JonnyC's Audi S3 build..

[jonnyc]

Hey all.. Just thought some of you guys make like to look at the progress of this car..

Quick background story on the car first of all..

I bought the car new back in 07' and it went through quite a transformation, from a high spec standard car to the first big turbo MKII S3 in the UK, and I think at that point, the world!

Here are a few pics of the transformation, pics speak for themselves..





[imghttp://i123.photobucket.com/albums/o304/jonnnny28/DSC00008-1.jpg[/img]




















I then sold the car and pursued the MK5 ED30, building (on a standard turbo) the fastest MK5 GTI in the UK (despite what some people say/claim) The fastest 2.0T FSI powered car in the UK and the the fastest DSG MK5 in the world, and all on the standard K04 turbo..

That was great fun, but really I felt that I wanted a change and when I saw that my old S3 was back up for sale, I jumped at the chance.. Big mistake so it seems...

I collected the car from Leeds (about 60 miles from where I live) and by the time I was home the car was struggling to even run.. Anyways after lots of investigation over the past week it turns out that its melted piston no. 1.. The head is being taken off tomorrow and we should then know what else has happened! Hopefully its just a case of a small hone to that cylinder and drop in some nice new low compression pistons and forged rods and away we go..

So for the next 3 or more weeks the car is going to be off the road, having the engine and turbo kit built..

Here is the spec that im aiming for on the car, this should make a pretty nice car!

Engine

* BSH race turbo kit - Purge welded tubular V-banded manifold
* GT3076R turbo with anti surge comp housing, billet compressor wheel, metal bearing cages, race spec bearings and Tial V-band exhaust housing
* Tial MVS 38mm V-band external wastegate
* Forged rods - non tapered little end
* Low compression Je pistons (yet to decide on bore or CR)
* Coated con rod bearing kit
* ARP 2000 rod bolts
* ARP 2000 head stud kit
* Revo stage 3 software
* N2MB Wot Box - 2-step / flat shift option
* OEM Audi RS4 injectors
* Autotech High pressure fuel pump
* Forge Motorsport remote DV kit
* Forge Motorsport PCV fix / catch can kit
* Forge Motorsport twintercooler kit
* Custom throttle body to intercooler pipe
* Forge Motorsport Twintake kit
* 76mm v-band downpipe
* 38mm v-band dump tube
* 76mm Ti exhaust system
* Full A/C system removed

Chassis

* KW adjustable camber plates
* AST race suspension with custom short springs & helpers
* Whiteline Anti Lift Kit
* KW race anti-roll bar kit
* Poly bushed suspension all round
* Project Mu 6 piston race calipers with 380mm discs
* Project Mu race pads - rear
* Braided front & rear brake lines
* Race brake fluid
* Spec Mini Twin race clutch & Aluminium flywheel
* Race Haldex controller
* VWR Engine mount - Race
* VWR gear box ounts - Race
* VWR billet lower subframe mount - Race
* VF engineering pendulum mount
* Forge Motorsport adjustable quick shift
* Forge Motorsport adjustable side-to-side quick shift
* Force fed engineering solid bushings - Shift cable support bracket
* Custom resin filled shift bushings
* Team dynamics Pro race 1.2 wheels (Powdercoated Red)
* Toyo R888 225/40/18 tyres
* Braille mini battery kit

Interior / Exterior

* Recaro Pole position seats (custom covers)
* Recaro Aluminium side mounts
* Recaro A3/S3 base frame kit
* Lightweight interior
* Custom rear carpet
* OEM optics front grill
* Black mirrors
* Front splitter center section - Satin black
* Rear diffuser section - Satin black
* PIAA 6500k xenon bulbs upgrade
* PIAA 6500k side lights
* Silvervision indicator bulbs all round
* 6500k rear number plate bulbs

And thats about it!! haha.. So quite a list really..

