Audi S3 GT3582R stroker Build (previously GT3071r)

[ibizacupra]

No real experience building manifolds ......I can't see it being a major headache as such..

 

[rae1001]

not mine no.
I wont be selling badgerwagen any time soon

Good, you have done wayyy too much to that to sell up

Haha this means its a PITA.
Ill probably take about 17 attempts to make mine, give up, get someone to do it for me then book into you for more mapping and lots of advice regarding lots more plans in mind

 

[tufftybloke]

Ahh, i always thought it was best for equal lengths, may make it a fair bit easier for me. Where do you plan to mount your turbo? Still tucked down behind or is it too big for that now? Are you still keeping the same tial gate?

Certainly sounds like i need something with 4wd haha, that much power but still usable in all weathers. Even in the wet my ibiza spins in 5th if too happy. Thats a total different thing to yours though haha.

Being honest, watching yours come along aswell as a lot of others on here, its really making me want to take mine to bill next year. It was previously done at r ****. Wherever i go it will be a travel and a week or so in a hotel but bills work, mapping and customer service never seems to fail.

Does bill do your mapping or do you get let loose?

I posted pics a page or so back on where I plan to fit the turbo... plan is to tuck it away as much as I can... I am also using a 44mm Tial gate rather than the 38mm previously (pics also posted)

I can do mapping and have done mine before but Bill has much more experience and we will be using the emulator so just easier to let him do his magic tbh...

<tuffty/>

 

[rae1001]

Ah yes i do remember, totally forgot ha.
Good that you have experience and the capability of mapping. Yeah he is good from what ive heard alot, would trust him a lot like

 

[Pimped up vario]

I read an interesting article once on exhaust manifold design, was years ago so don't ask me what it was, which covered pulses and back pressures. It was interesting to see the importance of the design relative to the desired flow characteristics.

 

[tufftybloke]

Nothing much to report... basically cleared up all my stuff that was under the car and made the car pushable if the ramp is required... beyond that I have reading up on making merge collectors and after a little thinking and eying stuff up I have come to the conclusion that while I am sure I could make one I am not sure if I can be ar*ed... so...

...either gonna get the Treadstone one or.... I am going to have a chat with a couple of the UK mani builders... the problem is getting the cuts right and accurate to enable lining them up right and stuff... while I am sure I could do it the amount of effort getting it done just for a one off is a PITA and I just want to get things moving on the build... I can't get the build engine/box out of the car until the mani is done... I can't fit the new engine until the heatshielding is done and I want the engine out for that... I can fit the engine until I have sorted the gearbox the build engine is attached to which of course can't come out unitl the mani is done and I can't start the mani until I have the merge collector as this is the bit that dictates the mani build and position of turbo etc blah meh....

Have initially emailed the guys that built the sidewinder mani for the Mk2 Golf we had in a while back... they are great fabricators so this should be no issues for them...

I only need the collector bit as the rest I can do... will drill a hole and create the wastegate take off once I know where its all going

So... as is tradition... I painted stuff...

Hopefully it won't take too long to sort a collector out... I am also now going for 1.5" rather than the 1.25" pipework I was going to do... if spool is affected then so be it but it at least means I shouldn't have to run the turbo hard to get the power which at the end of the day is the end game..

<tuffty/>

 

[Pimped up vario]

Did you see the show were the guy builds a kit car in his back garden and gets it craned over his house? He uses some company in England that specialise in exhausts. I wander would they be any good to cater to your requirements.

 

[tufftybloke]

Little something turned up at the Badger Cave today

...project manifold is a go then

<tuffty/>

 

[rae1001]

That looks almost identical to the one that i bought from america haha

 

[tufftybloke]

Been a little while since my last update as I have been helping Bill catch up on stuff and had to send the collector back as they had made it in 1.25" ID tube rather than 1.5" ID tube... in the mean time I got the 70mm TB blasted ready for having beads welded on and of course painting

I also painted the cam belt cover and modded it for the manual tensioner

The new collector turned up Friday so game on...

...Nortech (the stars that they are) even did the final capping run on this one...

...and of course the obvious difference between 1.25" and 1.5"...

...it begins...

So tomorrow I am gonna make a start and see where I end up... what is evident from my initial faffing is that its not as easy as you would imagine to work out where all this goes and to keep it all away from stuff that could melt...

I have not discounted going underslung either...

Hopefully some progress pics tomorrow...

<tuffty/>

 

[rae1001]

Good to see more progress bud. Will be watching very closely how you get on. Im just about to go get some argon then im getting started too.

sent from my tapatalk cos my laptops gay

 

[Hobbiniho]

looks like its going to be quite a ballache to get that all to fit good luck i can wait to see how it turns out

 

[tufftybloke]

Long but productive day...

rigged up a bracket to hold the collector in place as its next to impossible to hold that and tubing etc at the same time...

Started with cyl 1 runner as this would have to tuck close to the block..

