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Everything posted by tuffty

  1. Would appear that this forum is now dead... I haven't been able to get my last post 'approved' (still unsure as to why after all this time its decided to be approved rather than just post) so I won't be posting any further progress on here... Sad times that forums are slowly dying off and Facebook groups are taking over... I will continue to update my original thread on Audi-Sport.net for those interested in following.. https://www.audi-sport.net/xf/threads/my-minor-modding-thread.76389/ <tuffty/>
  2. Hi folks... been a while since I was on at all let alone posting an update but... here I am and here is an update The world that is DSG tuning is an "interesting" one to say the least... the S3 wasn't driven much if at all over winter and with the rubbish weather its not been high on the to do list at all... That said I have now got the gearbox tune to a point its changing pretty quickly and producing around 15bar of clutch pressure... I have also turned the boost back up and been popping over to Mexico every now and then to tweak it... its still a bit of work in progre
  3. For most port injection VAG based engines up to 6 cylinders its pretty epic... I have some limited exposure to ECU's such as Emerald, DTA, Megasquirt etc (the typical after market ECU's used in these types of projects) and Ignitron is night and day better... I ran an OE ECU on the 20v for as long as I could putting off going to the typical standalones as despite being far more difficult to tune the OE always drove better than any emerald or other standalone high power 20v I had worked on... First time I fitted the IECU was a revelation... fired up and idled sweet as a nut out the b
  4. The gearbox is now mapped... I am also in the process of building up an XDF purely for shizzles and giggles so I can see if I can understand what the box is doing etc... The XDF format is what Tuner Pro uses... this is fine and so far its going well... have added a few maps and everything tallies with OLS so far... Whether or not I will do much more with it beyond keying in all the maps I don't know... having the map pack is one thing but I still need software to read/write and also checksum the files... will see what I can dig up as it would be nice to have the same
  5. As the weather was decent this afternoon I popped out to wire up the DSG oil temp sensor Used pin 26 on the ECU as this is spare for the input and earthed it to the distro panel I fitted previously for all the extra relays I had fitted Double checked the VCDS label file for the definition of the temperatures in group 019 so I could see what temp I need to compare the reading from the sensor vs what the TCU is reading... G93 trans fluid temp seems to be the sensible one to compare too to checked that on the colorMFA... was miles out!!... chec
  6. Small update... the temp sensor for the DSG oil filter housing turned up... Popped out to the car to fit it and noticed the top of the box was wet... turned out to be gearbox oil... this could only have leaked from two places.. the oil filter housing or the oil cooler... the filter housing had a new o-ring and didn't look wet directly where it screwed in mount so my money was on the cooler and the generic o-rings I used... Decided to replace everything (as you do) so ordered genuine o-rings and a replacement cooler... This one is the larger version fitted
  7. Have been driving around a bit getting used to the box... I am feeling less inclined to 'dip the clutch' and snatch the gear lever now... having the paddles makes the transition a lot easier as the muscle memory keeps kicking in using the selector in tiptronic... I have also now replaced the faulty Febi ball joints with the MEYLE ones and can confirm that the taper was different and the MEYLE ones just fit fine with no dramas... I managed to grab a ramp at Bill's to do this so I also topped up the DSG box fluid... took another ltr which I expected tbh... and my modded
  8. Some good news with the ball joints... seller just refunded me for them which covers the MEYLE ones I have ordered... these have arrived now so will fit them at the weekend... The CAN gateway arrived today as well... fitted that after work... ...basically connected power train CAN to the power train and convenience CAN lines... power train CAN is then connected to the back of the cluster along with the DSG selector and DSG gearbox CAN lines... I also ran the CAN diagnosis lines to the OBD port so I can connect using VCDS directly... having the
  9. First job of the day...well... the afternoon... PAS pipework sorted... for now Next task was to look at the brand new FEBI ball joints as they didn't appear to be tightening up despite loading them up under the weight of the car with the jack... undoing them and having a look in the daylight (was getting dark yesterday when I was doing them up) I soon saw what the issue was... Seems the taper of the ball joint is protruding past the nut face and all I was doing was tightening the nut to the protrusion
  10. Flexi for the oil drain finally arrived so Alex welded it up... Happy days... cracked on putting the car back together... Yes... the PAS pipework isn't where its supposed to but there is a reason for that... Some idiot had put a gert gearbox in the way and not told it!!!.. I will need to get hold of the right return pipe at some point to replace this... but in the mean time the disc cutter came out to play Need to clean up the end
  11. As I am still unsure when a replacement flexi will arrive (they are typically made to order) I have decided to try a more available solution... I have ordered up some AN10 fittings.. 2 x stainless weld on bungs, a length of PTFE stainless braided hose and suitable fittings... PTFE hose should be fine for this application as its not got to wind past a hot manifold like a tubular 1.8t one and if it does get damaged I can replace the hose more easily or I will have the flexi to fall back to when it eventually turns up... This is all due to arrive by the end of the week so I am really
  12. The replacement manifold turned up this week... pretty quick considering... Next job then was to carefully remove the adaptor flanges from the old mani so I (and by that I mean Alex) can weld them onto the new one... ...that went as expected Bit of clean up required then.... ....and bingo... After Alex TIG welded them I needed to do a bit of porting... Waved the die grinder at it... Happy days...
