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Andy P

Homemade T25 Garrett S4

Thought I'd make a bit of a project thread for my car now that I've done a fair bit of work already.

I'll introduce you to the car -



A pretty high mileage (185k!) noggy S4, pretty standard aside from wheels, coilovers, revo map and also running LPG. I bought the car to be my daily motorway cruiser as I was doing 800 miles a week and with the LPG it was cheaper to run than a 2.0tdci Mondeo.

I've got another project S4 track car (noggy saloon) so this was destined to stay standard and eventually become the tow rig.

I've since changed jobs and I'm down to "just" 250 miles a week, and although the car was still to remain standard, fate had different ideas...

So, this brings me to a few months ago when this happened - DOH!


The OS turbo had started howling and whilst trying to baby it home a huge plume of blue and white smoke erupted behind the car creating a smoke screen Dick Dastardly would be proud of!

A little annoyed but i suspect the car is on its original turbos and clutch so they had a decent innings.

Once home I had a little think on what I was going to do. Decided that for the effort of pulling the motor out I didn't really want to put another k03 in and the cost of k04's didn't get me so excited either.

Turn's out I already had a few "spare" T25's in my workshop so thought why the hell not! Worth a punt.

So, out comes the engine (what a *%&$^£*X?!!)






I checked the blown turbo...




Turns out the failure has been caused by a foriegn object - I found one of the airbox clips in the inlet pipe!!!

Here's a comparison of the k03 and T25 (19mm spanner for ref) -


To be continued..
Jamo

Ouch! question is how the hell did an airbox clip get into the intake system?
Andy P

So the plan is to cut and shut the stock manifolds with a T25 flange. Why? Reliability. I was going to get some tubulars but then I don't want the issue of potential cracks etc. Its not the best solution I know but everything here is being done on a budget - to see if it can be done!





Whilst I was at it, I changed the clutch with a LUK RS4 set. I've seen mixed reviews for these so will see how it goes.





Managed to spill plenty of gearbox oil when taking the engine out so drained and refilled (ignore the pikey bricks!)


Quick shot of my drive - wish I had a garage to work in!


And then started mocking things up with new inlets to suit the T25's. The keen eye'd will spot a mistake with these...




And then I mocked up a downpipe. Made from 2.5" stainless, will have a flex and Vband connection.






To be Continued...
Andy P

Now to sort out the lines to the turbo, I wanted to keep as much of this as stock as possible.

The oil drain lined up exactly and only needed a reflange


The rear coolant line and oil feed bolted up directly with no need for modification. (thought I had a pic of this, will edit if i remember to take one)

And going back to that "mistake" I mentioned earlier, the inlet pipe I mocked up fouled the engine mount so I had to make a slight S bend




And this is pretty much how its sat currently - all lines are done, I've re-used the K03 wastegates with modification to the T25 wg bracket. I've ordered a tight radius 90 to weld to the inlet and then this side is virtually complete.


I've forgotten to also mention all my rocker cover seals were pissing oil so all the top end seals have now been replaced with new. I know I've taken pics of this, I'll find and upload... OH, also replaced the timing belt and all pulleys / tensioners...

As my existing exhaust is full of oil, decided that I'd get a new one as they're cheap, and it'll make life easier to see if there are any issues on start up. I don't really want the exhaust bellowing blue smoke and hiding any engine / turbo issues...

XSpower exhaust -


Thought it was a decat... Beau had other ideas




Thats all for now...  

..Flame away  
Andy P

Jamo wrote:
Ouch! question is how the hell did an airbox clip get into the intake system?


No idea! But it was in there!!!
RACK

Loving the cat lol
ScottR

Brilliant to see something different and also DIY. Hats off to you. Was feeling smug as I knew it was the engine mount which was going to be the problem... but now I just feel sad as I've had to see my engine out so many times!

What sort of power will these be capable of?
Jamo

You are installing 2 X T25's right?
Challice

Ace! Nice handy work, it's all coming together nice, ash hoses are pretty damn good for their price.

Would have tought the T25's are about K04 size and flow?
Andy P

ScottR wrote:
Brilliant to see something different and also DIY. Hats off to you. Was feeling smug as I knew it was the engine mount which was going to be the problem... but now I just feel sad as I've had to see my engine out so many times!

What sort of power will these be capable of?


Thanks for the positive comment. I've found with these cars that there aren't many home built cars and even fewer that aren't using BW turbos.

A few rudimentary calculations suggest these should be coming on song by 3k and pull hard to the redline. Difficult to pinpoint the power these will make... more than stock k04's?
MichaelG

Nice wee project and a break from the tried and tested KO4 route. I'll be keeping an eye on this thread.

Keep up the good work
Andy P

Jamo wrote:
You are installing 2 X T25's right?


