MK1 Leon GT2x Build - thats it folks

[DPJ]

......is it just the 3" MAF housing that I need and my current MAF goes into this housing? ..

Depends on who is mapping it - you'll need to ask them.

 

[jamiebennett81]

ok guys, if you could help me out please. I am pretty dam sure I have everything in place now (either with me or being fitted very soon in preparation for the turbo and remap) but if you could please provide a sanity check to ensure I have not missed anything. Thanks for your help

As a reminder, parts on the car are:

Pro Alloy FMIC

Blueflame Turbo Back Exhaust (3” Downpipe with 100 cell race cat)

Carbonio CAI

Insulator gasket

Forge Turbo Intake pipe

Forge Re-circ DV


Parts checklist for turbo install (already with me or to all be with my by end of May at the latest):

Stg3 clutch & lightened flywheel (being fitted on the 30th May)

GT2x (with all relative connecting pipes, jubilee clips etc)

ATP TIP (to replace Forge one)

4bar fpr

225 injectors

Walbro inline fuel pump

JBS Manifold

4 x New coil packs (just in case as typically one or two always fail after a remap)

All Seat turbo gaskets, bolts etc


I am also just checking with AMD if I need a 3" MAF or if I just need the 3" housing and can use my current MAF (awaiting a response)

I think thats it

it is all coming together now, finally!

your help is much appreciated

 

[Willie]

Do you have lamda probe wells in the exhaust/DP?
If you don't you'll need them to map this out during the mapping process.
Are you thinking about engine mounts or Dog bone mounts to control any extra engine movement to allow you to get the power to the wheels better?

 

[jamiebennett81]

Do you have lamda probe wells in the exhaust/DP?
If you don't you'll need them to map this out during the mapping process.
Are you thinking about engine mounts or Dog bone mounts to control any extra engine movement to allow you to get the power to the wheels better?

yeah, I did try the lamda probe mod, but it didn't work (long story) so they will be mapping this out, as currently my engine management light sits on all the time due to the race cat

engine mounts will be done, but probably not untill later this year.

final mod will be a set of AP 6 pots (312mm version so they will fit behind my current wheels) next year, but for now this is the bulk of the work, and give my poor bank account a time to recouperate

 

[caveo]

good stuff m8 but i would recamend the engine mounts, for 2 reasons 1 to get the power down a little better but most of all to reduce engine rock and stop it pulling away from your downpipe ( some fitters wont give a warrenty with out these or some kind of brace )

 

[jamiebennett81]

good stuff m8 but i would recamend the engine mounts, for 2 reasons 1 to get the power down a little better but most of all to reduce engine rock and stop it pulling away from your downpipe ( some fitters wont give a warrenty with out these or some kind of brace )

thanks mate, I will ask AMD about costs for them

although I wont be putting out quite as much power as you so I will see what they say

finally managed to check the turbo last night, and was very impressed (sorry I did not have the camera with me, but I will get some pics up of the turbo, clutch etc before they all go in!)

turbine is bigger (although will compare before and after pics when I get a chance) and they have done an excellent job on the internal housing of the turbo. The internals were very rough and far from smooth, but they have smoothed off all of the inside, and it is as smooth as finest silk, so this will definitely aid air flow (quicker air flow due to less turbulance from rough edges inside the turbo)

clutch and brakes will be bedded in by end of June, so just awaiting a final date from AMD now for fitment and mapping. I am aiming for July

will post up pics and further comments when the clutch is fitted

friend who has a stg3+ clutch said its a pig to drive when first bedding in - happy days lol!

anyone else want to share their experiences on their clutch?

 

[DPJ]

Bigger turbine or bigger compressor?

.........Fit modified thrust bearing, fit larger compressor wheel and reprofile to suit.........
!

..........
turbine is bigger (although will compare before and after pics when I get a chance) ...........

Now thorougly confused.

 

[jamiebennett81]

Now thorougly confused.

ok so kill me for not being a complete techie in the continuity of using correct modiificational terms (it's been a long day!)

"compressor wheel" looks bigger is what I meant Dave

 

[DPJ]

ok so kill me for not being a complete techie in the continuity of using correct modiificational terms (it's been a long day!)

"compressor wheel" looks bigger is what I meant Dave

We'll let you off as long as you cease causing (me) confusion!

 

[jamiebennett81]

We'll let you off as long as you cease causing (me) confusion!

I can now rest easy

 

[Robbie C]

Out of interest, what's the total cost of this so far then Jamie?

I'm going round and round in circles in my head deciding whether the gains you get from the gt2x over the k03s are worth it for the money you have to spend on the whole package (i.e. uprated clutch, injectors etc etc).

 

[jamiebennett81]

Out of interest, what's the total cost of this so far then Jamie?

I'm going round and round in circles in my head deciding whether the gains you get from the gt2x over the k03s are worth it for the money you have to spend on the whole package (i.e. uprated clutch, injectors etc etc).

