Author Topic: My A3 Sportback Progress Thread/Diary  (Read 20653 times)

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Offline JPK

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My A3 Sportback Progress Thread/Diary
« on: March 10, 2013, 05:58:37 pm »
EDIT: Updated start of thread with current photo and modifications to date






Body:
Genuine Oettinger Body Styling Kit (with RDX front lip)
MY09-MY12 (Facelift) LED Tail lights
Debadged
LED number plate lights
Gloss Black wrapped roof and mirrors
42DD Exhaust Tips

Engine:
Unitronic Stage 2 HPFP ECU Tune
Unitronic Stage 1 DSG Tune
APR HPFP
d088 Intercooler
Forge Twintake
3" Downpipe
Remus Catback
CTS Turbo Discharge Pipe
BSH PCV Fix
Rev D Diverter Valve
R8 Coil Packs
034 Motorsport Engine & Transmission Mounts
HPA 75a Puck (Lower subframe mount)
Audi TT-S Engine Cover
Porsche Oil & Coolant Caps

Wheels & Suspension:
RS5 Replica Wheels 19x9 ET43 (Refurbished in Gloss Black)
Nitto NT830 235/35/19 Tyres
H&R Sport Cup Kit (Dampers & Race Springs)
Whiteline ALK (Anti Lift Kit)
Whiteline front control arm bushings
Whiteline Rear trailing arm bushings
Whiteline Adjustable Rear Sway Bar
Whiteline Adjustable End Links
Tyrolsport Deadset Subframe Kit

Brakes:
Tyrolsport Calliper stiffening kit
Hawk Performance Ceramic pads
Stoptech Drilled Rotors
Tyrolsport Stainless Braided Lines

Interior:
RS3 Steering Wheel
RS3 Gearknob & Gaitor
S3 Handbrake Cover
S3/RS3 Pedals
OSIR Dead Pedal Cover
Facelift Chrome Air Vents
Carbon Wrapped Trim
LED Interior lighting Kit

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Thought I had better start one of these before I get too far down the track with the car!

Car: 2005 Audi A3 Sportback. 2.0T FSI. DSG. Reflex Silver

Initially bought a very similar car in April 2012 (2005 2.0L FSI Auto) before looking online at suspension and wheels, the modification bug hitting again after a few years hiatus and deciding I was much better off with a 2.0T. Traded it in on this one a month later and only lost $500 or so in the process so couldn't complain too much.

I'm pretty sure most of the options it came with are standard on the 2.0T; but in any case I have Xenons, Auto Headlights, Electric folding Heated mirrors, Coming/Leaving home lights, Highline DIS w/ trip computer, Rain sensing wipers, Aluminium trims & leather bound steering wheel.
A few options I would like are cruise control, interior (ambient) lighting pack, Map/Ambient lighting LEDs, Bluetooth, Ipod connect, & Multifunction steering wheel. So I will be retrofitting these at some stage.

It is a Jap import with 107,000kms on it at time of import and the previous owner had put on a Remus catback exhaust. Auction grade 4. The trims are a bit scuffed up and some of the dash buttons are worn, otherwise it is in very good condition.

Why not just buy an S3? An S3 Sportback is unfortunately out of my pay grade at this stage and I wanted a Sportback. Paid $19,000 for this car in May 2012. At the time an S3 Sportback was around $60,000. It is also nice to have something a bit different that I can put my stamp on, where as an S3 is pretty much complete out of the box.

I like the MK5 Golf GTi which is pretty much the same car, but I like the fact the 8P shape is still current (up until later in 2013, albeit with a facelift in 2009) and the A3 has a load of OEM+ mods which can be pulled off the MY09+ A3, S3, RS3, R8, TTS/RS etc. We also have a MK5 Golf GT, and I feel the A3 is a fair bit ahead in interior build quality. The Golf interior is nice but does look and feel a bit 'plasticy' in my opinion. The Golf GTI at the time also cost a little more (and is still the case to an extent) which is a bit strange considering the A3 2.0T costs a fair bit more than the GTI when new. It seems Audis lose their value a bit quicker than VWs in NZ although its not the case overseas. Either way, it means the A3 2.0T is a great value proposition.

Here is a few pics of the car when I purchased it.









« Last Edit: November 11, 2016, 11:01:48 pm by JPK »
A3 8P Sportback 2.0T DSG
- Progress Diary -

Offline JPK

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Re: A3 Sportback Build Thread/Diary
« Reply #1 on: March 10, 2013, 06:10:04 pm »
Drove the car pretty much straight off the lot to GLIDNs to get a few tips on what to do next (he had helped me out with a MK4 GTI a few years ago).