Unfortunately some idiot had put a transfer box in the way and both the runner and the collector was too low to get anything else in so pulled it apart and started again... moved the collector a little higher and re-did runner 1

runner 2 in weld tape (tm) stage...

Runner 2 coming together...

Now clears stuff and fits nice...

Runners 3 and 4 were pretty straight forward comparatively...

Had to make some adjustments to the bends to allow clearance (not loads of course but hopefully enough)

Need to trim the transfer box bracket though...

...but it seems to fit ok and looks pretty good all things considered...

...so of course I had to try it on the new engine...

...and of course I made sure that all the studs were accessible... the most "awkward" ones being..

...and

The manifold should be easy to fit in situe which of course is the next thing I have to do and once fitted to the mock up engine in the car I can work out where the wastegate will go

All in all not too bad considering its my first attempt and I have never used a welder before... started just after 10am and finished up around 7pm... rather tired now to say the least lol..

Plan to grab a couple of days off work to finish it off and then it can be welded up...

<tuffty/>

 

[wild willy]

Fair play Tuffty that is an excellent days work and top quality at that. Great to see you cutting your teeth on new skills and to see a fellow enthusiast making good progress. Bill must be happy with apprentices progress.

 

[rae1001]

Good work. All in a days work eh. Looks the nute that and i bet it will flow perfectly. Did you just use a grinder to cut it all or a chop saw? That just tacked up with mig? Bill going to do the full welds for you?
Again good work as usual

sent from my tapatalk cos my laptops gay

 

[tufftybloke]

Thanks all... went better than I expected tbh... surprised myself...

I used cast bends of which I only needed to tweak the angle of two bends to get it aligned correctly... using a combo of tight and not so tight 90 deg bends plus 45 deg bends seemed to allow enough flexibilty to use them out the box... had to tighten the bend coming from the collector to cyl 4 so it would clear the transfer box..

Used a chop saw for the straight pieces, cleaned up the ends with a grinding wheel and bevelled the ends (for butt welding) on a linisher...

Tacked using a MIG (first time I have ever used a welder) and either Bill or another guy we know will be doing the final TIG once I have sorted the wastegate out

<tuffty/>

 

[mk4 cupra]

Wow that all I can say about that manifold good job there I love it some very good craftsmanship has gone into that in fAct the hole project is amazing been watching this for a while now just never posted keep up the good work lookin forward to seeing it finished

 

[rae1001]

Thanks all... went better than I expected tbh... surprised myself...

I used cast bends of which I only needed to tweak the angle of two bends to get it aligned correctly... using a combo of tight and not so tight 90 deg bends plus 45 deg bends seemed to allow enough flexibilty to use them out the box... had to tighten the bend coming from the collector to cyl 4 so it would clear the transfer box..

Used a chop saw for the straight pieces, cleaned up the ends with a grinding wheel and bevelled the ends (for butt welding) on a linisher...

Tacked using a MIG (first time I have ever used a welder) and either Bill or another guy we know will be doing the final TIG once I have sorted the wastegate out

<tuffty/>

Maybe i have to invest in some of the tighter bends, i only have the long ones and a length of straight pipe.
Looks very tight there which worries me, as im trying to do the same but in a mk3 ibiza not an s3 haha.
Im tackling the whole job myself aswell, bought a tig welder for doing all my own work plus for other people too, so will be teaching myself how to weld strongly and neatly with tig, back purging and welding the mani myself.
I do look forward to seeing yours fully welded and on the car. Are you getting it ceramic coated or wrapped?

 

[tufftybloke]

Maybe i have to invest in some of the tighter bends, i only have the long ones and a length of straight pipe.
Looks very tight there which worries me, as im trying to do the same but in a mk3 ibiza not an s3 haha.
Im tackling the whole job myself aswell, bought a tig welder for doing all my own work plus for other people too, so will be teaching myself how to weld strongly and neatly with tig, back purging and welding the mani myself.
I do look forward to seeing yours fully welded and on the car. Are you getting it ceramic coated or wrapped?

Biggest issue you will have is the rear engine mount... this is a ballache... if you are using 1.25" though things will be a lot easier... the overall OD of 1.5" makes it well tricky... if you use a similar path for cyl 1 and 2 you should be fine... mine was compounded by me wanting to have the turbo sit low...

If yo don't mind the turbo being a bit higher and using 1.25" nominal bore tube then you should have no worries at all

If I remember at the weekend I'll take a pic of my mani on a block with an ibiza rear mount fitted..

I was gonna get it wrapped but depending on how things turn out I 'might' go ceramic..

<tuffty/>

 

[rae1001]

See i have 1.5" fittings already, did already try to make it up but kept fouling different parts. My turbo is already as high as it could go without coming through the bonnet so thats no issue at all.
The biggest problem im having is leaving enough space for a 3" dp to go between the mani and mount. Ill get there though, im sure.
That would be great if you could do that, would give me an idea as to wether or not to follow the same general shape of yours.
Yeah ceramic seems to be the way to go, its just the price of it haha, but then again, for good quality wrap, thats not cheap either