HI Mate

the thing is, when you get to a point where you want to go over the "realistic" 240bhp mark which is what a k03s typically puts out, it is not cheap, no matter what route you go for. K04 would be cheap, but then is not a bolt on mod and is quite difficult with re-routing of pipes, different manfiold etc

a well mapped k03s will hold the power till about 5500-6000rpm or there abouts, but even after that, it starts to run out of puff

it depends what your budget is and how much you want to spend, or indeed could you justify a "realistic" 290bhp, or possibly more if you hybrid the gt2x (to be proven). But then this power is held right the way to the redline, and more if you have the rev limiter raised (to about 7200rpm)

Robdon on here puts out about 285-290bhp with about 305lbft which holds right the way throughout the rev range. I think it is certianly a worthy justification for the cost (to me it is anyway)

and yes before others say, I could have gone for the GT28rs turbo or bigger, but then when you start to get to the realm of 350bhp+, then you have to uprate the internals, which is when it gets VERY expensive (unless you can do the work your self).

Two reasons I did not want to go this route:

1. I did not want a laggy turbo and wanted a medium size turbo which still offered up a decent amount of power lower down the rev range, similar to the standard k03s (so not too lose too much of the low type boost driveability)

2. I want to prolong the life of the engine as long as possible due to having to keep this car for a few years and I dont want to go through the extra cost of uprated internals

So in answer to your question, below is a run down on what I have (Engine modifications only) or will be on the car in terms of a complete kit

Forge Recirc Dv - £90 (on car when purchased)
Carbonio CAI - £165 (on car when purchased)
Insulator Gasket - £65 (purchased from badger bill)
Pro Allloy FMIC - £600 (purchased from Pro Alloy)
Blueflame Turbo Back Exhaust - £450 (purchased from Blueflame)
Garrett GT2x - £800
ATP Turbo intake pipe - £150
JBS High Flow Manifold - £500...I think (purchased from JBS Designs)
4bar fpr - £35 (purchased from a guy off here)
225 injectors £110 (purchased from Backdraft motorsport)
Walbro Inline fuel pump - £70 given the exchange rate (from US seller on Ebay)
3" MAF Housing - £30 (purchased from TTS Roadsport)
Spec Stage 3 clutch - £450 (purchased from TTS Roadsport)
Lightened flywheel - £320 (purchased from TTS Roadsport)

Fitting will be about £300-400 and mapping (stg3 custom map) will be about £400 - £600 dependant on the tuner

total cost £4445 - scary aint it (total cost including fitting and mapping)

depends if you can justify that really, but this is stuff bought over nearly 12 months.

to me the justification is I will have a very fast road going car, a car which will be very capable of upsetting a lot of supposedly faster cars (as any of the big turbo boys will tell you is great) and a car which can handle the power very well (due to full suspension, brake and anti roll bar package which cost a mint!)

a friend added it up for me the other day, and I was shocked!!

I bought the car £5000 and have to date spent a shade over £7000 on it.....

but hey, thats tuning, it is NEVER cheap, and it is a very slippery slope

 

[jamiebennett81]

well only a minor update

4bar fpr arrived the other day, got it for a good price so was quite pleased

clutch, flywheel, discs, pads, braided hoses, brake fluid and bushes all being sorted out on the 2nd of June at Storm Developments

payment for Walbro fuel pump has just been cleared today, so this should be arriving soon

engine mounts will hopefully be on order as part of JuniorSenior's GB (cheers mate!) - Trackdensity engine mounts and trackdensity dog bone mount. Apparently these have a lot less vibration than the Vibratechnic ones but still offer very good durability. Perhaps not as stiff but will certianly do the job

still awaiting final costings from AMD for fitting and mapping....still pushing for July and done in time for E38 (well it best be done by then!)

I will hopefully get round to taking a load of pics of all the stuff on Thursday night i.e. turbo, clutch etc, as I want to get pics of up what it all looks like before it all goes on

pics to follow

progress is slow I know, but getting there

 

[jamiebennett81]

well as promised, here are some pics of some of the parts to go on

I have got some before and after pics of the turbo. As you can see the compressor wheel is bigger, and also the turbo has been completely reprofiled so is a lot smoother which will definitely help. The casting inside of the turbo as standard was quite poor actually, as in it was very rough, but I guess thats what you get for mass produced units

enjoy....

Turbo:

compressor (before)

compressor (after)

Casting inside of turbo (standard)

As you can see it is quite rough

Casting of turbo (after)

A lot smoother (although 2nd pic does not show it quite as well, but it is)

Spec Stage 3 Clutch & lightened flywheel

 

[jamiebennett81]

ATP Kit (did not include everything, but washer, bolts, gaskets aside of course)

New brake discs EBC Racing

final parts awaiting now are braided hoses, fuel pump, streetdensity mounts & dog bone, MAF housing and she is ready to go

fingers crossed clutch will be run in by end of June for the fitting of the turbo etc before the 13th July in time for the RR shootout...it's gunna be tight now

 

[Willie]

Mmmmmmmmmmmmmmm Toys!!!!

 

[jamiebennett81]

Mmmmmmmmmmmmmmm Toys!!!!

car **** indeed

typical female comment though - showed a female friend the pics who is into cars, she says "I like the blue colour on that clutch"

 

[RobDon]

Did CR Turbos tell you exactly what they did and what was the bill for their work, I'd like to get this done to mine too. Any idea what extra HP they anticipate?

 

[dsrr]

Rob,

I am in discussions with them regarding a similar project....all I can say is that so far they are VERY professional, no BS and extremely knowledgeable.....and willing to work with you...a breath of fresh air in the tuning industry?

 

[RobDon]

I've only heard good things about them in Ford circles, so that's why I contacted them, seem a really good company.