The car looked like it had been well serviced and looked after but there was a few things to attend to. The DV was blown for starters and the car was way down on power and had a misfire fault code. It had a service done by the AA when it arrived in the country but I didnt feel too happy with the type of oil used (some type of Sinopec) and wanted to know exactly where I was at with the car.

The next week it was in at German Automotive to get the following done to get a nice clean slate to start some modifications off with.

*Cambelt Replaced (Full kit with water pump, G12 coolant & flush etc)
*DSG Service (new fluid & flush, filter, seals) - GA outsourced this to Tristram European
*Revision D Diverter Valve (Piston Type)
*New HPFP Cam follower
*New OEM spark plugs
*Oil change w/ Valvoline Synpower 5w30

The car was a completely different beast after having the diverter valve replaced. The old one had a big tear right through it. The cam follower wasnt too bad but had definite wear on it.

I also ordered 4x new coil packs (revision F) from DBC Tuning in the states for $150 landed (over $350 here at the time!).
It turned out the car had received new coil packs in Japan in 2009 with a recall that was going around at the time from Audi (Giltrap Audi looked up my chassis number and that came up), however one coil pack wasnt working correctly so thought I would replace them all and be done with it.
« Last Edit: March 10, 2013, 09:03:09 pm by JPK »
A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: A3 Sportback Build Thread/Diary
« Reply #2 on: March 10, 2013, 06:24:20 pm »
Needed to do something about the scuffed trims and new trims from Audi are $500+ so bought some 3M Carbon Di-noc film to try my hand at wrapping (excuse the bad quality photo).



Not 100% happy with it but its much better than before and I will have another crack at it further down the track.



« Last Edit: March 10, 2013, 09:03:42 pm by JPK »
A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: A3 Sportback Build Thread/Diary
« Reply #3 on: March 10, 2013, 06:31:15 pm »
At this stage I was pretty happy with the performance from the car. Felt significantly quicker stock than our old MK4 GTI with a Chiptuning flash.

Then a Forge Twintake came up, and was still chasing an intermittent idle issue so put a BSH PCV Fix/Delete on too.
Around the same time replaced the fuel filter and a throttle body realignment was done on it, which reduced the issue by around 80%.



Engine feels like it revs more freely with the Twintake but I wasnt expecting much of a gain before tuning the car. DV sounds are now a lot more pronounced and it sneezes like darth vadar between changes.
« Last Edit: March 10, 2013, 09:59:15 pm by JPK »
A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: A3 Sportback Build Thread/Diary
« Reply #4 on: March 10, 2013, 06:42:09 pm »
Started stockpiling more goodies over the next couple of months..



*H&R Sport Cup Kit (Monotube Shocks & 55/40mm 'race springs')
*New OEM strut mounts, bearings & bolts etc
*034 Motorsport Street Density Transmission & Engine Mounts + Torque mount insert
*Whiteline Anti-lift kit (KCA316)
*Whiteline Front Control Arm - lower inner front bushing (W0503)
*Whiteline 24mm Adjustable Rear Sway Bar (BWR21XZ)


Decided on the H&R Sport Cup Kit as it is very good value for a matched Spring/Shock set and felt I would be happy with the ride height due to NZ roads.
Coilovers would be great but would cost over double by the time I took low volume certification into account.



Didnt want too much NVH so after a load of researching decided the 034 Street Density mounts would be the best bet for my application. They use an OEM housing with a denser higher durometer rubber. Pretty much the same product as the THS mounts from the UK. Thought I would leave out their subframe mounts as I dont want to have to drop the subframe at this stage and there is a lot of reports online of significant NVH when using their subframe mounts.
« Last Edit: March 10, 2013, 08:28:58 pm by JPK »
A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: A3 Sportback Build Thread/Diary
« Reply #5 on: March 10, 2013, 07:18:00 pm »
Back into German Automotive to have the parts installed and got another oil/filter change at the same time. Had only done 3000kms since the last one, but mostly round town driving so thought I may as well.

Got a call from GA saying that the front dampers were the incorrect size (for 50mm front strut, instead of 55mm). The rest of the kit fitted fine.
This was infuriating as I had specifically asked the supplier for the 55mm front strut version and provided my chassis number and full vehicle details.
The supplier (Frank from Orange Tuning in Germany) initially told me he was happy to swap the front dampers over, then promptly disappeared off the face of the planet. Fast forward 6 weeks and he had still not replied. The only reply I ever got from him was after I emailed him links to me posting threads all over the place warning people not to deal with him - "nice job mate" was all I got. Couldn't get a paypal refund as it had been 10 weeks or so since the initial purchase.