Haha, yeah, 2 of them! Half way there
ian52

How about a T28 from a 200sx if these work ok. Think they are good for high 200's in them or the T28 from a GTI-R over 300. If this works good T28's could be good for big power cars maybe.
Andy P

Challice wrote:
Ace! Nice handy work, it's all coming together nice, ash hoses are pretty damn good for their price.

Would have tought the T25's are about K04 size and flow?


Yup, have used ash stuff for years now. Can't be beaten on quality at this price!  Cheers for the comment
Andy P

ian52 wrote:
How about a T28 from a 200sx if these work ok. Think they are good for high 200's in them or the T28 from a GTI-R over 300. If this works good T28's could be good for big power cars maybe.


Yup, it's half the reason why I'm going with turbo's i had lying round test the theory without spending out too much. If it works I can straight swap to any T2 flange turbo... GT2871R for example...
Andy P

Tiny update!

Wanted to make a start on the link pipes before things got fitted to the car as i don't have the luxury of ramps!

Started by fitting up the standard downpipes at the gearbox mounts to get the positioning of the cat back



Took off the left hand side and fitted the new downpipe and started mocking up


Then started tacking up..


The problem with having the workshop out the back and the engine out the front...!


And finally lined up with the v band clamp on


That's it for now.
calibra_se8

Great effort

I'm running Garrett based Tial 605's and they were peaking at 33 Psi with more potential!
ian52

33psi! That's a lot of boost!
Andy P

Another mini update. Didn't get loads of time today to work on the car because we had to get off to a BBQ but got a bit done none the less.

Started the day by finishing up the near side lower inlet pipe. Had some tight radius bends delivered during the week.

Offering up the bend to mark off where the pipe needs to be trimmed.


Trimmed and marked ready for tacking


Tacked and test fitted


Welded it all up and fitted, didn't take a pic mind. I then set to work on finishing up the downpipe. Drilled out a hole for the lambda bung and welded in, also trimmed off the supports of the original downpipe and modified it to fit the new one. I've made the new downpipe to sit tighter and higher up than standard - the car runs quite low and the flexies have been shredded by grounding out. The modified support is now upside down where the downpipe has been raised. Hope this wont cause any bulkhead interference!


Stock heatsheild will get reused


I'm pretty much finished on the near side so I turned my attention to the other side, firstly by refitting the knackered k03 in place to get an idea of the orientation and clocking


This turbo is fitted slightly off axis in comparison to the otherside to make room for the wastegate actuator to pass between the turbo and block


The 4 bolt T2 flange compared to the 3 bolt BorgWarner flange... and yes I'm allergic to Penicillin!


A pic of the marked up manifold with the T2 flange overlayed


A few minutes with an angle grinder later!


Finally tacked in place with the turbo offered up. Plenty of clearance on the compressor housing, hopefully tomorrow when I offer it up to the engine I wont have any issues either!





Hopefully I'll have more to share tomorrow  
Player No.1

Wow strong work going on here! Looks like I'll be watching this!
Andy P

Fairly productive day today! Started off by test fitting the manifold and turbo to see if it was sitting in the right place



Looked pretty good so I went about seeing how the stock lines lined up to the CHRA

Oil feed looked good


Coolant line will fit with a minor fettle


And oil drain just requires reflanging like the other side


So things were looking pretty good and I was happy with where the turbo was sat so I cracked on.

I wasn't looking forward to working on the actuator, there really isn't an abundance of space back there but I had to get it done. I was pretty lax with the camera so didn't get any pics of the process but this is how it turned out


And things are starting to come together with oil feed, coolant line and oil drain fitted up to the Garrett


An upskirt shot of the oil feed. I had decided to get as much of the work tacked up for speed. I'll fully weld up later in the week.


So, time to get fabricating the offside downpipe. Started off looking like a 180 deg bit of tube


A few moments later..




Threw a few welds at it


And a shot with the flexy and V band


Shot of the turbo in relation to the lower charge pipe, will have to get a hose joiner in there.


Fabbed up the lower inlet pipe


Cut off the downpipe bracket and modded it to fit the new dp


Another job on the list was one of the front inner cv's


After getting pretty well covered in CV grease (I hate that stuff)


And that's pretty much where I left it for the day!

Not too much left to do before it goes back in!
ScottR

Epic work so far. Interested in a 5 puck paddle clutch?
Andy P

ScottR wrote:
Epic work so far. Interested in a 5 puck paddle clutch?


Haha, not after reading your review on it! Though if it does slip I might be contacting you
MichaelG

Can't wait to hear how it all goes once reinstalled and given a good thrashing
BNBboyo

subscribed
Graham

Moved to projects and builds.

Great updates, please keep them coming.
Andy P

Thanks for the thread move Graham    
BennyBoo

Excellent work, Most of my build is going to have to be this side, Wish I had the time you did!
Andy P

Benny, time is something I'm actually really short of I've got SO many projects on the go - The S4 track car, the house we're renovating, this daily, keeping the new fiancé happy & riding in trials shows every other weekend, I'm spread pretty thinly!