Heres some pics of the turbo kit, I considered the ATP kit, but this will make far more power when its really being pushed, and the Tial v-band stuff is so nice! I want to do this once, and right the first time round! For sure I would be able to do it far cheaper, but this is going to be a no compromise project, and a one of a kind car for a long time to come!







The end goal is 600hp and 1200kg.. That would make for a 500hp/tonne power to weight ratio.. Similarly powered Evo's run 10's no problem, and that is the aim for this car.. 10 second 1/4 mile on STRAIGHT pump fuel, no additives, no nitrous, just fill it up with V-Power and go!

Bare in mind my Golf ran a 12.6 1/4 with 290hp/tonne and FWD.. Yes it was DSG, but you get the idea.. Its not going to hang around!!

Anyways here we go, this should be quite fun! Its going to be at least 3-4 weeks before I get the car back, but by then it should be running the spec above.. My god I cant wait to drive it.. Its going to be amazing!!

[jonnyc]

Here we go!

[jonnyc]

Engine is all apart now and the true extent of the damage to the piston can be seen, pretty shocking really! Amazing that the damage to the bore was so so light, I mean, you could hardly even feel it.. 0.5mm bore out will remove that no problem and I should be good to go with the 83mm bore pistons..

Damaged piston.. (Not for the faint hearted!!)




Strange thing is that the crown of the piston is ok, this leads me to believe that it was more a lack of oil / sh*tty oil problem rather than pre ignition as surely there would be damage to the crown if this was the case?

Head off..




Engine out ready to be stripped down..



Old pistons and rods.. (All the rods look in top condition, amazingly the bearings are all in perfect condition too)



Crank.. (Again, no damage..)



Valve train..



Intake valve.. (all of them look like this, because of the recirculating PCV system, just shows how important it is to run a catch can with this engine)



Block and head ready for machining..



Lots of bits..



The engine should be back from the machine shop Thursday and be fully built up with the new parts by the end of the week.. So thats good news..

One thing that was pretty amazing was the weight difference between the Supertech valves and the standard items.. Huge difference, ill get a figure to compare but a lightweight valve train can only be a good thing..

Also the new rods and pistons are a lot lighter than the old items, this should make the engine really free revving.. Combined with the new lightweight clutch and flywheel im estimating around 8kg off rotating mass to be saved..

Im hoping that the parts from the US should be with me within a week but you can never tell with customs!

Anyways im feeling a lot better about it all now, before it was all doom and gloom, everything that was discovered seemed to be a big negative but now its on the way to recovery..

While the car has been up in the air we have also had a chance to plan some nice chassis bits that should really help out the some what wooly handling of the S3 compared to the Golf.. Everything is on the way so fingers crossed the bits get to me from BSH and I can get the car back on the road soon..

[Great North USP]

The complete engine work you are doing is something only a few can do and something many wish they could do.
The dyno charts from your 1st posting looked scary enough, can't wait to see what the new build will look like.
Good luck on everything mate.

[Sales@RAI]

awesome project

[tpliquid]

good sstuff

[mikevets68]

wowow good stuff thus far bro!

[the4ringer]

make youtube your friend! that looks monsterous! tip o the cap to ya.

[W3rkd]

Is this a fsi motor or like the one in the 225 TT?

[Krieger]

just look at it. its FSI.

cant wait to see this puppy tearing the track up!

btw, how many miles on those valves? they arent that bad!

[jonnyc]

Is this a fsi motor or like the one in the 225 TT?

The car it came out of is a clue..

just look at it. its FSI.

cant wait to see this puppy tearing the track up!

btw, how many miles on those valves? they arent that bad!

32k on the valves, I know there not as bad as some, but still its unacceptable amount of build up for a modern engine!..

[Krieger]

oh yes, absolutely it is.

im glad everything looked good as far as wear goes. that means our fuel dilution isnt as bad as some hoped.

moar pics.