To buy the dampers on their own cost me $600 a few months later... Those are the risks when buying online. Although I was quoted $1700+gst for the cup kit locally so I still saved $200NZD on buying local after the whole fiasco.

GA ended up using the OEM Sachs front dampers with the rest of the cup kit for now.

Here is some photos after the suspension had settled in a bit. Doesnt look super low but its definitely a 55/40mm drop from stock. That horrible arch gap is gone
and looks how it should have from the factory.






Very happy with how the car performed after everything was installed.

H&R Cup Kit - Happy with the ride height after it settled in. Corners beautifully and whilst it is firm, definitely not unbearable by any stretch.

Whiteline ALK & Front control arm bushings - Probably the best value mod ive done to date. The car feels 'planted' and steering is improved; feel more in touch with the road. Wheel spin in 1st & 2nd is drastically reduced. Obviously I did both at the same time so I cant be 100% sure but im thinking the front control arm bushings improve the effect of the WALK and improve traction further; reviews ive seen elsewhere would support this.

Whiteline RSB - Big reduction in understeer. Initially had this on medium setting. I dont drive like an idiot but I did get a fair bit of surprise oversteer around a corner on one occasion. Also had a bit of creaking from it initially. Packed a bit more grease in which fixed this and put it on 'soft' setting which I believe is still around 100% stiffer than stock from memory.

034 Mounts - My OEM transmission mount was completely shot so I would have got a big improvement with even a stock replacement. No real increase in NVH with these mounts including the torque arm insert. The car feels far more solid and the engine movement that was felt under load before has disappeared. Would also thoroughly recommend these.

At this stage there is very minimal wheelspin/axle tramp/wheel hop. It has pretty much disappeared completely.


Also installed this around the same time to try and get rid of the low speed subframe clunk that plagues A3s & MK5s. Worked for a short while...
« Last Edit: March 10, 2013, 10:47:06 pm by JPK »
A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: A3 Sportback Build Thread/Diary
« Reply #6 on: March 10, 2013, 07:20:51 pm »
De-badged rear. Much nicer and cleaner look IMO.

BEFORE:


AFTER:
A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: A3 Sportback Build Thread/Diary
« Reply #7 on: March 10, 2013, 07:33:53 pm »
Found a guy in Melbourne selling an Oettinger bodykit (minus front bumper & grille). It was brand new and he had decided to part out and sell his car before installing it.
Picked it up for $750AUD. Which was a huge saving on the $3000 or so it would have costed to get the parts landed here. You either love or hate this kit. I have always liked it and with the right wheels etc I think it will look sharp.

Shipping turned into a nightmare (another $600+ for air) as the boxes are big. Was looking at sea-freight then it turned out there was a good excuse to go to Melbourne a couple of weeks later so flew over to pick it up.

A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: A3 Sportback Build Thread/Diary
« Reply #8 on: March 10, 2013, 07:50:13 pm »
Time for new wheels & tyres. Went with replica RS5s. I would usually be careful with replicas as I have heard a few horror stories, however the company making these, WSP Italy seems to have a very good reputation and makes a great product. They have more of a concave than an RS3 wheel and a lower offset.
19x8.5 43et.

Also tinted the car around the same time. At this point I feel the wheels are far too aggressive for a standard A3 and it would need to be lowered a lot more to look right. This will be fixed when I install the Oettinger kit later on.







Could only budget for a mid range tyre so after a few recommendations chose Neuton NT5000s. 225/35/19. Fantastic dry performance and grip and cant complain too much about wet performance either. Although I don't push the envelope too much with FWD in the wet!

Offset is pretty aggressive at 43et. Stock is 54 or 56 from memory. Not getting any rubbing or anything at this stage.
There is much more stretch than I thought there would be with a 225/35/19 on a 19x8.5 wheel, but im told this is a characteristic of the tyre?
In any case, its not enough to reduce performance I wouldn't have thought.
Scared to death of curbing them and have been using the electric mirrors on every single parallel parking manoeuvre. Touch wood I haven't curbed them yet.


A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: My A3 Sportback Build Thread/Diary
« Reply #9 on: March 10, 2013, 08:09:05 pm »
The other half got annoyed with the Oettinger kit lying around the house so I had it painted and fitted before deciding what to do with the front bumper.
Im not a huge fan of the Oettinger front bumper, although I do like the mesh grille.