This car is getting a fair bit of attention recently though as my loan car off a mate is an Evo 8 Mr FQ340, 450hp and seemingly hose pipes for injectors. Costing me an arm and a leg just to get to work and back! That and he'd perfer it on his own drive rather than mine!
BennyBoo

Andy P wrote:
Benny, time is something I'm actually really short of I've got SO many projects on the go - The S4 track car, the house we're renovating, this daily, keeping the new fiancé happy & riding in trials shows every other weekend, I'm spread pretty thinly!

This car is getting a fair bit of attention recently though as my loan car off a mate is an Evo 8 Mr FQ340, 450hp and seemingly hose pipes for injectors. Costing me an arm and a leg just to get to work and back! That and he'd perfer it on his own drive rather than mine!


haha, well  as I haven't been in my garage since Feb, you have more time than me!

Gotta keep everyone happy though bud
F12KYB

VERY INTRESTING PROJECT MATEY
Noggymike

F12KYB wrote:
VERY INTRESTING PROJECT MATEY


+1

Great updates
BNBboyo

spec on evo?  
Andy P

Thanks for the positive comments guys!

BNBboyo wrote:
spec on evo?  


The Evo as mentioned is an 8 MR FQ340. Not 100% sure what the spec is but its running a mildly uprated turbo, FMIC with HKS hardpipe kit, HKS cams, Bosch 044 pump, Hayward and Scott 3.5" system, exeddy LWFW and uprated clutch. It's had the FQ piggy back ecu removed and remapped. Makes something like 440hp with similar torque. Goes pretty well but it gets pretty tiresome having to rev the tits off it to overtake anyone. My mate did a pretty decent job of rearranging the front end with a motorway barrier on the M4 so I had to repair it, Now sports an Evo 9 front end with carbonz



Anyway, bit of a pointless update to keep things ticking over..

Couple bits arrived in the post. RS4 injectors


Garrett wastegate clips!!!!  


The aim was to get the tacked up bits fully welded. Was going pretty well until I ran out of bloody gas!!


Best get some gas tomorrow!
brasiliangringo

Funny just bought some actuator clips of this same bloke on ebay for a TDI actuator last week - only place i could find them being readily available online although i was replacing them in situ and lost 2 out of three, one on the ground somewhere and another fell into the engine bay never to be found again but i was quite prepared to loose them
Challice

Nice work, my mig welder kept seeping gas out the regulator so I leave it off the bottle when not in use
brasiliangringo

Challice wrote:
Nice work, my mig welder kept seeping gas out the regulator so I leave it off the bottle when not in use


I have had exactly the same problem - having lost probably 17 litres of gas recently from leaving on ( from 2x 10 litre bottles) as it wasnt done up tight enough - a quick spray of washing up liquid revealed reg not tight enough - annoying silly mistake.
Sam_

Nice work Andy. You'll have to take me for a spin when I'm back next.
Challice

brasiliangringo wrote:
Challice wrote:
Nice work, my mig welder kept seeping gas out the regulator so I leave it off the bottle when not in use


I have had exactly the same problem - having lost probably 17 litres of gas recently from leaving on ( from 2x 10 litre bottles) as it wasnt done up tight enough - a quick spray of washing up liquid revealed reg not tight enough - annoying silly mistake.


Very annoying, i had a new regulator on it too so now i just leave it off
Andy P

Midday update    couple of things have just come in the post - firstly 2x EGT gauges with sensors. When I first got my S4 one of the EGT's were knackered and the car was running at reduced boost. Decided not to replace after seeing how frequently these can go so I had them coded out. As it happens because I've cut the flanges off the manifolds, there's no longer anywhere for the sensors to go now anyway. Thought it'd be a good idea to keep an eye on them so I got a couple of these (cheap) gauges to tap in to the manifold elsewhere.


And not in the least bit exciting, a bit more bent stainless to make up the second link pipe and some copper flashed turbo/ manifold nuts!
Andy P

Sam_ wrote:
Nice work Andy. You'll have to take me for a spin when I'm back next.


Haha, signed up just to post a reply?! When are you back? You were back fairly recently weren't you (xmas)?
BNBboyo

mmm evo looks great mate  
Why you only going rs4 injectors?
Kent

So is that just a mig with stainless wire? What gas are you running?

How does it differ from welding steel? Is it ok.. i was going to get some and give it a try some time.
Andy P

I only went for rs4 injectors purely for the fact that I picked them up for £70 including the spacers.

With regards to the welder, yes I'm just using stainless wire and argon mix. The quality of the welding isn't amazing but that's mainly down to having quite a poor machine. Whilst it really has earnt it's keep for the 6 years I've had it, it's now time to step it up a bit!

Andy P

Weekend update. I had hoped that by this time I'd have the motor in place but in the end I didn't get a chance to work on the car on Saturday and what with running out of gas during the week, I didn't have everything ready to go come Sunday.

