Robbie C's Ibiza Cupra

[Robbie C]

Engine
1.8 20VT (AYP)
Block overbored to 82.5mm (1847cc)
Ported & polished cylinder head w/ uprated stem seals
Ferrea Super Alloy inlet and exhaust valves
Ferrea valve springs and titanium retainers
JE 82.5/86.4mm 9:1 CR 2618 alloy pistons
Integrated Engineering forged conrods
Uprated sputter big end bearings
ARP main studs
Turbo Dynamics MD445 hybrid K03S
Jetex FC-08001 conical filter (w/ 102mm CAI in wing)
Custom turbo intake pipe
LCR (3") MAF housing w/ OE Ibiza Cupra element
LCR (4 bar) fuel pump
BAM 386cc injectors
JBS K03 cast exhaust manifold
AEM Stage 2 water methanol injection
Badger5 custom stage 3 remap
Zeitronix ZT-2 Wideband controller w/ Bosch LSU-4 sensor
Blueflame bespoke 2.5" full exhaust w/ 3" downpipe
Forge Motorsport 007P diverter valve (relocated to cold side)
Turbosmart e-Boost2 Street electronic boost controller
NGK BKR7E spark plugs
Forge Motorsport black silicone vacuum and coolant hoses
Mocal braided fuel and oil breather lines
Backdraft Motorsport baffled sump
Phenolic 10mm insulator intake manifold gasket
Saikou Michi 951 catch tank
Removed/resistored N112/N249, SAI, PCV and EVAP
Pro Alloy bespoke FMIC w/ custom 2.5" mandrel bent ali pipework
Vibra-Technics Race front and Fast-Road rear/gear box engine mounts
Battery relocated to spare wheel well
OE washer bottle replaced with 1.2L bottle (hidden in front bumper)
Inlet manifold, strut brace and rocker cover resprayed anthracite
034 Motorsport carbon fibre coil cover
ECS Tuning carbon fibre intake manifold cover

Transmission/Drivetrain
SQS Racing 02J 5-speed Synchro Street Strong (SSS) semi-helical gear set
Neuspeed short shifter
Peloquin 02J ATB differential
Helix 6 paddle clutch and lightened (6.5KG) single mass flywheel

Handling/Suspension
KW Variant 1 coilovers
Vibra-Technics front wishbone rear bushes
Neuspeed 25mm/28mm front and rear anti-roll bars
OMP front lower strut brace (Golf MK2 fitment)
SEAT Sport (MOMO) front upper strut brace
RaidHP rear upper strut brace (MK1 Golf GTi fitment)
Vibra-Technics rear beam bushes
FK 5mm/20mm front and rear hub centric spacers

Brakes
HiSpec R114-4 (4 pot) radial mount calipers
310mm x 28mm two-piece grooved front discs with anodised ali bells
Ferodo DS3000 front pads, stock rear w/ black OE calipers
Braided front hoses
Motul RBF 600 brake fluid

Wheels and tyres
Winter use: OE Cupra alloys powdercoated anthracite, wrapped in 195/45/16 Uniroyal Rainsport 2s
Summer/track use: Compomotive MO 5 alloys powdercoated anthracite

Exterior
LiteTuned carbon fibre bonnet
De-badged/de-wipered bootlid
Tinted windows
LCR splitter
Osram Diadem indicator bulbs
LED sidelights & number plate lights
6000k HIDS
Front retro-fit aero wipers
ROB813 C private plate

Interior & ICE
Autogauge mechanical boost gauge housed in Nomad Racing A-pillar pod
VEI Oil Temperature/Pressure dual gauge
VEI AFR wideband gauge (both housed in Cupra R holder)
Flamebeater 0.6KG powder car extinguisher
SEAT Sport tax disc holder
Infinity 6520CS components

MD445 Hybrid turbo specification:
CNC modified compressor housing
K04 2078 series (RS4) compressor wheel
CNC modified turbine housing
Ported wastegate
RS6 full trim turbine wheel
Lightened RS6 shaft
Uprated turbine seals
360 deg thrust bearing
Other blueprinting modifications
12 PSI uprated actuator
Rated to approx. 280 BHP

Click here for latest RR graphs

Peak figures: 274 BHP, 310 lb/ft

Click here for previous dyno results on OE 1.8 bore

Recent Pics:

Other pics within this thread:

• Castle Combe Action Day Sept 2012
• Nurburgring August 2012
• July 2011 - after the engine rebuild pt1
• July 2011 - after the engine rebuild pt2
• July 2011 - after the engine rebuild pt3
• Castle Combe October 2010
• Waterloo tunnel photoshoot Aug 2010 pt1
• Waterloo tunnel photoshoot Aug 2010 pt2
• Nurburgring May 2010 pt1
• Nurburgring May 2010 pt2
• Nurburgring May 2010 pt3
• GTi Spring Festival April 2010
• January 2010 - pics in the snow
• September 2009 - just after completion
• Brands Hatch Jan 2009
• Various pics taken before the hybrid conversion

 

[Robbie C]

Older Pics

Pics from when I first owned the car in September 07, completely standard on 44,700 miles:

A few months later after a few engine mods (Revo Stg1, Forge TIP and Blueflame):

Few shots taken over Christmas '08:

 

[Robbie C]

Few pics of my hybrid turbo (full spec in post #1):

 

[Robbie C]

OK so today the work properly started on my hybrid build, getting everything ready to fit the new turbo with all accompanying mods, including my custom Pro Alloy intercooler and HiSpec brakes which should both be with me in the next 1-2 weeks

I'll let the pics do most of the talking, enjoy!

