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Discussion Starter · #2 ·
Update for the weekends progress.

Work started about 7pm Friday. Within 40 mins the head was off and out the way. Got the turbo and mani bolted on to the large port and had a mock fit. Ben's opinion was their wasn't really enough space and the bulkhead would need a little bit of tweaking and the air con pipes would have to go. Bugger. As I hadn't had it gassed since the k04 work in August and I wanted the turbo on the car, it had to be done. Put the new gasket on and the head was fitted properly. All bar 2 turbo lines were fitted as well. Inlet mani was fitted back on to the car and the cambelt was back on the car and work stopped about 11.30ish.

Work started Sat about 1pm.
Jobs done were:
1 of the 2 remaining turbo lines were fitted. The fitting for the other one isn't the correct fit for the hose.
Ben decided to become an exhaust fabricator and got the downpipe well underway, mocked up and tack welded in place, ready for a mate to add some fancy looking welds to it.
Tip was bought and pretty much done. DV is welded straight onto an alloy 90, n75 boss to be added by the same fella that is doing the exhaust, then it's done.
The down pipe has been sorted so it can be taken out with the turbo in place and the head on which is a bit of a brucie bonus for any future works that might take place.
Beyond the down pipe, I have just bought some additional 3" stainless to make the exhaust 3" all the way to the back box. Partly because the car is very quiet and partly because one section of a straight in the exhaust has a massive dent in it..

I say all this very casually, but hardly any of it was done by me.

The work was done by Ben @ Parsons Performance, Sussex.
 

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How much did you need to hammer out the bulkhead? I know mines tight in there but my turbo sits on top of the manifold.
Love seeing project threads so keep up the good work.
 

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Discussion Starter · #5 ·
Matt B said:
How much did you need to hammer out the bulkhead? I know mines tight in there but my turbo sits on top of the manifold.
Love seeing project threads so keep up the good work.
Not masses to be honest, once the A/C pipes were out the way the bulk head needed tweaking. A top mount wouldn't have given this issue, but thats something to look into in the future.

Thanks a lot, car is pretty well set up for it so should be a good laugh.

S3TT, it's not an estate, it's a sportback. I'm hoping your TT won't be fast enough to get near to the boot of my car anyway!
 

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Sounds like a quick install, hopefully it will make you smile.
Hopefully you can live with the lag, unless you have a solution..
Steve
 

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It's a localish garage for me. Sounds like they are on the ball in so far as it's all got done super quick (normal time for me).
Are they expense? I guess once you've got it running and had it that way for a bit will tell if they are a quality company. Lets hope so, looks good so far.
I might have missed it but what vehicle is it on.
And are you letting them do the map?? Know a couple of people who got Revo then changed to WAK.
 

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Discussion Starter · #12 ·
dbbloke said:
It's a localish garage for me. Sounds like they are on the ball in so far as it's all got done super quick (normal time for me).
Are they expense? I guess once you've got it running and had it that way for a bit will tell if they are a quality company. Lets hope so, looks good so far.
I might have missed it but what vehicle is it on.
And are you letting them do the map?? Know a couple of people who got Revo then changed to WAK.
I first went to the garage earlier in the year and any work done since on the car has been undertaken by Ben. Not expensive for an independent garage and if you compare them to a VAG specialist/main dealer then they are very reasonable. They also did the k04 conversion I had earlier in the year, as well as a downpipe fitting, rear brake upgrade, coilover fitment and a cambelt change/service.
It's on an A3 quattro.
I have someone else doing the mapping, they offer Revo software but it needs a more custom job..
 

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Discussion Starter · #15 ·
jamman said:
Who is doing the mapping ?
I was tempted to go to R-Tech as they seem to be about the best in the country when it comes to 1.8T's, but I did some map testing for s3TT (Dan) when I had my k04 put on the car and I was more then happy with the variety of maps I tried, so I shall probably go to him again.
 

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Discussion Starter · #16 ·
Back from my holidays so time for an update:



Downpipe was a bit more of a mission then first thought, fella welding it has said it was a bit of an effort to keep the 5 bolts on the flange accessible, but as it can be done, it will be.

Downpipe was sorted and heat wrapped.
TIP was sorted.

All was looking good.
 

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Discussion Starter · #17 ·
Posted by Ben from Parsons Performance

Had a few hours spare this evening so replaced the dented scorpion 2.75" pipework with 3" stainless. It's 3" untill just before the backbox where it reduces to 2.75", this is a tempory measure until Reesy gets another backbox.
Tig welded by my own fair hands, first attempt at a cat back system, pretty pleased with the outcome.





240g/s @ 13psi!!!!!! This things got serious potential.


 

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Discussion Starter · #18 ·
Drove the car Friday night for the first time with the new setup.

It was running about 10psi with a slight creep towards 12/13 in the higher revs. It's quite strange in the way it drives though. It doesn't feel particularly fast until you look at the speedo. It was raining and their was also a lot of standing water but it was quite underwhelming really. With a tweak of the actuator it could easily be used like this every day though.

It also sounds really good, sounds more appropriate for the power it has without being too boomy. Need to do a few miles on it before I know exactly how it'll sound, but overall I'm happy with the exhaust.

Going to check everything over today before it is released back into my (lack of) care and going to put on a more boosty map I have got to see if I can get some epic g/s, as we all love epic g/s.

It also starts to pull comfortably in the higher gears from about 2.5k, so lag isn't really an issue either.
 

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Discussion Starter · #19 ·
Post from Sat evening:

It's not 100% healthy unfortunately, but I'll get round to that in a minute.

2 exhaust clamps have been fitted.

Jubilee clips fitted to the TIP and that's sorted.

The oil leak that was causing a bit of an issue was located. It was the oil feed restrictor, despite being up very tight it was leaking a fair amount. Re tightened it, went to the petrol station and it was still leaking. A washer or two was added and it seems to have solved the issue.

As the car was not making quite the 1 bar at actuator pressure, the actuator was wound out a tiny bit. Seemed to have made a bit of a difference and the car goes pretty well. Got back to mine and loaded the boosty map on, idle was instantly better. Opened it up on the bypass and the needle on the boost gauge shot up to and past the stop on the boost gauge (30psi) so i quickly shut off..

As it had done once on the k04, the hose linked to brakes popped off so as we pulled into the petrol station to wind the actuator down and sort the boost leak, the car had very little in the way of brakes. Not ideal. Ben has said that a one way valve can be put in place so it should stop it from happening again in the future..

Actuator slackened right off, we set off again. Car was still making late 20's psi so I'll be speaking to Dan about lowering the load. I have rods and the turbo could probably take 30psi as it pulled that all the way to the redline, but it isn't really necessary. I'll post the vcds logs that were done earlier, but it involved maxing out the MAF

Decided to take a couple of drive by videos. Car sounds epic, especially when it comes on boost, also makes large pops on overrun which is pretty cool. Left without getting a video though as the exhaust is making a horrible noise. Hoping that it's just the gasket for the blanking plate that is on the manifold, failing that it is possibly the clamp that joins the decat to the downpipe..

When trying to see if the car still drove O.K despite the noise, the same hose popped off again which is *** annoying. Popped back on yet again, N75 unplugged and I drove the car home. Drives fine, just sounds horrible. Over a 12 miles journey with the odd burst of boost but generally keeping with traffic, it averaged (supposedly) 37mpg, and before anyone says it: the dis is calibrated as it was running very early 20's when boosting and not boosting.

It has since been diagnosed at the wastegate blanking plate gasket, so I have two on order.
 

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Good read , keep it up
 
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