As mentioned previously I've picked up a new welder which takes proper refillable bottles. I didn't get a chance to get one in time and was limited to what I could pick up on a Sunday. Had to make it work one way or another.


The machine welds sooo much nicer than my old SIP!...Until it runs out of gas!!! AAAHH!! Must pick up a proper bottle ASAP.

Anyhow, after running out of gas I went on and carried on elsewhere. Started by drilling and tapping the manifold for the EGT sensor. Decided to drill through the join as it's the thickest part to thread.


Then started on the final fit.... Finally! Fingers crossed this is the last time I'll be fitting these turbos...


Had fitted up the offside setup last week. Had to take it all off to drill and tap the other EGT sensor. Refitted with copper flashed lock nuts all round


And the near side all fitted up


And here's that lower 90 deg pipe to mimic the specially shaped offside compressor housing


Both turbos on finally, and the rats nest of wires and pipes!


Downpipe in place on the offside (as it was the only one fully welded up before the gas ran out), egt sensor and lambda sensor in and heat shield on.


Getting there slowly, can't wait til its back on the road.
Andy P

Another mini midweek update!

During the engine removal I noticed the spider pipe was knackered so off it came


As you can see, not much use. The pipes were pretty gunked up too, not surprised all my seals were leaking.

I'll be replacing the pipes with a catch can setup which I'll fabricate myself. It should be pretty efficient at separating the air from the oil with it draining back to the crankcase so I wont have to empty it out every few months.

Anyway, with the catch can setup, a few of the lines will now be redundant. I'm assuming this can get ditched now??


Whilst I'm at it, what exactly does this do?


And as I've got external EGT gauges with the stock ones coded out, I ditched these


I thought these were supposed to be different? Or are they the same just a different angle and cable length?
MichaelG

The second valve is the N249 to control the recirc valves I'm sure, if you search N249 delete you'll find more info on it.

Not sure about the first valve, still learning about these cars myself even after 2 years ownership
Andy P

Thanks for the response. Looks like they're the N249 and N80, both of which can be removed  
mrgristle

Have a read about the N249 delete before you do it. Quite a few people have reinstated it to reduce lag between gear changes.
Challice

mrgristle wrote:
Have a read about the N249 delete before you do it. Quite a few people have reinstated it to reduce lag between gear changes.


Get Flat Shift  
mrgristle

I have it already, but realistically you're unlikely to use it for every gearchange. Can't think the gearbox and clutch would last very long if you did.

Have a look at this thread on AZ for more info on N249 delete.
Andy P

Yup, already read the article. Won't really apply to me, you'll see why in the near future
Andy P

More updates  

Well, thursday night I had a neighbour arrive home with a problem with her drivers window - it had dropped off its mounts and was rattling around in her door. Took a while to fix because it was done in the dark with a headtorch, around an hour, by which time it was 11pm! Chucked my tools in the tool box,  pushed the locks down manually, put the box in the car and shut the door.

Hmmmn, where are my keys???? In the tool box of course!!! Spare keys are at Emily's (the fiance) parents house. Stopped by there after work on friday and couldn't find them. Arse.

So I went home and got thinking...

Used these -



Won't tell you how on a public forum but less then 5 minutes later I was in without a mark on the car. Result  

I'm not far off getting the engine in so thought I'd get the bay a bit tidier. It's got nothing on most of the engine bays on the forum but it'll make it easier to spot leaks and it'd be nice to work on the car without having to scrub my skin off in the shower afterwards.

Before shot


And after. Just used hot water and fairy liquid to cut through the grease and a pressure washer to blast off the caked on shit


Yeah, its not beautiful.

Because I had the hose out I thought I'd show it a sponge just to get the worst off. I'll get it done properly once its back on the road.



And I'd have been in trouble if I didn't do the Mrs too..


Still not picked up more gas so I got on with other jobs. First up, exhaust. I was expecting this to be a bit of a pain because from reading the boards, not many people like to attempt this without ramps.


Jacked up the car and no more than 1 minute later the old one was off.


Another 2 mins later I had the back section on (well I did have to take it out the plastic bag) Hanging lop sided for now





The centre section needs a bit of modification. This is how it started




Slotted the ends so the clamps can actually pull it tight and create a seal



As I'm making my own link pipes which will sleeve over the larger part of the centre pipes


Fitted "ok" but was pretty close here


So massaged the pipe slightly to give a bit more clearance


And now looking much better. All in with the mods and smashing it on my head it only took around 30 minutes. No ramps required!




Then on to the engine. I wanted to make something to shield the silicone from the heat of the manifolds and whilst looking in the engine bay of the TDI Quattro doner car for a bit of pipe, I saw a nice flat sheet of heat shield that could be recycled (well it was the Mrs that saw and suggested it!) Cut it in half and jubilee clipped it on. Not pretty but quick, easy and should work.




