it does look quite cool but its a little OTT for me...

I think I made the right colour choice personally

In other news... the engine mount blocks came back from super George having been blasted

And the new OE heatshield turned up too...

Plan is to use this as a second layer to my old one to improve heat management...

Thats it until the weekend... gearbox will get a few coats of the same black as the block, mounts will get a bit of paint too... few more things I am waiting on (manifold, flexis and a clutch plate) but should be able to get all the heat shielding in place... I want to build most of the bits onto the engine before I put it back in the car so it will be after the manifold is done/ceramic coated/wrapped (whatever I have case left for lol)

<tuffty/>

 

[Pimped up vario]

If you could manage to do it, a thin layer of rock wool in between the two heat shield layers would be very effective in heat management. the layup method in our place was to wrap it in a fine gauze/silk like weave and then contain that gauze in a chicken wire like fine mesh. It was then sealed in behind metal plates with a weld. I would've masked off the mounting face of the wheel and matched the tyres to the axle but that's the trouble when you want a job done properly you have to do it yourself.

 

[tufftybloke]

If you could manage to do it, a thin layer of rock wool in between the two heat shield layers would be very effective in heat management. the layup method in our place was to wrap it in a fine gauze/silk like weave and then contain that gauze in a chicken wire like fine mesh. It was then sealed in behind metal plates with a weld. I would've masked off the mounting face of the wheel and matched the tyres to the axle but that's the trouble when you want a job done properly you have to do it yourself.

Not loads of space but as you will read in a bit I have a bit of an air gap so should be fine... everything will be wrapped and I have additional heat shielding to do once the engine is in too...

<tuffty/>