[jonnyc]

So!! The block is back, re-bored to 83mm for the new pistons, and everything is perfect, luckily enough the 0.25mm on the bore wall was enough to remove any damage from the piston.. In fact, the machine shop said that a heavy hone would have been enough, I think if it was going to be running standard power then yeah.. But with the plans that I have for the car immediately and in the long term, I want to make sure that this engine will be able to take everything that I throw at it!!

The engine will be getting built up starting next week, and shouldn't take long to complete, I should have lots of pictures of the build up to post soon!

Then its just a case of waiting for the parts from the states to arrive..

Thought I would post up a few more images of the turbo kit that BSH have just released.. (part of my kit is on that table I believe)






Can't wait to see this stuff on the car! Looks like amazing work!!

Plan is to run the car in for a week or so gently, drop the oil and see how everything is looking then go down to Revo and see what it will make! Limit is going to be the stock in tank fueling system at the moment but there are lots of things in the pipe line to sort that out!

On straight 93 octane (98 euro equivalent) guys in the states have got to around 450WHP on the stock fueling system with RS4 injectors before its maxed out, so thats what Ill be aiming for as a first shot.. Thats around 525hp at the crank.. Even with that power its going to be a very quick car!

[viziers]

Hmmm REVO Stg III huh????

Do you have the same fuel system that us B7 A4 guys have as far as having a saddle tank???? If so thats great because ive been told by REVO they have no intentions of working a stage III tune for a GT3076r OR a GT3071r until the LP fuel solutions is found.. And if you have found one please share with the rest of us who have been waiting?? Is it a drop in solution??


Just curious....

Edit: Unless its a totally different type of tune that the S3 model???

vizi

[jonnyc]

Hmmm REVO Stg III huh????

Do you have the same fuel system that us B7 A4 guys have as far as having a saddle tank???? If so thats great because ive been told by REVO they have no intentions of working a stage III tune for a GT3076r OR a GT3071r until the LP fuel solutions is found.. And if you have found one please share with the rest of us who have been waiting?? Is it a drop in solution??


Just curious....

Edit: Unless its a totally different type of tune that the S3 model???

vizi

LP fuel system is the same as the GTI, so no issues there really.. I know that the B7 A4 has a different system, but I dont know much about it..

For sure the S3 is the same as the GTI.. So 450WHP is within range on the stock LP system

[viziers]

LP fuel system is the same as the GTI, so no issues there really.. I know that the B7 A4 has a different system, but I dont know much about it..

For sure the S3 is the same as the GTI.. So 450WHP is within range on the stock LP system

Yes the only difference from what ive researched and have heard is that the actual fuel line from the rear to the front on a GTI is larger than that of the audi and obvioulsy the pumps are different in that ours draws from 2 sides of the tank...


vizi

[dbcperformance]

good times

[Phil@BSH]

Hi Johhny! It was nice speaking with you yesterday :smile:

The custom bits for your car are just about complete and you are correct, your manifold is the first one in the row. We are excited to work with you on this project, talk to you soon.

-Phill

[IzzyS4]

Wow I love your car!!!!

[jonnyc]

Hi Johhny! It was nice speaking with you yesterday :smile:

The custom bits for your car are just about complete and you are correct, your manifold is the first one in the row. We are excited to work with you on this project, talk to you soon.

-Phill

Thanks Phil,

Wow! I seriously can't wait to get the kit fitted and run her in.. Then! Time to make some serious power!!

N2MB WOT box is on the way too, that will be in as soon as it turns up, should really help with launching and maintaining boost through the shifts..

First 2.0T FSI into the 10's? Lets see..

[drew138]

Pretty awesome. I thought I read on as.net that you were selling it. Put it on a boat and send it to me!

[jonnyc]

Pretty awesome. I thought I read on as.net that you were selling it. Put it on a boat and send it to me!

That was about a year ago.. The car was sold and then bought back.. I said that in the top post..

The car is going to have about £40k in it so if your willing to pay that then your more than welcome

[SoFresh]

I always loved your car and was surprised you sold it to begin with, lesson learned ;-p

Its gonna be a beast when you're done with it!

