Robbie C's Ibiza Cupra

[Robbie C]

A lot less than that Bill. I followed JBS' fitting instructions for their stainless bolts which was 22 lb/ft, torqued cold.

Even when I did them as tight as I could reach at Combe the manifold still blew like a cheap wh0re as soon as I turned the key

 

[ibizacupra]

A2-70 grade stainless bolts list lower at 28nm (20lbft)
10:9 steel bolts like you had are 63nm (47lbft)

need more tightening & possible new gasket once its blown once

 

[Robbie C]

NOW you tell me That'll explain it then.

As you've now got some stainless in stock do you think I'm better off going with those instead?

 

[ibizacupra]

the stainless one's i would hope expand at the same rate as the manifold, but the tensile on the 10:9 ones you have is higher.. I do personally tighten the stainless ones more than the spec.

 

[Robbie C]

Cool. I think I may just opt to go back to stainless and see how I fare as the original bolt nearest the head hasn't _yet_ budged.

Just starting to have a look at my options for the gearbox and had a look at the different flavours of 02J available, which led me to this page

I think Alex and Phil both opted for the MKIV Golf GTI (ENJ) gear sets which has the 3.684 final drive, so slightly shorter than the EDT 3.389 which should give slightly better acceleration vs a lower top speed if I've interpreted that correctly?

I've also read in the MK3 forum that a friend of pj1985 sourced a brand new box from TPS for ~£800 which may be an option depending on the extent of the damage found in mine once it's taken apart. Too early to say yet.

I'm just not sure I trust it not to happen again... which leads me to the SQS site

While the dog box is completely overkill for the ikkle k03 I notice they also supply a 5 speed syncro kit: http://www.sqsracing.com/produkt/276:362:synchro-box-racing-competition

Does anyone have any experience with this?

Open to any thoughts/recommendations at this stage while I weigh up my options.

 

[PhilW]

Seen a few Gemini gear sets kicking about lately on CGTI and E38, might be worth checking those out as well?

 

[Robbie C]

I was hoping you'd chip in Phil

Not come across Gemini before, I'll have a search, cheers

Are you still running the 3.684 final drive and how does it compare against the EDT 3.389 in real terms?

I've found Bill's spreadsheet but didn't see EDT on there and this is all still a little bit of a foreign language to me at the minute while I read up on ratios etc.

 

[PhilW]

Yeah im still running the 3.684 fd in mine, i much prefer it to the longer standard one, even tho you do lose about 10mph top end, think it tops out at 145 instead of 155 according to someone i know who runs a stage 2 ibiza. But it does rev quicker and easier.

Yeah, you read that correct on the acceleration thing. In one go i changed trhe FD, diff, clutch and flywheel and the difference was immense.

 

[Robbie C]

Interesting. Just found the GB thread on CGTI: http://www.clubgti.com/forum/showthread.php?t=163619

Only the overdrive 6th gear available by the looks of it but worth considering at least. Seems like Vince at Stealth has some experience with these sets as well who Bill's mentioned before.

I'm intrigued by the SQS set too as I'm not aware of anyone running this. The last thing I want in the back of my mind is a niggling doubt that the gears might give way again, which based on other members' experience seems fairly likely once one goes. If I end up needing to replace them then I may as well make sure I fit something stronger.

 

[IbizaAlex]

I think mine was an EBD. I still managed 170mph gps with it. Just about to touch 8k.

The EDT on the smaller turbo managed 165mph gps at around 7k.

The EKW is meant to be good for 215 at 8K. Just need the power to get that fast.

 

[Robbie C]

I think mine was an EBD. I still managed 170mph gps with it. Just about to touch 8k.

The EDT on the smaller turbo managed 165mph gps at around 7k.

The EKW is meant to be good for 215 at 8K. Just need the power to get that fast.

The power and the minerals to actually travel that fast in an Ibiza.

The more I read about the Ricardo Gemini 6spd gear sets the more I like the idea of it tbh. If I coupled this with the 3.684 FD and my Peliquin diff it should all complement each other nicely and stand up to any abuse I care to throw in its general direction.

 

[ibizacupra]

SQS is what badgerwagen uses.. dog ox and plated diff
lovely box

avoid quaife like the plague - shyte gear sets, plagued also by vag's rubbish synchros - crunch tastic when you pile on the revs

i preferred my 3.3 fd to the 3.6 - long legged suits the 1.8t power band

 

[Robbie C]

Have you ever seen the SQS synchro kit or the Gemini gear set Bill? Interested to gather opinions.

I'm not sure you can compare the dog box to the synchro kit, that's in another league of its own.

I remember you talking about the problems with Quaife, which also seem comparatively overpriced.

In terms of hybrid power delivery I imagine the 3.6 FD may suit it better?

Decisions...

 

[ibizacupra]

lower FD more wheelspin in lower gears.,, = bad thing in my mind

I have'nt seen SQS synchro kit no.. I have had a quaife one tho, and it was awefull. high revs and it would'nt engage without crunching but that in part is vw's crappy synchro's which are used.

they whine also, worth mentioning.. not an issue if its a track car, but some road users might not like the noise.

 

[Robbie C]

Valid point on the traction.

I assume your dog box uses straight cut gears as opposed to semi-helical on the synchro kit though? I didn't find anything on the SQS site to confirm either way, though the Gemini kit is semi-helical and retains the synchro's so there is no pronounced whine, as commented in the CGTI thread.

Personally I'd love it to whine like a little bitch, the louder the better, but that's just me.

 

[IbizaAlex]

Personally I'd love it to whine like a little bitch, the louder the better, but that's just me.

 

[ibizacupra]

quaife is semi helical, as would be gemini... they are stronger gears because of this..
they will whine

dog box more so

 

[Robbie C]

Here's a good spreadsheet I found to appreciate the differences in ratios, available from here

Standard 02J EDT ratios:

Gemini 6-speed overdrive kit with 3.389 EDT FD:

Gemini 6-speed overdrive kit with 3.684 ENJ FD:

So, with the Gemini kit and the standard final drive I'd be changing from 3rd to 4th at 92 MPH as opposed to 105, but with a higher _potential_ top speed.

The 3.684 FD ratios do seem a little short to me.

 

[Robbie C]

I've been talking with Alex and doing some further research into the SQS 5-spd synchro kits available from here, who offer three different ratio gear sets; Street Strong, Drag Race and Atmosphere Race.

If I stick with the standard EDT FD of 3.389 then this is how they all compare against one another:

	     |  02J EDT	 Gemini	   SQS Street
--------------------------------------------------------          
1st to 2nd    |	42       	   42          48	
2nd to 3rd    |   71       	   71          72	
3rd to 4th    |	105     	   92          105	
4th to 5th    | 	134     	   115         138	
5th to 6th    | 	165     	   145         172	
6th top speed |       	   184

@ 6750 RPM

The SQS Drag and Atmosphere ratios are far too short for fast road/track use, hence I've not bothered to include these here.

All that's really left is for me to decide which gear set would best complement my setup; the Gemini 6 speed or SQS Street kit..?

There's not really much in it between the standard ratios and the SQS set, but would a 6 spd benefit me I wonder. Opinions?

 

[GTi T]

car looks great mate on the new rims!

great write up too,shame about the things going wrong but im sure it'll come back stronger than before

Get the other pics on

Tom