Audi S3 GT3582R stroker Build (previously GT3071r)

[tufftybloke]

A few more days off and some more stuff done... fitted the locking tabs to the Tial hotside bolts and fitted the turbo properly... also fitted the oil drain and discovered a small issue with the downpipe...

Boo!... oh well... easily fixed by adding a small section in to extend the DP past the oil drain

Added the bottom section and a v-band for ease of fitment... still all very close though lol

Bit more to do with it yet to extend out past the prop and to connect up to the centre section and of course fit the flexi etc...

Once thats all connected up I can sort the wastegate pipe work and of course the back box...

<tuffty/>

 

[tufftybloke]

Bit more progress...

Have joined the exhaust up but because I have had to run the DP more over to the drivers side of the tunnel to allow for the wastegate pipework it has pulled the centre section over and now the middle box touches the propshaft... will fix that once the DP is welded, wrapped and fitted into place...

Next problem is the exhaust hanger... in its OE position it will get in the way of the way of the wastegate pipes...

So... I cut the hanger from the bracket, put it on the other side and sprayed some metal at it

...with that in place I could then make the DP's hanger...

And thats the DP done ready for welding and wrapping

In other news... a good fiend dropped off a spare airbox as mine has been hacked around so much with the different mods I have done with it that its lost its integrity and so the plan will be to use the lower section to make a good one again...

..and Bill got busy with the lathe turning my lump of acetal into an adaptor ring for the RS4 MAF...

And viola!... RS4 MAF tube ready to fit into 100mm silicon...

...and of course I painted the exhaust hanger bracket

Wastegate pipework to do then I can essentially put the engine bay together ready for initial start

<tuffty/>

 

[wild willy]

Nearly there now matey, looking good. Such good skills on display in this thread.... a pleasure to read.

 

[Pimped up vario]

I wanna go, been yonks since I was let loose on a lathe.

Looking good.

 

[mk4 cupra]

Wow not too far of up and running I love reading the updates on.this

 

[tufftybloke]

Thanks all

Bit more progress...

made a start on the wastegate pipe... 2" pipework should prevent wastegate creep...

Among the list of small jobs done is the injector wiring... binned off the plastic retainer and used convoluted tubing instead running the the wiring under the fuel rail...

Prepped the tail pipe for welding...

...and talking of which, super hero Bill finished off welding the downpipe (just the lambda and EGT bungs to do...)

So... once the bungs are done I can wrap it and fit the top section into final position then finish the wastegate pipe as the DP needs to be in for alignment etc...

Once thats done then I can finish assembling the engine bay (once I have sorted the oil drain issue of course) and should be able to start the engine

Then... need to tweak the position of the centre section as its touching the prop, once thats done I can finish the back box and should be able to move the car off the ramp (I can hear Bill cheering as he reads this lol) and run in on the dyno... phew!!!

Not too long now

 

[tufftybloke]

Bit more done... getting closer

Catch can turned up... has 19mm inlets but these are getting changed anyway to 25mm...

...and will go roughly here...

Finished the wastegate pipe work...

And tweaked the centre section to realign it....

...and made a start on the back box which managed to defeat me a little but its was gone 9pm and so I called it a day lol...

Will have a look tomorrow when I am a little more with it

<tuffty/>

 

[Luke ED30]

Not sure what you mean mate?

<tuffty/>

the numberplate i mean mate? private plate? with vag on?

 

[Luke ED30]

and nice updates

 

[tufftybloke]

the numberplate i mean mate? private plate? with vag on?

I don't have a private plate dude..

and nice updates

...thanks

<tuffty/>

 

[vroomtshh]

This is available at £250

 

[tufftybloke]

More progress

Sorted the oil drain issue with a bit of tweaking of the lower pipe to get the flexi to sit right...

Wasn't happy about the speedo sender being as exposed as it was either as it will be quite close to the wastegate pipes

...so made a heatshield for it...

..also added a little more heatshielding where the wastegate is as it didn't come over as much as I would like...

Bill finished welding all the exhaust bits I had fabricated so far...

...so I wrapped them...

Once that was done I fitted the coolant lines... had a small issue though...

...that wouldn't end well for the brakes line so removed it again and put a small set in to clear...

With those done I could fit the downpipe...

Fitted the wastegate

Connected it all up to the centre section so I could tighten all the vbands in the right place...