[jonnyc]

I always loved your car and was surprised you sold it to begin with, lesson learned ;-p

Its gonna be a beast when you're done with it!

Very true, to be honest.. The reason I sold the car was simply at that time no one could support my wishes! Now its a different story.. BSH and Revo to the rescue!!

Update..

Hey all..

All things are coming along nicely, the turbo kit from BSH is being send tomorrow, and should be with me (fingers crossed) by early next week.. There has been a hold up due to a few adjustments I wanted making to aid the fitting and performance of the kit..

Couple of annoying things have been found, not going to make any difference to the build but just pisses me off how people can neglect a car so badly..

This is the oil filter



And the sump..



Notice the gunge that is coming out of the filter, and the shit that is sat in the sump! This is after being flushed out, the stuff you can see is residual gunk that has been dislodged! Its almost the consistency of tar, just shows that there is no way the car has been regularly serviced as suggested by myself..

Luckily all of the bearings on the crank and oil pump look mint!



The only damage is some wear on the oil pump chain tensioner, so that will also be changed..



The oil and water gallerys were in perfect condition with no metal particles or blockages.. The oil pump is in perfect condition. Im having the oil cooler changed out of precaution as there is a super fine matrix inside which could easily hold metal particles.. Better to be safe than sorry really, especially as the whole engine is going to be basically new!

Good points!!

Engine is coming along nicely, block is built up with the new pistons / rods and crank and the head is back from being skimmed tomorrow and will be fitted with the new Supertech valve train parts hopefully by the end of the day!

Heres some pics..

New piston and rod combo



Clean..



Machined block.. 0.5mm overbore



Built bottom end..




So coming along pretty well, engine and all ancillaries will be built up tomorrow so that the engine is sealed and can be wheeled in and out of the engine compartment of the car when testing the fit of the turbo kit!

Im really hoping that I should have the car back on the road for running in for my birthday which is the 24th! Will be a nice present from me to me!! haha..

[Krieger]

good stuff!

yeah, im wondering if all that junk in the engine isnt actually normal for our engines.

i mean, so far, FSI engine havnt really followed normal logic, when compared to other more mainstream engine... so whos to say this isnt another example?

maybe what ur looking at there is all the carbon and crap that got blown pass the seals, or coked up from getting too hot...

but yea, glad she is coming along!!! btw, u gonna get a EJ valve cover on her too? would be a nice look to top her all off, plus u would have a bulletproof PCV system.

u doing anything about the valvetrain? maybe camming it, or anything special? also, P&P?

yumm..... lol

[jonnyc]

good stuff!

yeah, im wondering if all that junk in the engine isnt actually normal for our engines.

i mean, so far, FSI engine havnt really followed normal logic, when compared to other more mainstream engine... so whos to say this isnt another example?

maybe what ur looking at there is all the carbon and crap that got blown pass the seals, or coked up from getting too hot...

but yea, glad she is coming along!!! btw, u gonna get a EJ valve cover on her too? would be a nice look to top her all off, plus u would have a bulletproof PCV system.

u doing anything about the valvetrain? maybe camming it, or anything special? also, P&P?

yumm..... lol

At the moment im doing as much as I possibly can whilst the car is apart to try and save myself labour costs but im running out of money very quickly..

There is a long list of stuff that I would have loved to do at the same time but at the moment its not viable.. Should have another go at the car in a couple of months and get a load more bits done to to it!

Valve train is being built up with Supertech parts, I was considering the Ferrea parts but to be honest im not going to rev this thing that high, with the Supertech parts im comfortable going to 7500rpm and I think thats going to be enough to make the power..

Ill be using the Forge Motorsport PCV / Catch can system with the stock rocker cover, but I do like the look of the Eurojet part.. Again, maybes in the future..

I just wish someone would come out with some really solid fueling options for the LP fuel system so that I wont have an issue with fuel delivery!