  13. Few more jobs done today... refitted the tunnel heat shielding and the front end of the prop... also fitted the left drive shaft as this wont get in my way for anything... Made up a panel out of 3mm ali to block the hole where the clutch master cylinder passed through... Fitted brackets for the DSG selector and transfer box... Fitted the engine bay heat shielding and connected up the PAS pipes... Built up the front subframe... ...and painted some more things...
  14. I have ordered a replacement exhaust manifold... yes.. its another Aliexpress special but I am kinda hoping that this one may actually be made of metal this time... I like the manifold, it works (when its not cracking) so will give another one a go and see where we end up... I am still getting the current one welded... this will be used to get the car back on the road and the DSG tested etc... I will pull the mani off over the winter and sort it then... Other jobs that got done... Drive shafts made up, brackets de-ruste
  15. Things have slowed a bit what with being back at work and the weather but have managed to get a few jobs done... First up was to drain the oil and remove the exhaust mani and oil drain... ....done... took it up to Bill's and aqua blasted the mani... Sad face Alex tried to weld it but... He has a plan... will see what happens... worst case is I buy another and sort that one out in the hope that they used actual metal this time around... its a shame as the mani is actually rather decent as a 'thing'
  16. ...and now with added electricity <tuffty/>
  17. Having a chill day today as my 'holiday' is now over and its back to work tomorrow!! booooo! Got hold of a length of 3.0mm wire to finish the starter inhibit and a 'U' tube to finish the coolant system off with... I can start to put the front back together now but will drop the engine oil and remove the manifold and oil drain first... Also over the past couple of evenings I have been sorting the gear gaiter out... I obtained a spare manual gaiter and re-dyed it black... Went to try it out and hit another issue...
  18. decided it would be a good idea to drain the coolant and remove the rad to get better access to the area by the top and front of the box... Somewhat of a surprise was how much coolant came out... I collected it all as its less than a year old (changed when I fitted the CFS rad) and wasn't grotty looking... ...yep!... 8 ltrs!!! and I think there is still a bit left in there... I needed to do something with the coolant anyway to sort the gearbox cooler out but removing the rad has made working on the car a lot easier... (if I ever have to do this again the e
  19. Weather looked iffy this morning but had cleared up by lunchtime so out I went.... Ended up having a go at fitting the box myself as my mate couldn't get to me until after 6pm and wasn't sure what the weather would be like... figured if it got to a point I felt it needed an extra person then I would wait... If I got it in then winna.. Getting the box onto the jack and centred enough to balance was the challenge... that way at least the jack would be doing the heavy lifting and I can use less effort to keep it balanced and more making sure it was heading in the right dir
  20. May have a solution for the short s-tronic gaiter... fitted a spare 8L one I had kicking about and this seems to work perfectly in park and S mode positions... its a bit tatty but I have another one on the way so will look to remod the mod to get that ticked off... part of me actually likes that the lever looks like a manual with no auto display but then I also kinda like that its there for the double take Went to Bills to sort out the box... fitted a new filter and pumped 6ltrs of oil in which in hindsight was not really the best idea (more on that in a bit)... the box was p
  21. Day at home doing things.... I painted the transmission cooler as it was looking a bit scabby... Then moved onto the car... first job was to swap out the old fuse box for the inline pump and WMI for a new 4 fuse setup to allow me to fuse the DSG selector power... the fuses have LED's that light up when blown as its difficult to see where I have it fitted and had the fuel pump fuse blow on me a month or so back and only noticed as I didn't hear it running Redid all the crimps too.... Now for the 'fun' part (said nobody ever!)...
  22. Gearbox stuff done today.... the mechatronic cover was pretty rusty so I bought a new one to replace it with... Bottom two bolts were particularly difficult and shock (actual) horror!... ...one sheared... yay!.... (said no one ever!) Probably should have cleaned the box first too as all kinds of nasty was falling in places I'd rather it didn't... Bit of vacuuming and careful cleanage later and I was ready to tackle the sheared bolt... first job... flatten it enough to get the punch on it..
  23. Made a start :) Had to drop the exhaust and the front of the prop to get the heat shielding off the get at the selector... Now that the shafts were out I could see how they compare to the Mk1 TT 3.2 DSG shafts I have... Left shaft is more or less the same length which tbh I was expecting based on my previous measurements... I could in fact replace the left drive cup with an 02M cup and use the S3 shaft but tbh I would only want to do that if I could run the right side on a normal inner CV but the R3
  24. Car is now MOT'd so no excuses for not cracking on with the DSG swap... other than lack of motivation at the moment!!... the recent rather warm weather and being a little busy work wise has numbed my enthusiasm some what coupled with spending a good couple of months sorting the body work out I feel I just needed a break... That break will be coming soon as a week off work in which time I might even build up a bit of motivation to make a start... in the mean time... I bought these... My car never had them fitted as standard (they were an option?) and have been on
  25. Busy few days despite the heat... which is annoying (I am typically British!) Finished cleaning the inside of the car... All the dustiness from the bodywork is gone and I refitted the passenger seat (still chuffing heavy!!)... I left the drivers seat out so I had more room to sort the DSG wiring out... Attaching the CAN wires and power wires for the selector... I am waiting on another fuse block to replace the 2 way one I use for WMI and inline fuel pump so I can fuse the selector power too On the subject of wirin
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