JonnyC's Audi S3 Project..

[jonnyc]

A pair of these will be in order there i think

Just bought the exact pair for inside..

[Rabbit222]

Hi Jonny!

Nice to see you back in the Four Ring stable

[94Luke]

Thisis gonna be mad! Can't wait to see it finished!  

[jonnyc]

Can't wait to see it finished!  

Your telling me!! 

[jonnyc]

Hey all..

So again some more progress has been made..

The clearance between the exhaust housing of the turbo and the transfer box was very small, around 12mm and as little as 8mm in certain places so I decided to use the new Zircoflex material from Zircotec to shield off all of the transfer box, any anything that would be subject to heat from either the turbo or manifold..

Some pics..

£100 worth.. humm, hope its good!



Transfer box covered with 3 layers..



All of the lines from the turbo have also been wrapped in the ceramic matting, which will protect them from the heat..

Next thing that needed to be worked on is the downpipe, this is not yet finished but some pics of the mocked up downpipe.. Features full 3” Tial V-band connector and high flow flexi.. Will have some better pics of this tomorrow all wrapped in exhaust wrap..





The downpipe required lots of work, obviously the kit is designed for the downpipe to run centrally down the tunnel, exactly where the prop sits on my car, so we had to go round and under the shift cables and down the left hand side of the prop with the downpipe..

The dump tube will exit down the other side of the prop..

Whilst everything was out we took the opertunity to strengthen the rather flimsy looking support bracket for the transfer box, all helps..



A pic of the fully mocked up turbo (complete with intake pipe) manifold, wastegate and dump tube




This pic shows just how close everything is..



And some nicely routed lines, all tucked away as much as possible whilst retaining a good flow..



Looks so good!!

Also had a call from Recaro today to say that my seats are finally here! Only taken 12 weeks!! Just in time though I guess, they will be in the car tomorrow, and im going to take the opportunity to remove lots of interior weight whilst im at it, ill be able to see just how much I have saved from that too!

What else needs doing?..

Downpipe needs finishing off, and wrapping

Dump tube needs some adjustment, and wrapping

Bottom boost pipe needs some work to clear the transfer box and drive system at the front, obviously quite different to the GTI!

All the front end putting back together

Fluids in and then its ready for firing up! We’ll have to see, but im thinking tomorrow we may have a video of it taking its first breath!!

[Poppa Dom]

Can't wait Johnny - this is progressing well - it's a great feeling when it is at the point of all coming together and be ready to get turned over for the first time. Am sure Phil is just as excited as you, it's a big step for BSH and I'm really looking forward at seeing the results.

[JPC]

looking suitably insane jonny, nothing less than id expect! ;)

[Sunglasses Ron]

Jonny, with the turbo and the transfer box being sooo close together. I take it you have allowed for any possible expansion when everything gets rather warm?

[jonnyc]

Jonny, with the turbo and the transfer box being sooo close together. I take it you have allowed for any possible expansion when everything gets rather warm?

That really is my only worry, I have no idea how much the manifold will grow when its hot, and in what direction, need to get it hot then have a look, thats about the only way we can do it..

If its a problem then it will require the manifold being reworked to raise up the position of the turbo, but then it would mean downpipe and dump tube would need to be re made also.. I really hope it doesn't come to that!

fingers crossed I suppose! 

[QD MBE]

On the braided lines in the last pic, have you used Nylon Ty-wraps?  Might be a bit warm for them in that area?

But good luck with the first running tomorrow.
 

[jonnyc]

On the braided lines in the last pic, have you used Nylon Ty-wraps?  Might be a bit warm for them in that area?

But good luck with the first running tomorrow.
 

Thats only mocked up with cable ties, there is a bracket there now..

[QD MBE]

On the braided lines in the last pic, have you used Nylon Ty-wraps?  Might be a bit warm for them in that area?

But good luck with the first running tomorrow.
 

Thats only mocked up with cable ties, there is a bracket there now..

Good man!
 

[Poverty]

Wonder how this will stack up against the 500hp tt-rs once its done.

[jonnyc]

Wonder how this will stack up against the 500hp tt-rs once its done.

Theres a 500hp TT-RS?

[chungster]

Wonder how this will stack up against the 500hp tt-rs once its done.

Theres a 500hp TT-RS?

Revo mapped one perhaps lol.

anyone know what turbo the TT-RS uses, and its potential?