Robbie C's Ibiza Cupra

[Robbie C]

Cheers Tom Yeah that's it, onwards and upwards.

Just waiting on the photographer to send me the shots he managed to get, though here's a thumbnail of one I found on the site:

As for the gearbox, after a bit more thought and speaking to a few people I think I'm probably going to opt for the SQS 5 speed synchro kit as per http://www.sqsracing.com/produkt/276:362:synchro-box-racing-competition which is a full semi-helical gear set with very slightly longer ratios than the standard EDT (as per my last post).

The Gemini 6 speed is tempting but it only replaces gears 3-5 and in all liklihood may end up being slower than a standard 5 speed where the 1.8T has a wide torque range that is best exploited with longer gears. Opting for a 6 spd would also mean less time on the throttle with more frequent changes. Novelty vs practical function really.

The SQS gears themselves also look nice and beefy:

 

[barnsley]

been looking as these robsqs is a nice set up just havent got the spare money at the min

 

[Robbie C]

You nor me Liam. Cupra is now SORN'ed over winter so I can get it back uptogether again in my own time Does look like a very nice gear set though so should be worth it.

Yours still raping the tarmac I trust?

 

[barnsley]

You nor me Liam. Cupra is now SORN'ed over winter so I can get it back uptogether again in my own time Does look like a very nice gear set though so should be worth it.

Yours still raping the tarmac I trust?

euro needs to get alot better befor look at buying one

ya its still doning damage to the road

 

[jpcibiza90]

that car is a beauty!! iv got a mk 1.4 could be selling and buying a 51 cupra same colour blue for 2k its got 90 on clock tho should be ok shouldnt it?

 

[Robbie C]

Cheers. Impossible for me to comment without full details but this isn't the place.

Have a browse of the MK3 forum, look for related topics and post a new thread if needs be so we can point you in the right direction

 

[Murdered LCR]

Really do love this car , carbon bonnet looks the nuts on the car ,

 

[Robbie C]

Cheers mate.

As per this cheeky little thread and seeing what Bill has recently been able to do with a CR K04 hybrid using the billet "K06" (RS6) CHRA along with his custom 3" TIP I'm tempted, very tempted, to see how much Turbo Dynamics/CR Turbos would want to rework my turbo into a similar spec. In essence, a K04 hybrid squeezed into a "K03" (what would be left of it). This would in theory allow for a realistic (key word) 300 BHP, with a much higher sustained torque band higher in the revs where mine currently peaks and falls.

I knew this would happen when it came off the road. But thems the rules...

This is a plot of Welly's CRT Stage 4 K04 hybrid is red vs mine in blue:

You can see that my boost comes in quicker and harder but peaks and tails off quicker than the K04, which sustains a truck load more torque right up in the revs. A considerable difference.

All being well I should also be looking to order my SQS semi-helical gear set this week too. If I send them my Peloquin diff they are able to supply, build and ship an 02J box with their gear set and my diff fitted and ready to go. Happy days

 

[barnsley]

which gear set you going for rob and how much is it all built up if you dont mind me asking

 

[joehirth]

If you go for the SQS where will you get it from and who's building the box, are you going to use standard housing with uprated gears or get a new housing? Sorry so many questions, just something I'm going to need to think about for mine....

 

[Robbie C]

which gear set you going for rob and how much is it all built up if you dont mind me asking

If you go for the SQS where will you get it from and who's building the box, are you going to use standard housing with uprated gears or get a new housing? Sorry so many questions, just something I'm going to need to think about for mine....

No worries, I'm ordering through Alex at Backdraft who has been sorting me out with quotes etc. If I send SQS my Peloquin diff they'll supply, build and ship an 02J box with their 5 speed synchro (street) kit with my diff fitted ready to install straight back in the car for what is looking like ~£1900.

I'm waiting on Alex to confirm a definite price shortly so watch this space. Not the cheapest option to get it back on the road but it should make the box pretty bullet proof and it gives me the piece of mind that it's been installed by people that know what they're doing with their own product.

If anyone else is interested in this kit now is the time to shout as multi-buy discount may be possible...

In other news, following on from this thread I've been in contact with Matt at Turbo Dynamics about the possibility of transforming my MD445 K03 hybrid into the equivalent of their Stage 4 MD421 K04 hybrid in a K03 shell (loosely speaking, what's left of it) who has said:

From: Matt Waterman
Sent: Tuesday, November 16, 2010 2:43 PM
To: Rob C
Subject: RE: MD445 K03 hybrid specs

Hi Rob,

Not a problem. You are correct in saying the MD421 and MD445 share the same turbine wheel. Whilst both housings are of a similar A/R the K04 item found on an MD421 is slightly larger than that found MD445 meaning is would ultimately support slightly more airflow but in all honesty the difference is probably negligible at best!