Went about tring to tidy up some of the rats nest of wires. There's more here than usual because of the LPG



And pulled these off


More tomorrow!
MichaelG

Excellent work
ScottR

Are you going to be replacing the recirc valves or bypassing it all completely?
Andy P

Sunday update.

I HATE CARS.
boost addict

Will you enlighten us ? Cheers !
Andy P

Haha, will do! I've uploaded all the pics to photo bucket and I'll stick a proper update at lunchtime when I get the chance. Yesterday wasn't particularly successful unfortunately.
Andy P

I had some issues finding suitable coolant hoses for one of the coolant pipes on each turbo. Had loads of 8mm stuff which is more than adequate however on these garrett, one side is oversized for some reason? came up with a solution which, although not particularly pretty will serve the purpose.


Finally, time to put it in! By this time it was probably around half 9, plenty of time to get it in and mostly plumbed up....



Looking good here but it wasn't to be. Downpipes were hitting the body where I've raised them up tighter. Arse


The easiest way to lower them without having to start again was to extend the straight downward portion and rotate the gearbox hanger support backwards and down.


One of the casualties of the early efforts of fitting


Both extended sections in and downpipes now a bit lower. They're actually much more symmetrical than they were originally, which despite the ballache of having to cut and shut them was a bit of a bonus.




Close up of one of the extensions fully welded. They're not super clean, I was worried about running out of gas as I've still not got a proper sized bottle yet and was running the regulator as low as possible.


Then I tried putting it in again and again ran into fitment issues! downpipes are better but not perfect and the gearbox mounts were catching on just about everything.

It was SO close to gong in. Both front mounts were in their respective holes but the gearbox was skewed to the left for some reason. Could really have done with an extra pair of hands today   Pulled it out again (actually the 3rd or 4th time today) put it back on the trolley and packed up as I was already an hour late for a 40th birthday bbq and I was still covered in oil, grease, dirt and shouting at my car.

The day was full of promise but in the end was just frustrating.

If the weather is ok tonight I might get the crane out again for attempt 5.

Don't hold your breath.
Andy P

Last nights update - The engine is IN!  

Finally had the help of a mate who couldn't believe how little space there is to work with and admitted that just to get the engine in place is a task in itself. I didn't take any pictures myself but the Mrs grabbed my phone and took a few snaps, all of which are of me on my back  

This is me, on my back, feeding the shifter rods through into the car


This is me on my back, probably doing the same


This is me on my back again


Engine in place. As you can see, I'm on my back


Final pic of me putting in the rear gearbox mounts. On my back.


It didn't go particularly smoothly. We got it in place but I wasn't happy with how close the downpipe was sitting to the body so it came out and was modified again. Whilst going back in my friend rammed his thumb into the end of one of the lower charge pipes and opened up quite a large gash which leaked blood all over the drive.

But, its finally in! Hopefully tonight I'll get most of it connected up so I can get it turning over and get oil pumped to the turbos and then do an oil change. I want to do it this way so that if there is any swarf anywhere it'll get drained out asap in the old oil.
Player No.1

That's a scarily familiar sight right now mate, only it's normally CJ on his back under my motor!

Real nice job you're doing on this, the downpipes look really well done, the vertical extension looks like a neat fix I can imagine it was a difficult time (easy, easy, nearly in, oh dear).

Out of interest, those stainless flexi joints, where from, what size and how much?
Andy P

Player No.1 wrote:

Out of interest, those stainless flexi joints, where from, what size and how much?


Got them from ebay (where I get 99% of my parts from   )

£15.99 - 2.5" dia 4" long

http://www.ebay.co.uk/itm/1611297...:IT&_trksid=p3984.m1497.l2649
Player No.1

Thanks Andy!
F12KYB

nyc work matey keep the updates cumming
Aragorn

If your staying on ME7 (and i hope you are!) the N80 and N249 need to remain plugged in, even if your not using them.

If you dont have them plugged in you'll get a partial limp mode and no fuel trims.

You can code them out properly in the tune with a bit of effort, but if they're not mapped out just leave them plugged into the end of the loom.
Andy P

Cheers for that! Will keep them plugged in for now until I've had them mapped out.
Andy P

Fairly productive evening last night with only the one hiccup.

Lots of tracing wires and plugging in - mine has the addition of LPG so there's even more than normal to contend with.

Got to a point where I could turn the engine over on the key to prime the turbo's with oil but I noticed oil gearbox oil pumping out the cooler pipes - I was hoping in neutral it wouldn't do this - only lost a bit anyway. So I then went to connect up the pipes and then came to the realisation that the pipes that I had failed to fit the pipes that run from the front of the car to behind the engine before putting the engine in!!!

AAARRRGGGHH! Thought I might have to pull the engine again to get them in but with a bit of patience I managed to thread the first one in. The second was more trouble so i slackend off the front engine mounts and raised the engine by about an inch which gave me just enough room to feed it through.