[viziers]

I just wish someone would come out with some really solid fueling options for the LP fuel system so that I wont have an issue with fuel delivery!

Lol.. You and me both..... Soon though hopefully!


vizi

[A4Rob]

Rep points for an awesome build. I love the red wheels!

[jonnyc]

Lol.. You and me both..... Soon though hopefully!


vizi

Need to find out more but it seems that in testing the S3 2.0T FSI with a GT3071R turbo fitted was un able to max out the stock LP fuel system.. So there is certainly a difference in the stock LP fuel system on the K03 cars compared to the K04 cars..

If thats across the board on all the K04 2.0T FSI variants im not sure, but certainly the S3 seems to have more head room, how much I dont know.. Should be finding out soon lol..

[kwik_shift]

This is the 1st S3 that is sexy as a mo' fo'!!!

[viziers]

Need to find out more but it seems that in testing the S3 2.0T FSI with a GT3071R turbo fitted was un able to max out the stock LP fuel system.. So there is certainly a difference in the stock LP fuel system on the K03 cars compared to the K04 cars..

If thats across the board on all the K04 2.0T FSI variants im not sure, but certainly the S3 seems to have more head room, how much I dont know.. Should be finding out soon lol..

If you can check to see what the ID of the fuel lines are that go from the end of the fuel filter side to the engine are the VW's are 5/16 ID the B7 A4's are smaller but I don't know exactly how much smaller...


vizi

[Wizard-of-OD]

Build looks amazing guys !

[Urtorsen]

cracking car,will be scary fast,lashing sti's out of it will be a good feeling foryou me thinks....would i have seen this same car for sale on pistonheads ages ago???

[Urtorsen]

sorry,it obviously was ,just after reading into your post...audi-sport.net is a really helpfull site...got some really hard to find things for the mk1 s3 and the info there is endless...best of luck with the car ...as if youll need it

[jonnyc]

Update..

So lots of things are happening pretty quickly now, coming along really well..

First of all this little thing arrived yesterday!! Thanks to Neil and Ollie at THS..



Core is rated to 600hp so should be up to the job!!!

First of all the engine build.. Parts are all here now and the head is all built up. Ported and polished and fitted with the new Supertech parts!

Head back from being skimmed, 30 microns were removed, so not much.. At this point the internals of the head had not had any attention!

Before..





About an 1/8 of an inch of build up!! Crazy really..



After..




Check out the inlet ports!!

Before..



And after, you can see a small difference!!



Everyone that has seen the state of the inside of this engine has been shocked. Its got nothing to do with the piston problem that I had. This is just how the 2.0T FSI runs with the stock PCV system, pretty nasty really!!

More bits, stretch bolts, seals, gaskets etc etc etc.. Now the bottom end is all built up, oil pump is back on, everything cleaned up and a new filter!!






Happy about all of the progress on the engine build! Nothing is being left to chance so everything is being replaced.. Not the cheapest way of doing things but I know for sure that im giving the engine the best chance possible of lasting and being strong enough to cope with the power.

Final spec of the engine is as follows..

* Head skim
* Block re-bore & hone to 83MM
* Integrated engineering non-tapered 2.0T FSI connecting rods
* JE 83MM bore 8.5:1 compression forged pistons
* JE pistons rings
* ARP 2000 rod bolts
* Calico coated rod bearings
* Ported and polished inlet / exhaust head
* Supertech stock size inlet and exhaust inconel valves

Turbo is on its way from the states now.. Should have some pics from BSH and a video of there 450WHP GTI running pretty soon.. Apparently the dump tube sounds incredible!!

[Mr_Mark5]

Great build. Enjoyed your build up of the GTI as well. Have a picture before sold? I can't find your thread on the MK5 forums..

Found it..

[SoFresh]

awesome, keep us updated!

[KarimS3]

Thanks for sharing your build with us. All the best!

[Zetetic]

So.... All this with a FWD?

SCARY!

[jonnyc]

So.... All this with a FWD?

SCARY!

S3???