In theory the outlet from the K03S could be mated to a K04 cover (providing both pieces have the same internal diameter), to do this would require quite a complex jig to ensure correct length and angle. We saw how critical these are when you had your problems with the exhaust manifold so it’s not something that should really be attempted by eye! Luckily these sort of jigs are something we are familiar with through our work on RS4 and RS6s!

Pricewise, including the price of an overhaul of your existing turbocharger including new uprated thrust kit, I’d anticipate the price being around £400-£500 + vat (providing your turbo is ok). This price excludes the modifying of the outlet to suit a K03S, having not done this before there is a small amount of guesswork involved but I anticipate this would take no more than 1 hour charged at £60.00 + vat per hour.

I hope this helps

Kind Regards

Matt Waterman

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From: Rob C
Sent: 16 November 2010 14:08
To: Matt Waterman
Subject: Re: MD445 K03 hybrid specs

Hi Matt,

I'm good thanks. Thanks for the quick reply and useful information.

Is this to say that the RS6 wheel in the MD421 is the exact same spec as already installed in my MD445? If so, is it only the physical difference in the size of the turbine housings themselves that are different?

I understand that I'd need to alter my cold side pipework to suit which isn't an issue - though I'm curious as to whether you could weld the sleeve of a K03S onto the K04 to maintain OE fitment, assuming they are the same internal diameter?

Can you advise how much I'd be looking at to get this work done if I sent you my MD445?

Many thanks,

Rob

--------------------------------------------------------------------------------

From: Matt Waterman
Sent: Tuesday, November 16, 2010 1:39 PM
To: Rob C
Subject: RE: MD445 K03 hybrid specs

Hi Rob,

I’m very well thank you, I trust you are the same.

The first thing I should say is that your MD445 already has an RS6 turbine wheel in it (this is what we refer to as the large trim turbine wheel). On neither the MD445 nor the MD421 do we normally cutback the turbine wheel blades (unless you specifically request it) as going up to the large turbine wheel will potentially increase lag as it is without doing cutbacks. If you wish we could perform a cutback though.

Fitting the MD421 compressor cover in itself isn’t a problem (you would have to modify your pipework to suit the new inlet & outlet though).

The K04 exhaust housings are not available as separate items so it would have to retain the K03S turbine housing but other than that the spec would be identical to that found in the MD421.

I hope this helps…

Kind Regards

Matt Waterman

--------------------------------------------------------------------------------

From: Rob C
Sent: 16 November 2010 12:45
To: Matt Waterman
Subject: Re: MD445 K03 hybrid specs

Hi Matt,

Hope you're well.

There's been a few threads flying around the SEAT Cupra forum lately regarding the K04 Hybrids that yourselves and CR Turbos are supplying to various customers, with very healthy results.

I am currently still running the MD445 K03 Hybrid but have a request....

Are you able to take a K03 (either my MD445 or another standard unit) and build this to an MD421 spec that is currently offered as a K04 hybrid. In effect, a K04 hybrid in K03 fitment.

By this I mean, replacing the compressor housing with a milled out K04 housing, fitting the K06 billet-aluminium compressor wheel and fitting the standard turbine housing (milled to suit) with a clipped RS6 turbine wheel?

Obviously it wouldn't be the simplest of jobs, but it ought to be possible?

For reference, see http://seatcupra.net/forums/showthread.php?t=291477&page=3 and http://seatcupra.net/forums/showthread.php?t=261476

Your input would be appreciated and I look forward to hearing from you soon.

Many thanks,

Rob

So, on the plus side it looks as though my turbine housing already uses the same spec RS6 wheel as used in the K04 hybrid so it's just the actual physical size difference in the housings that differ here. If I get the cold side uprated to a milled out K04 compressor housing with the K06 RS6 billet-aluminium wheel then I'm looking at a very similar spec to that of Welly's which recently made consistent 300+ BHP figures on Bill's dyno.

Where do I sign?

 

[joehirth]

No worries, I'm ordering through Alex at Backdraft who has been sorting me out with quotes etc. If I send SQS my Peloquin diff they'll supply, build and ship an 02J box with their 5 speed synchro (street) kit with my diff fitted ready to install straight back in the car for what is looking like ~£1900.

I'm waiting on Alex to confirm a definite price shortly so watch this space. Not the cheapest option to get it back on the road but it should make the box pretty bullet proof and it gives me the piece of mind that it's been installed by people that know what they're doing with their own product.

If anyone else is interested in this kit now is the time to shout as multi-buy discount may be possible...