Day 1:

Boxes of parts to be fitted:

Peloquin diff:

Silicone joiner hoses for intercooler:

First off, up on axel stands and removing the exhaust to get the downpipe off (it's sleeved) so I can get an extra boss welded in for the wideband sensor:

Then the fun really began, removing the manifold, turbo and anything else in the way:

 

[Robbie C]

Standard manifold off and compared with my JBS tubular collected replacement:

Next off was the TIP (complete bitch to remove), compared next to an ATP 2.5" metal TIP although I'm now going with something else instead:

Turbo off and compared to my Turbo Dynamics hybrid (standard K03 in background):

Compressor assembly of MD445:

 

[Robbie C]

While I'm still waiting on 3 washers to complete my K03S fitting kit we decided to get the bumper off ready for the FMIC and remove the SMIC, boost pipes, washer bottle and carbon canistor (EVAP):

(When I get the chance I'll post up a guide on EVAP removal but it really is easy when you look at where the pipes go)

SMIC removed:

Washer bottle removed:

Old 6.6L bottle vs new 1.2L bottle:

Carnage in the garage:

That's pretty much as far as we got today. Tomorrow we're replacing the engine mounts with my Vibra-Technics goodies

Thoughts/comments welcome!

 

[Ibiza125]

It will be some beast when your finished!!

 

[nick-barnes07]

looking good, some quality bits you have there, who's mapping it??

 

[-pseudonymous-]

Looking good Robbie, some good progress made there! Was it easy enough to remove the turbo and manifold on axle stands? You thinking of making up a similar TIP to Danny?

 

[Reuvers]

Nice mate.

How long are you planning on keeping it off the road? Or is this something which you want finished within the next couple of days?

Nice work you've done on the car, and nice to see you're taking the time for it and have thought about your steps properly.

 

[Robbie C]

Cheers guys

looking good, some quality bits you have there, who's mapping it??

I'm getting it mapped by Bill using his own software, as used for Benny's hybrid. I went out in his last week and was impressed and works out cheaper than Custom Code too as I'm currently running Revo Stg1

Looking good Robbie, some good progress made there! Was it easy enough to remove the turbo and manifold on axle stands? You thinking of making up a similar TIP to Danny?

Cheers Ollie. The manifold and turbo were fairly easy, just time consuming more than anything as there's a few awkward bolts that require a bit of patience. A ratchet spanner is a must though unless you want to bend a cheap set. The TIP was the biggest pain to remove, it just didn't want to budge.

Yeah I've decided to run the same TIP as Danny now - ordering the bits up today

Nice mate.

How long are you planning on keeping it off the road? Or is this something which you want finished within the next couple of days?

Nice work you've done on the car, and nice to see you're taking the time for it and have thought about your steps properly.

Thanks Reuvers. I have a Peugeot 106 as a daily driver (1.0 beast) so I'm planning on having the Cupra off the road for 3-4 weeks while me and a mate get everything done, taking the time to do everything properly rather than having to rush it which is ideal.

 

[Reuvers]

I completely agree robbie. Thats usually the problem I run into; not enough time to finish it whilst I need it to get to work every day.

I do have acces to a 74 beetle convertible however its my dads, and I can really only drive it when the weather allows.

When I have a big task I always need to start on friday and hope I'm done by sunday. Usually I really do miss the extra day or so though. I am thinking about maybe getting a cheap runner for days like that, but afraid costs will rise above the time I will really use the thing.

anyway, some nice work you're doing. Wish you the best and will keep my eye on this.

great pics btw

 

[redcupraboy]

Cracking build thread Robbie, looks like you have made good progress too, your spec list is awesome you certainly have been buying the best parts for it bud, look forward to more pics and progress, well done!

 

[Robbie C]

I completely agree robbie. Thats usually the problem I run into; not enough time to finish it whilst I need it to get to work every day.

I do have acces to a 74 beetle convertible however its my dads, and I can really only drive it when the weather allows.

When I have a big task I always need to start on friday and hope I'm done by sunday. Usually I really do miss the extra day or so though. I am thinking about maybe getting a cheap runner for days like that, but afraid costs will rise above the time I will really use the thing.

anyway, some nice work you're doing. Wish you the best and will keep my eye on this.

great pics btw

Thanks Reuvers. That '74 Beetle sounds cool as Christmas

Yeah it's a big big advantage having a daily runaround, makes life much easier in situations like these - and always nice going from a 1.0 back to the Cupra

RedCupraBoy - thanks for the comments. I've tried to buy the best parts wherever possible just based on the knowledge I've gained here on the forum. It hasn't been cheap but hopefully will pay off in the long run!

 

[PhilW]

Loving the carnage.

Hope it goes well.

 

[IbizaAlex]

Looking very nice. I like threads like this Why dont you go to a Revo stage 2 early S3 map? As the turbo is almost a K04 and you are running downpipe and bigger injectors it will work fine. May save a few ££'s.

 

[Reuvers]

Thanks Reuvers. That '74 Beetle sounds cool as Christmas

don't want to disturb your thread but this is the one

as for revo stage 2, I heard from someone else that it was only 50 quid to go from stage 1 to 2.

Don;t know the direct advantages of CC over Revo stage 2 in combination with your mods though.

 

[IbizaAlex]

If you went from stage 1 Ibiza file to stage 2 S3 file it would be £100 but you dont need the 4 bar fpr.

 

[Robbie C]

That Beetle looks awesome Shame we never get enough nice days in the UK to enjoy something like that.

Thanks for the comments Alex. I hadn't heard of people using an S3 map before. Speaking to Bill his software gives him complete flexibility to adjust any tables he needs to which I feel may yield the best results if I want to advance the timing running water/meth as well. I just want to be sure I get the very best from what I'm running really

 

[krisbutler02]

how much was the turbo?