Polo Gti Badger 5 Big Turbo

[tufftybloke]

Blooody hell thats a tight fit! Awesome project though

I've seen Bill working on this and seen it up close... it is stupidly tight!!! There is still the heat shielding to go in too..

Hats off to Bill and Tony, I have seen a couple of BT cars come out of Badger 5 but this has got to have been the most challenging to date...

<tuffty/>

 

[barnsley]

any updates bill ?

 

[n_d_fox]

just read through the thread from start to finish... i remember speaking to Bill at a JBS RR day many moons ago when i had my Octy RS... i remember being blown away by his knowledge back then and from what i can see he's been a busy boy since !

awesome build work on the Bill... i'm sure it will exceed Barnsley's expectations

 

[ibizacupra]

update for ya.. sorry for delay.. been busy workign on it and not tinternetting updates

turbo on finally, coolant pipes, downpipe, tial gate,
most work has been on heat management so the turbo now wears a cute little hat, as well as the other heat reflective materials attached everywhere.

 

[cupramillo]

WOW!

 

[ibizacupra]

More assembly pictures, not all nailed together and appologies for poor quality images. iphone pictures and low light levels + shaky hand.. ( )

VERY VERY tight install..
inlet manifold tucked under front panel after some trimmage.
tubby with its little heat hat snugly in the new boxed scuttle panel.
exhaust is on. intake pipework re-attatchment, extending some map sensor & dbw wires across to the t'other side, and fuel pump install to do... battery relocation to boot.. and we're getting closer and closer.

 

[air121005]

Nice Work Bill

got to be looking to fire this beast up some time next week then?

 

[M1KEH]

Very nice Bill, any ducting for a cold air feed, as i can imagine it's going to get mighty hot under there.

 

[PhilW]

Looking good bill. No room for a catch tank or a section between the MAF and filter?

Should be a fun car. lol.

 

[barnsley]

coiming on great bill thanks for the pics

 

[Scott-o]

coiming on great bill thanks for the pics

Cant imagine how excited you are for it to be finished, im excited looking at that, looks awesome!

 

[barnsley]

Cant imagine how excited you are for it to be finished, im excited looking at that, looks awesome!

thanks
i carnt wait to take a spin in it

 

[ibizacupra]

Very nice Bill, any ducting for a cold air feed, as i can imagine it's going to get mighty hot under there.

its got more heat insulation than stock cars, ceramic + turbo cover etc, but yea, 1.8t engine bay is a warm place.

if I can find a space somewhere for a cold air feed pipe i will use it, BUT, its buggered for space as it is

 

[ibizacupra]

no more pictures yet, just update that the inlet manifold has gone for machining to adapt it back to stock fuel rail fitment. Back in a day or so, then I can paint it & fit it finally.

 

[barnsley]

thanks for the update bill does the inlet need much work?

 

[ibizacupra]

thanks for the update bill does the inlet need much work?

the mounting lugs welded on it were for a -8 billet fuel rail, so they arein the wrong location and also too long. They are being milled back down, retapped and the new aluminium mountings machined to bolt onto them. some other detail points on ait sensor mounting I will rework also so I am happy with it.

 

[Andrew@ALD]

Very nice

 

[powernut]

looking top notch pal , carnt fault ya keep it iup ,,, unlike me who has to make modify my own , but my aim is 500bhp and ill get there one way or another lol

 

[sabredylan]

Why have you put the wastegate recirc pipe at a poor flow angle? It would have been better going straight down to the exhaust elbow below. Also why no flex on the recirc, thats sure to crack.

 

[powernut]

ps pal weredo u get the airfilter from as i need a 4inch bore but extra long as mine died at 400bhp i need more airflow for 600bhp carnt seem to found any?