Not sure how I managed to get them done up nice and tight - there really isn't much room in there to swing a spanner! Then round the front I slipped a rubber pipe round to link the tubes so I could turn the engine over again.

The turbo's should now be well primed as I've had the engine turning over on the starter for a total of about 1.5 mins (in several 15-20 second intervals so not to overheat the starter) I was tempted to pull one of the oil drains (sump end) but because by this time it was pitch black and the Mrs had just arrived home with fish and chips, I quickly packed up and retreated indoors.

I'm away tonight and Saturday, hopefully Sunday it'll move under its own steam.....  
Noggymike

"Roll on" Sunday
Andy P

Well, Sunday was a day of much progress with lots of good but ending on a big low  

Managed to drop a clip down one of the inlet pipes so had to disassemble that to get to it. That then set the president for the day and the car fought with me every single step of the way.



The good part is that its all in, and fired up first time which I was most pleased with  

I decided to fire it up before fitting the front end just to make sure there were no issues before going forward. Oh, and there are no link pipes fitted.


Link


I then got it to a point where its 99.9% done with the last thing to do was to bleed the clutch - something I now know should have been done as the engine was going in!

Managed to get to it and slacken off the bleed nipple and got Emily to begin depressing and lifting the clutch - and then the bloody plastic bleed nipple rounded off!!! AAARRGGH!! It's too tight that I can't undo it to replace with a metal one and for some reason I decided to unclip the hose and try and bleed it from there. Circlip has pinged off into the abyss never to be seen again.

To round off a perfect day I thought I'd check the clutch pedal feel - forgetting the circlip wasn't in and pop! Has dropped the whole contents of the resivour over the top of the gearbox and onto the drive. Fantastic.

Oh and I think the oil feed to the nearside turbo has a small leak.

I want to set fire to it.

Challice

Andy P wrote:
Fairly productive evening last night with only the one hiccup.

The turbo's should now be well primed as I've had the engine turning over on the starter for a total of about 1.5 mins (in several 15-20 second intervals so not to overheat the starter) I was tempted to pull one of the oil drains (sump end) but because by this time it was pitch black and the Mrs had just arrived home with fish and chips, I quickly packed up and retreated indoors.


DaveDDCC

Andy P wrote:
I want to set fire to it.



For one horrible moment I thought this was your car until I clocked the plates.

Fantastic project.  I wish I had the skills to do something like that.

David
Andy P

So Saturday comes. I decide that I'm going to find this clutch pipe clip and fix that potentially weeping turbo oil feed. Start the day at around 9:30am with a fully running car looking like this -



With every intention of documenting the day fully a few minutes in it was looking like -



The start of parts being strewn across the driveway



Promptly joined by the driveshafts



And about 2hrs 15 mins after opening the bonnet we have success. I'm getting pretty good at doing this on my own now!



And here's the offender! It was tightly nestled on top of the nearside turbo. God only knows how it got there because its miles from the clutch slave and it had to get through a heat shield too!

Andy P

And by around 6:30pm.....

https://www.youtube.com/watch?v=N...amp;list=UUwuwkRASyfdvPlnR8CA7SMg

Still running the open downpipes in this video - fabricating link pipes up next!

I had an issue bleeding the clutch properly - the master really doesn't like the front end being jacked up does it!? Had to jack up the rear to get any sort of pedal.

It's still not perfect but as soon as the car went nose down the driveway the clutch pedal came back nicely so hopefully that's cured it.

Also I've got a bad feeling the offside turbo is a bit of a smoker but I'll wait until I've managed to have a proper drive out before I assume that's the case. A genuine replacement core runs at just £155 for this so it's a relatively cheap fix but its another engine pull....
ScottR

Have you kept stock s4 intercoolers on it?

Fair play for your patience. Mine has run out many times during my build, but once on the home straight it feels good.
Andy P

Yep, still running stock S4 intercooler's. Reason being, I want to get some miles on it and make sure it's working before I shell out more money!

When I'm happy with it, I'll fit a fmic, replace the turbo core if it's needed, throw in the injectors and get mapped
Noggymike

If it were me

and thank God it's not




I would have torched it by now



























but, hats off to you and your patience
Andy P

Last night I had a mate pop over to give me a hand. Whilst I was doing the link pipes he was fitting the headlights and the bumper (Thanks Nick!)

The first link that I had tacked together was virtually a perfect fit - I just had to trim off about an inch or so (probably the amount the DP's came back when I lowered them).

The second one I hadn't even made an attempt at yet so this was made from scratch, fortunately I had just enough straight material to fabricate something. I came up with a solution to make up a bit of a jig to get things in about the right place on the workbench before trying it out on the car. I slipped one end over the catback and held the V-band where it needed to go and tacked them together with a bit of rod. Now all I had to do was fill in the gap!



Couple of shots of the welds. Wind was a bit blustery but they came out well. Ideally should have given them a tidy up but I was fighting the clock and fading light.





And the finished pipes.



