My Stage 2 Golf Anniversary PD150 - 220BHP

[Sem]

Couple of pics of my build up, comments welcome:

August 2005 - R32 Brakes:

January 2007 - Sachs Race Engineering Clutch:

So with the clutch and brakes on, I began to think about a hybrid turbo conversion but not being in any rush, I started to research and collect some parts..

May 2007 - New Garrett GT1749VB turbo:

Picked this up on ebay for £300, brand new and unused. My plan was to send this off to Turbo Dynamics for a Stage 2 MD376 conversion:

June 2007 - Uprated clamps for boost hoses:

I decided to buy the Allard uprated pipe kit but as this retains the OEM front mount intercooler and turbo hoses I engineered a more robust solution to secure the stock hoses.

And the same again for the turbo:

Continued...

 

[Sem]

July 2007 - Intake manifold, Provent, and Allard pipe kit:

The Allard pipe kit comes with an EGR bypass pipe. From earlier inspections I knew my intake manifold was clogged up so I wanted to sort this out before fitting the new pipework. Thanks to Ed Jackson at APS who sorted me out with a spare (used) manifold. This allowed me to prepare/clean it in my own time ready to fit at a later date.

We then ran it through the shotblaster and it came up like new:

I bought a Mann & Hummel Provent as I wanted to keep the new pipework and turbo clean. We welded up a T bracket (painted in Silver Hammerite) and attached a clear drain tube with an easy clip on/off fitting:

And fitted:

(some better pics of the Provent hoses are shown further below).

And here's a pic of the remaining parts ready to be fitted:

August 2007 - Pipework, manifold and EGR bypass fitted:

The new pipework and clean manifold made an improvement the cars responsiveness, it felt noticeably quicker and almost eliminated smoke so well worth it. It's also reassuring to know you can push the car without worrying if your hoses are gonna blow off.

With a small trim, you can see I got the engine cover to fit back on []

You can also see I transfererd all the OEM clips to hold the coolant lines and made my own bracket to hold the fuel lines from the fuel filter:

Not a great pic but here's the new lower IC pipe (replaces the restrictive stock pancake pipe]

 

[Sem]

September 2007 - Hybrid turbo back from Turbo Dynamics:

This box arrives []:

And as you can see, the hybrid turbo looks completely standard from the outside. All changes are internal.

October 2007 - Milltek turbo-back and new turbo fitted:

The turbo and Milltek turbo back exhaust was fitted by Midland VW (another great job done by these guys). No pics of the turbo being fitted but here's one of the Milltek. Top marks for the perfect alignment as i've seen some pretty dodgy installs of these!

I decided to run the car on the standard Revo map for a month to ensure there were no hardware issues before getting it custom mapped for the new turbo. I had already selected my tuner a few months back so confirmed a date with him.


November 2007 - Custom mapping:

I have always been a big fan of Revo's TDI maps, I was put in touch with the person that wrote them.

All mapping has been performed by Richard Washbrook from Oscarli. Some of you may be thinking "who the hell are they?!", well without going into too much detail - if you drive a Revo mapped TDI then chances are, it was Richard that wrote your map. Some of you may know him from his previous work with Revo and Forge. He is now independent and deals mostly with trade work.

We spent a whole day mapping the car at Stealth Racing in Southam, 2 maps were written alongside the stock map. These are switchable using a Revo SPS1 or VAG-COM.

Map 1 is maxed out on fuelling, Map 2 is more conservative but the exhaust output is cleaner. Both maps run 1.8 bar.

It has been dyno'd on Stealth Racing's rollers (Sun-Ram dyno). This does over read but Richard knows the correction values and from his experience believes these to be 10bhp & 25lb/ft.

The first map was dyno'd at 229bhp and 364lb/ft (but realistically 219bhp and 340lb/ft)
The second map was dyno'd at 218bhp and 352lb/ft (208bhp and 327lb/ft after correction) This is not shown on the graph
The stock map was dyno'd at 176bhp and 260lb/ft (166bhp and 235lb/ft after correction)

In addition to this, the ESP (traction control) parameters have been modified so when it does lose traction it is far less obtrusive (i.e. when it does kick in it is far less noticeable).