Once that was done I then finished off connecting all the coolant hoses and all the other stuff I had left to do ready for the first start.... added fluids (power steering, engine oil and coolant), attached the battery and span her over with the injectors disconnected...

...and...

http://youtu.be/wABNMmOiPWw

Sounds a bit tappity in the video but I did another start after that to warm her up properly and the engine quietened down loads... only issue was the fans not cutting in when I expected... stopped the engine and carefully opened the reservoir and all the coolant suddenly disappeared! so topped that up again and checked the oil... will run her up again in the week and see if it was just due to an air lock or something but for now I am happy as larry

Had a quick look around while she was running in the air and could see no obvious leaks which is a result... will hold off being totally happy until I know the fans are working ok and I can run her up to temp and leave her running for a while...

Put the covers back on for now as it seems a safer place to keep them lol

No too bad considering... I have also got hold of some fancy stainless fixings for the covers....

They look a bit like this... I may paint them satin black though LOL

I am going to ask Bill if I can do a few evenings this week so I can sort the back box out, bleed the clutch and basically get the car ready to get off the ramp..

Excited much ;P

<tuffty/>

 

[tufftybloke]

Did an evening shift at the workshop lol (which after a rather rubbish day at work was welcome)

Bled the clutch, topped up the coolant and faffed a little under the bonnet... still need to sort the catch can out but thats next after.... the back box...

The elusive metal centre exhaust bracket that Audi decided not to fit on later cars... the system I have is quite heavy so it will benefit from the extra support..

So fitted that with a powerflex universal exhaust jobber and welded a hanger to the centre section...

Next up was to join the centre section to the back box... this didn't go so well Saturday night so I attacked it slightly differently and bingo....

Test fitted the tail pipes but its clear I need to tweak that area a little as they stick out too far...

By which time it was gone 11pm so thought I had better call it a night lol... put the covers back in the engine bay and jobs a good un

Tuesday night I plan to finish the back box (tweaks to the tailpipes and the hanger for that side to do) so that hopefully if Bill has a bit of time he can weld it all up and if I have time I will make a start on the catch can...

All in all a good end to a rather crappy day

<tuffty/>

 

[tufftybloke]

Bit more done last night... main focus at the moment is to get stuff done so I can get the car off the ramp... I won't be rushing to tax her for this month as lets face it there is not much left of it so as long as I can get her off the ramp and run in on the dyno all is good in the world...

So after a couple of tweaks the back box is ready for welding

I also spent a little time finishing off some other little jobs and made a start on the catch can/PCV stuff... I am not in a rush to get that done at the moment but will need something in place before I can get her MOT'd which should be towards the end of next week

<tuffty/>

 

[tufftybloke]

http://youtu.be/AECcBBIWEmE

Just say'n....

<tuffty/>

 

[wild willy]

Woo hoo well done, but you forgot to stop at the dyno on the way out.

 

[swedey21]

Yep well done mate...
Bet that felt great when you drove it off.....for both you and Bill!!


Looking forward to the RR results...



Bet you can't wait till it's been run in...happy days ahead.

 

[majesty78]

WOW! Insprirational!

 

[tufftybloke]

Thanks everyone.. all your comments are appreciated

Last piece of the puzzle nearly done... have altered the catch can to suit my requirements...

Might use the filter initially but suspect I will change to a hose running under the car to get rid of the smell...

Sorted the lack of fans issue too... essentially an airlock... ran the engine up to just over 80 degrees when the stat should be open (left the expansion tank cap off)... jacked the car up and drained a little coolant out the radiator drain tap while the engine was running... this was enough to sort that issue and the fans kicked in as they should..

I also washed the fleet...

...and pulled her in for a wipe down and a quick once over with Werkstat Jett Acrylic... (I love that stuff...)

...and did a little under the bonnet too

I also managed to find a small leak... typically on these builds you do find the odd leak here and there... comes with the territory but after a few runs up to temp she appeared pretty much water and oil tight then I noticed the tell tale pink tinge of G12... the CTS was leaking :/

Not much but enough and prob wouldn't have noticed it until she was under load on the dyno so pleased I spotted it when I did...

I can report that the exhaust is amazingly quiet with a nice deep undertone... obviously no idea what its like when driving yet but plan is to run the engine in on the dyno Sunday and take her for an MOT early next week... I will then tax her for the beginning of April...

<tuffty/>

 

[David_smith_909]

Love this, just amazing attention to detail