Well no pictures or videos but I got the car to a point where I could drive it! Started up the car and it's sounding lovely and smooth - exhaust giving a nice burble.... Dare I say it - a bit quieter than I had hoped!   I've only given it a little throttle but the turbos spool up at about the 3k mark though I can't really test this out yet. No EGT or boost gauge wired up so I don't know what its doing.

There's a few bits to sort out before I can put some decent miles on it - mainly the catch can that I need to fabricate - that'll be later this week.

It's not all good news though, the OS turbo is most definately smoking - its getting borderline acceptable to be driven on the road but will try and see what its like in the daylight. Means the engine will be coming out again!!        

Got to do something with the longer link pipe too - hanging down low and at catches (badly) on my sloped driveway. Hopefully I can just rotate this round and it'll pull up nice and tight.

david1980

one step forward = two steps back

looking forward to seeing what this goes like once you've sorted the little bits
Andy P

So last night I managed to get the pipes up higher without too much effort. Will need to get a mikkalor style clamp at the back because the U-bolt hangs down too low.

Turbo is still smoking so looking at my options to source another or get a rebuild kit etc.

Anyway, despite the smoke and scrapes, I'm glad to have the car back in one piece



...for now  
ScottR

Hats off to you for trying something different.  Had always wondered why so few people try anything other than KKK's.

Andy P

Thanks Scott. I've always been one to go against the grain and try something different.

If you think this is different, you should see my other S4...



ScottR

A Saab engine??  What the flip?!?!?!?!  

Got a mate who is massively into his Saabs.
Andy P

ScottR wrote:
A Saab engine??  What the flip?!?!?!?!  

Got a mate who is massively into his Saabs.


Got a couple of engines for this car. 2.0 and 2.3. Where do you think the t25's came from?  

Perhaps I should add that's it's dry sumped, jag gearbox, rwd, with a 200sx rear diff?

Now that's different!  
DaveDDCC

Andy P wrote:
Now that's different!  

I'll say  
Wow  
jimbo

   
Andy P

It's still a project at the moment - one of many that has been put hold. Once I've fixed this, finished the house renovation and moved to a place with a double garage it'll be back to the build and I'll put a thread up here.



Noggymike

Boy!

You mod big
ibzzzzz

Any updates on this...? really wanna see how this goes!
Andy P

I'll be honest - this thread is WELL overdue an update  

So, what's happened since I last posted? Well I stuck another seemingly "good" turbo to replace the one that was a bit smokey - that's right, another engine pull to replace a turbo. Fitted it pretty quickly actually, think it was probably only 1.5 days to pull, replace and refit. started up and all appeared ok - no smokes.

So it's ready for driving - check paperwork, MOT ran out the day before. Arse

So I get it booked in for a MOT at a friendly garage and then it all goes wrong. I had been getting a low signal from the MAF so I think its knackered - it sometimes likes to stall or hunt idle (and yes I've checked that there are NO leaks)

Because of the MAF issue, emissions were a definite no go even when running the LPG test and with the fast idle test in progress the workshop was filling with white smoke and/or steam. MOT aborted. What visually looked like an "ok" turbo clearly wasn't. I don't know why I do it sometimes and take a "punt" on second hand items but in the past it has always served me well - my luck has clearly been used up.

I'll be honest, even without the smoke, I knew there was trouble. On boost it squealed like a little bitch   Oh well - you know whats coming!

Anyway, since all of this has started I've moved jobs and moved up the chain position wise which brings its perks! I've got a pretty understanding MD and he's happy to use the workshop to store and work on the car.

So just before Christmas, I brought it to the office-


A bit of a shuffle round with some of the "toys" and it sits in its temporary home. Finally warm and dry - on a nice level surface!


It sat there over Christmas but before the new work year started I popped back and started the teardown.

All I can say is, having done it 5, 6, 7 times now (I really don't know!) and this time with the luxury of warmth, dryness and a flat surface to work on, pulling the engine is EASY lol. I still hate doing it mind







And after the engine was out -



At Christmas the Mrs got me a GoPro type camera. No excuses...

Part one

Link


Part two - there's a bit of a jump at the end, the damn cam ran out of battery for the big lift!

Link


Part 1 & 2 were filmed on separate days but overall time was probably about 3 / 3.5 hours to remove completely.

In addition to the camera, the Mrs also got me an AWESOME set of rims for the track S4. I'll be running 17x10j all round. Offest is a pretty crazy et15.

The amount of poke will probably give you some idea of where the bodywork will be going in future....









And finally, I've managed to source a pair of brand new CHRA's for the Garrets. Had them sent over from the US





And that's where we're at now. Not so much progress but I've been flat out working on the house which has been put on the market - and sold within a few days. And our offer has been accepted on the new place.