Well, this is a little early for myself as I haven't even gone BT yet... I also have brand new gears in my current box so as the power won't be upped to max straight away then I should be able to make this one last a while... What sort of discount would be available do you think? I will be needing one eventually....

Joe

 

[PhilW]

How much for just the gearset robbie?

 

[Robbie C]

1380 Euro plus VAT, however they work it bearing in mind they're based in Czech Republic

 

[Robbie C]

OK so I've just got off the phone to Mark at CR Turbos to see what he had to offer on the subject of fitting a K04 hybrid cold side onto my K03 hybrid to give me a spec similar to the Stage 4 MD421 (see here) which recently made 330 BHP on Bill's dyno, also retaining a shed load more torque (see RR above).

Ultimately as Bill has already noted, the restriction here is going to be the turbine housing but it's difficult to know how much of a bottleneck this will impose.

Not only is the turbine housing of the K03 smaller than a k04 (though they share a similar A/R), it is crucially much less efficient as the wheels are in very different places.

In a K04 the turbine wheel is very near the exit of the housing and faces straight out, meaning the gases flow nicely into the exhaust and backpressure is kept as low as possible. In a K03, the turbine wheel is nested further inside the housing and at an angle, meaning the gases have to travel further and at an angle before flowing into the exhaust which will act as a restriction.

These pics give a rough idea of what I mean:

K04 housings (standard on left, CR hybrid on right):

My hybrid K03 housing:

According to my spec sheet this housing has been CNC modified with a ported wastegate but I wonder if it's possible to port the housing any further to accomodate the increased flow...

Aside from this there are also fitment issues to consider. I had asked whether it would be possible to weld the sleeve of a K03S onto a K04 assuming they were the same ID but am assured they are very different in size, though it may be possible to weld an ali pipe onto the outlet to maintain OE fitment if necessary. It shouldn't be much hassle to rework my intercooler pipework however.

Interestingly Mark quoted £250 for the necessary work if I send him my existing hybrid with some of the necessary modifications already in place, allowing him to fit the K06 billet RS6 comp wheel, modified K04 compressor cover and if necessary, an uprated thrust bearing (depending on the condition of my existing one)

All food for thought. If Bill has managed to persuade 330 BHP out of a K04 hybrid of identical spec I wonder how much of a bottleneck the K03 exhaust housing will restrict me reaching such figures. One thing to consider is that I would be using the JBS K03 manifold which _may_ fare better than a standard K04 manifold to aid flow...but that flow is still heading into the same bottleneck.

Decisions....

 

[ibizacupra]

I will take a closer look at the k03's hotside housing and see what it looks like for flow.. It exits ultimately in a 3" hole to downpipe so is huge there, same as it is on a k04 outlet.. It has to travel a littl edistance and round a band first however once left the turbine.. the wastegate exit is isolated from the turbine tho, so less interferance on flow compared to a k04

std k04 comp housing I am sure can be accomodated to your charge pipe outlet..
the other work will be moving coolant pipe out of the way and gear cables to shift perhaps also slightly to allow a 3 inch TIP

 

[Hartosh1]

Interestingly Mark quoted £250 for the necessary work if I send him my existing hybrid with some of the necessary modifications already in place, allowing him to fit the K06 billet RS6 comp wheel, modified K04 compressor cover and if necessary, an uprated thrust bearing (depending on the condition of my existing one)

So how much extra power would you expect to see out the hybrid if this was carried out? When you say about taking the hot side of a K04 and mating it with the K03 would that mean the downpipe would exit at the side instead of underneath? (sorry im a bit confused)

 

[Robbie C]

Other way round - maintain the hotside of my K03 (which already runs the same RS6 turbine wheel as found in the K04 hybrids, with CNC modified housing and ported wastegate) and change my compressor housing from K03S to a milled out K04 cover to accommodate the billet aluminium K06 compressor wheel.

My manifold and downpipe fitment would therefore remain the same, but I'd need to rework my TIP and charge pipe which isn't an issue.

Power wise it all depends what the k03 hotside is capable of flowing in comparison to the equivalent K04 hotside as shown above but with Badger5's 3" TIP it should produce consistent 300+ BHP figures. More importantly though, the torque should be held much stronger higher into the rev band, whereas mine peaks and tails fairly rapidly - typical of all K0x turbos.

 

[arron2004]

Robbie awsome car mate! Reading this thread is making me excited to get mine back from Bill!

 

[Robbie C]

Cheers - yeah you shouldn't be disappointed

I see you've gone for rods; are you going for an aggressive map?

Not much news on mine lately but I should be moving the Cupra into a friend's garage next week to begin taking things apart ready to send my diff off to SQS and my turbo over to CR/TD for the K06 hybrid work. I'll be ordering the gearbox on Mon/Tues