 

[Sem]

Finally, a couple of shots of the car, all looks pretty standard...the way it should be.

Oh, and how does it drive? Well yeah....it's pretty quick!

 

[UncleFester]

Cracking motor that Sem, it's your pipework clips i'm waiting for SFS to produce!

Have you seen the deal piper are doing on exhausts right now, unsilenced sounds the dogs danglies ... just what you need hanging off the back of a hybrid ;-)

 

[Sem]

Hmmm SFS....the clips they wanted me to provide the measurements for

I'd like to see their finished solution because my final solution was changed and actually differs from the photo above (i.e. that version wouldn't have worked 100%).

 

[UncleFester]

Hmmm SFS....the clips they wanted me to provide the measurements for

I'd like to see their finished solution because my final solution was changed and actually differs from the photo above (i.e. that version wouldn't have worked 100%).

I think the theory is sound enough - they're an engineering firm so they 'should' be able to come up with something that works. That said i've not (touch wood) blown a pipe yet and their pipework kit is very nice quality.

I do like that your car looks factory clean, no real signs of the monster under the bonnet. After doing all the work, would you still hybrid the derv or would you have gone for a petrol with that power as standard / left yours alone?

 

[Sem]

I just prefer TDI's, my next car (which is on order at the moment) is also a derv.

I'm not really a fan of the SFS kit, there's just too much silicone involved. IMO it should only be used on joins/bends. I'm sure the kit is very good quality though.

 

[sssstew]

I think that is lovely. ive always like the Anni's and that ones spot on, the fact it looks standard outside makes it perfect for me

top work

 

[UncleFester]

I just prefer TDI's, my next car (which is on order at the moment) is also a derv.

I'm not really a fan of the SFS kit, there's just too much silicone involved. IMO it should only be used on joins/bends. I'm sure the kit is very good quality though.

Shame Allards and SFS didn't talk then, i saw the nightmare people had with their stuff which put me right off. It's good fun tinkering though, what we spend on this, some people spend on clothes / drink / holidays / drugs .... who's to say which is less value for money.

so ... the hybrid, wrapping and tinsel aside, was it a worthwhile upgrade from what you had, did you have it remapped ( stage 1/2 ) first and how much difference did you feel whilst driving?

 

[basstard]

Very nice car! Besides all the mods, I'm liking the BBS a lot,,,

Also, what's that this Provent thing? is it a sort if CCV filter?

 

[olaf]

I'm tempted to get a Provent, looks nice and OEM.

What are you thoughts on it?

Car looks very nice and the figures are pretty impressive too!

 

[Sem]

Cheers for the comments. Yes, Provent is a CCV filter - very good piece of kit.

The car is actually for sale at the moment, I don't think i'll be taking my next car this far though.

 

[basstard]

I'd buy it just for those alloys LoL!! Shame it's a right hooker,,,

 

[ChrisGTL]

Superb work.

Great price for the turbo! What a steal

Car looks really clean and OE, love it

 

[sssstew]

Very nice car! Besides all the mods, I'm liking the BBS a lot,,,

Also, what's that this Provent thing? is it a sort if CCV filter?

The BBS's are standard on the anni, i love them, look really nice. but ive heard they can be a pain to keep in good nick, corrosion is a problem.

 

[basstard]

yeah, I know they're standard on the anni,,, and that's another reason I like the anni so much,,,

There's some very similar alloy in 4x100 16" flavour on the mk5 polo gti and mk3.5 golf cabrio,,, I'm still looking for some to put on the old beeza,,,

 

[phpgear]

Can I just ask did you get the boost pipe clip's from Allard themselves? I'm currently using two Jubilee clips since mine popped off a few weeks ago and maybe these would ease my mind a bit of it happening again

 

[sssstew]

yeah, I know they're standard on the anni,,, and that's another reason I like the anni so much,,,

There's some very similar alloy in 4x100 16" flavour on the mk5 polo gti and mk3.5 golf cabrio,,, I'm still looking for some to put on the old beeza,,,

sounds like a lovely idea, reckon they would look superb

 

[basstard]

yeah, I know but they're rally hard to find, especially here in italy,,,

btw, what car you got down there in brisbane stew?