Busy busy busy.
Akis

Excellent update and really good to see the car in a comfortable spot. Thoroughly enjoyed the time-lapse as well, neat touch! With regards the bodywork, will you be going OEM RS wide or a different route? Fantastic work though, can't wait to see more updates  
BNBboyo

Nice wheels bmw CSL design? Keep up the interesting work 👌
Andy P

Akis wrote:
Excellent update and really good to see the car in a comfortable spot. Thoroughly enjoyed the time-lapse as well, neat touch! With regards the bodywork, will you be going OEM RS wide or a different route? Fantastic work though, can't wait to see more updates  


I quite enjoyed doing the time lapse! Lack of decent software and more-so lack of editing talent forced me to steal audio from any youtube video that ran for the same length!  

I think you've already sussed I'm not one to go OEM RS WB route   and will be doing something a little different though it'll still see a historical link to previous generations of WB Audi's. It's a risk and won't be to everyone's taste but I do like to do things that make me stand out from the crowd. Obviously.

If it doesn't work, its no big deal to revert back to standard or source WB panels.
Andy P

BNBboyo wrote:
Nice wheels bmw CSL design? Keep up the interesting work 👌


BBS RC concave reps



Mine are made by Dare
C J

Awesome update!

Been a while, but worth it!!

Keep em coming!!
Akis

Andy P wrote:
Akis wrote:
Excellent update and really good to see the car in a comfortable spot. Thoroughly enjoyed the time-lapse as well, neat touch! With regards the bodywork, will you be going OEM RS wide or a different route? Fantastic work though, can't wait to see more updates  


I quite enjoyed doing the time lapse! Lack of decent software and more-so lack of editing talent forced me to steal audio from any youtube video that ran for the same length!  

I think you've already sussed I'm not one to go OEM RS WB route   and will be doing something a little different though it'll still see a historical link to previous generations of WB Audi's. It's a risk and won't be to everyone's taste but I do like to do things that make me stand out from the crowd. Obviously.

If it doesn't work, its no big deal to revert back to standard or source WB panels.

I like your style  
Definitely a good thing to venture out and try something a bit different, and it's especially rewarding when it works out nicely!
ian52

I want those wheels! I have genuine BBS RC on my RS but not concave.
Andy P

So a bit of an overdue update (as always! )

House work is almost complete and the house is now on the market (it did sell after 2 days of going up but that fell through    ) so I've had a few hours to spare recently - although not enough to take decent pictures it seems!

As it was a sunny day I wheeled the engine tot he front of the workshop so I could work in the fresh air. I had borrowed the bosses Bentley for the weekend and sent him this pic saying "thanks for the donor engine mate!"





As big as the 2.7T is, its only half the size of the W12T in the Conti GT!

So, pulled off the old turbos and began to split them





Gave the housings a bit of a clean (in the office dish washer )



Ready for assembly with the new cores


And made the clean housings nice and grubby again with my dirty mitts!




My mate Nick (Prawn) popped over to give me a hand putting the turbos back on. Not sure if hes a member on here but hes "kind of a big deal" over on ASN and in the 1.8T world of tuning He owes me one or two favours - I've put quite a few days (weeks) into his car during the middle stages. Fitted the roll cage among a host of other things. I'm still finding myself getting dirty every time I go over to his!

Images stolen from his thread -

Wrong wheel drive A3 with Bentley in the way.



All back together


And we had to steal a bit of vac hose from his car. Annoyingly orange lol


Before I chucked the engine back in I remembered the AC pump bracket threads were knackered - at least one of the bolts went "soft" as I was tightening them up last time it went in so I got myself a new helicoil kit. Ebay bargain at £35 delivered. You take your chances with ebay kit but I was pleasantly surprised with the quality when it arrived. Decent bits and taps. I'd have chucked it if were a  load of rubbish.



And that's all I have pictures of unfortunately. Currently the engine is sat in the car, clutch is bled but the rest of the plumbing and wiring needs doing. If you want a pic of this - scroll back a few pages, there'll be plenty! Haha!

I'll be working on it over this weekend but there'll be a limit to what I can get done. Fingers crossed by Tuesday I'll have a FMIC kit here so I can put the front end back on.

I have also decided that I'm going to stick the brakes that were originally intended for the track car on to the daily and then get some 18z's for the track car with floating discs. This means in the mean time IF I want (need) to do a track day I could use the daily.

The calipers are brand new 4 pot TVR / AP racing CP6600's. I've got DS3000's and the discs are S3 345x30mm with the centre bore opened out. I've been in the process of hand making caliper brackets for the last 3 years lol (ok so I spent an hour on them once, and I've just unearthed them again!)

I believe the discs have a lower offset to the usual ML's so there is no need to grind the upright. The AP's are slimmer than brembos so I *shouldn't* have spoke clearance issues.

Here is a pic of the setup under the track wheels...




Yep, that's a rear hub used for illustration...

Hopefully a bit of progress this weekend then  
Kent

spot on fella! keep it up.
ScottR

FalleN

Amazing work! That Bentley is just WOW, love those things.
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