I had purchased an S-Line front bumper on 'Trademe' but unfortunately I failed to realise/notice at the time it didnt have the facility for headlight washers. After a bunch more research I decided against an S-Line front as even with a Cupra lip it wouldnt be aggressive enough for the rest of the car. I love the sleek S-Line look, but its not the route I have decided to go down with this car.

CarPro in Milford did a great job matching the paint and fitting the kit. It looks a bit unfinished with the stock front, but that will be fixed soon.
There was a little shaving of the skirts required to fit perfectly, but otherwise it fits like a glove.








« Last Edit: March 10, 2013, 10:50:44 pm by JPK »
A3 8P Sportback 2.0T DSG
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Offline RobClubley

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Re: My A3 Sportback Build Thread/Diary
« Reply #10 on: March 10, 2013, 08:44:48 pm »
Very nice car. I love the Sportback version but you've done a great job of refining it without going over the top.
Keep up the good work!

Offline JPK

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Re: My A3 Sportback Build Thread/Diary
« Reply #11 on: March 10, 2013, 09:34:07 pm »
Thank you :)

At this stage I desperately needed a bit more go to match the looks. I had spent the last 6 months researching different tunes and whilst most options in NZ seem to be decent and get good results, I decided to go APR Stage 1 and the price was a bit more affordable during their XMAS sale - www.goapr.co.nz . The guys have great customer service and im happy with the experience.

APR quote 189kw/252bhp and 303lb/411nm with 98ron. A significant increase on the standard 147kw/197bhp and 207lb/280nm that Audi quote stock.
I'm not sure if the Remus Catback & Forge Twintake would add anything much to this. Im thinking another 10kw or so tops. I will have it dynoed before doing any more engine mods as a matter of interest.

First drive. Fairly big wall of torque from around 2500rpm and it gives you a decent push back in the seat, but dies off by 5000rpm and it just feels like its going to redline for the sake of it. Nothing to do with APR as all K03 cars suffer this and im told this improves with the HPFP upgrade and downpipe, but there is of course limits on the K03. Probably better off changing gears at 5500 to get the most out of a Stage 1 car.

Seat of the pants. Its a quick car now and as I havnt dynoed it yet I can only compare it to other cars ive been in/driven. The most recent car ive been in to compare was a fairly stock Evo 8 and I would say that this is quicker. Definitely not off the line and probably not over 120kmh, but otherwise it seems to have a bit more punch.

I didnt opt for ECMS as I dont have cruise control fitted yet. I will do this when I go Stage 2+.

As a side note, I wouldn't say I have any real issue with traction. I had less traction with the stock car before suspension, WALK, mounts, tyres etc. Will see how I fare with Stage 2+ further down the track but im stoked with how the car is putting the power to the ground to date.

APRs standard stage 1 dyno sheet is below. It definitely feels like what it shows on there. (It is a US dyno, so 93 = our 98)
« Last Edit: March 10, 2013, 11:25:03 pm by JPK »
A3 8P Sportback 2.0T DSG
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Offline JPK

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Re: My A3 Sportback Build Thread/Diary
« Reply #12 on: March 10, 2013, 10:23:09 pm »
A couple more minor mods.

Bought an interior LED kit from a guy in the UK. Error free. Not the best pics.



Old Left, new right



Picked up a set of MY09+ A3, S3, RS3 vents. Will fit a bit nicer once ive updated the rest of the interior with the chrome trimmed buttons etc.



BEFORE


AFTER

« Last Edit: October 28, 2016, 10:06:57 pm by JPK »
A3 8P Sportback 2.0T DSG
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Offline 1.8t

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Re: My A3 Sportback Build Thread/Diary
« Reply #13 on: March 11, 2013, 12:28:46 pm »
Great thread, good reading and lots of detail. Makes for a interesting argument between this and a mk5 gti!
Dudlee the 86 318i
Past.. 95 328i M Coupe, 97 Pug 306, 97 Vento

Offline slowmo

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Re: My A3 Sportback Build Thread/Diary
« Reply #14 on: March 11, 2013, 12:42:35 pm »
Car looks great. Thanks for sharing the info and your journey so far, certainly gives me a lot of ideas of what to do with the mk5 GTI.
MK6 Golf GTI DSG (Hers)
MK5 Golf R32 6SPM (His)
B5 A4 TQ MTM (For Sale)