My Ibiza Cupra MK4 1.8T 20vt.Big Turbo GT28RS setup in progress

[brwmogazos]

Small update...

replaced my INA manifold which had a crack and its flange bent quite a lot with a new INA manifold i bought.

I am affraid my new mani will end up like the first one...

So spent a lot for 2 manis whereas at the ned of the day with a custom tubular manifold would have been better

Also built some custom 60mm intercooler pipelines...

http://www.youtube.com/watch?v=A5ZouQyneO8


Next mods?...hmhm...thinking of going BT....either light with an 28r Garrett of a proper big turbo with a GT2871 or bigger...time will tell...

 

[brwmogazos]

Finally decided to drop the hybrid turbo upgrade and go Big Turbo.

Unfortunately the market arround here in second hand cars got even worse so decided its not worth selling my beeza with just 37000 Kms and so many mods very very cheap in order to get a Leon 2 cupra.

Therefore i am going Big Turbo and i have already ordered some parts.

The setup will be the following.

GT2860RS turbocharger (in the future i might upgrade it too)
New turbine housing with 0.63ar without wastegate etc..
Unitronic Chipped Remap
Pag parts manifold Htc coated with V band
for the Tial 38mm MVS V band external wastegate
630cc SDeka injectors
Full 76mm exhaust etc...
APR in tank fuel pump
Greddy profec B boost controller
S3 Maf etc
Will be keeping the stock SS intercooler and recently upgraded inox piping (will need upgrading if i go for a GT2871)

all the bits and bobs etc...

Will run on stock engine internals at first since i do need quite a lot of days off work (which i havent) so arround summertime i suppose i might be able to also upgrade the engine internals too with SCAT Rods and genuinde audi S3 pistons instead of forged ones in order to maintain a higher CR.

Flywheel and clutch: Hopefully the stock i am using will last me for a little while (till summer i hope)

Will be keeping the forge dv and relocation kit for now.
Might also upgrade to a Tial bov during summer if i am going to use a De maf file.

Fingers crossed and mid March i will have enough time to start with the upgrade.

 

[cupra.al]

intresting update,keep us posted.

 

[Hartosh1]

I think the GT2860RS will be a good enough turbo for this car any higher and traction will be an issue, i didnt see anywhere if the car has had a diff fitted or not? Engine internals might be ok as its not an instand powered turbo which will be easier on the rods.

Im liking your IC pipework aswell mate

 

[brwmogazos]

No i have no diff fitted buddy.

So far i got the Garrett GT28RS turbine without the turbine housing

Pipercross C0187 cone filter4

and i also received today the Garrett T3 turbine housing .63 ar as i will be using an external

the APR intank fuel pump

few gaskets and a flange for the downpipe along with a coil cover powdercoated

the boost controller is with my friend already and he is also waiting for the remaining parts he ordered for me...

Mid March i will be installing the parts.

Aint got time for engine internals yet. But during summer i hope or before summer (depends on my day offs) i will be installing scat rods and audi S3 pistons to maintain a higher CR and avoid oil consumption blah blah, as well as a flywheel-clutch combo .

few pics




















and a turbocharger vid

http://www.youtube.com/watch?v=uvsmN94Or6k&feature=player_embedded

 

[Hartosh1]

That inlet is huge

Plans sound good mate look forward to watching the progress

 

[brwmogazos]

am also excited

 

[BeezaDave]

wel lad, what sideskirts do you have??

 

[brwmogazos]

ive got the MS designs mate.

Bought them off the Seat Dealer here and had them installed. You can get similar ones of lower quality a lot lot less .

Motordrome make similar ones. I dont like them though.



Small update.

Got an audi S3-LCR Maf and Maf case 80mm for my BT project today too...



Uploaded with ImageShack.us

 

[brwmogazos]

Ok i postponed my big turbo setup date for early April as i will have a bit more free time...

So Wiseco 9.1 pistons have been ordered , calico bearings, Scat rods, Goetze gaskets, blah blah blah.

So engine internals will also be upgraded...

Full boost madness coming soon that means...

clutch-flywheel etc will be upgraded as soon as the stock ones are worn out

 

[cupra.al]

what are you doing about engine mounts?

 

[brwmogazos]

nothing

already got vibra techniques dog bone but if there too much play ill just make an engine damper i guess...

 

[cupra.al]

im not sure but i think ina might make somthing i could be wrong.
i keep looking at your lower custom ic hose im in the process of trying to get forge to make somthing similar.

 

[Hartosh1]

Just watched the video at the top of this page and that is some nice pipework mate, have you kept the charge pipe aswell or replaced that? I think im gonna start to size things up and see if theres anyone local to me willing to make the pipes.

 

[brwmogazos]

Its the stock charge pipe. However i had it removed and we cut down that section where the diameter increases and where that little clip shaped edge is located.

Then we increased that section further to reach 60mm and did a few spot welds circumferential to the pipe edge so that when the forge silicone hoses were installed, they would bite a bit over those spot welds to make it even more secure.

Well everyone is doing the same things in their custom pipework so nothing new there.

I did custom pipework because i bought the Forge relocation kit for the BOV just to find that it wouldnt clear the front headlight.

Took a video and Forge claimed that i was the only one claiming about this problem...And that it could be down to my left hand drive car or something...

Few months later theres a few more lads having similar problems as the throttle body hose was too short (as i figured out in the first place too)...

So making custom pipework for the top intercooler to throttle body part was the only way....

I also did the lower intercooler piping custom since the oem ones have many size variations...

Its also cheaper to make them custom.

Anyways...

it depends on your future plans for your engine mods.

Normally the turbo outlet diameter should be kept constant till the intercooler inlet.

Then the intercooler outlet diameter should be kept constant and with the same size as your throttle body...

Heard that from many custom built exhaust etc garages too....

 

[brwmogazos]

http://www.youtube.com/watch?v=fzQK1kMbl4Q&feature=player_embedded

http://www.youtube.com/watch?v=Gag-tJeTDVo&feature=player_embedded



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Few more parts arrived.

AEM wideband gauge, Tial MVS external wastegate, Siemens Deka 630cc injectors, Sai block off plate, some Goetze gaskets, head bolts, cam cover gaskets, forge hoses etc etc...

Still waiting for my Rods, Rod bearings, pistons and exhaust manifold though...

 

[brwmogazos]

Got my Scat 144x20 rods yesterday (thanks isaam from INA)

http://www.youtube.com/watch?v=lDRnL5iEDKY

I need to get hold of some arp moly lube though and i dont seem to find any arround here lol...

My pistons, bearings and manifold are waiting for me in Athens(had a mate to pick em up in Athens)

so hopefully in two weeks time ill be able start with the built of my new setup provided that i can leave work.

3 days are needed for the engine internals upgrade+turbo upgrate etc, then another 2 days for new exhaust, external wg exhaust, ic piping modification+turbo inlet all custom.

Ecu reprogramming will be performed by Unitronic chipped (Cupraman) during that time so in 5 days fingers crossed i will leave Athens and start my trip back to south greece " low cruising speeds' in order to break in the engine.

(thats going to be a pita)

2000kms i suppose with 500km non synthetic oil change intervals...so its gonna take a while...

then ecu fine tuning provided that my stock clutch and fly wheel can hold...will get a vr6 fly and clutch masters clutch for the time being.

So hopefully everything should run smoothly... (fingers double crossed )

 

[dava]

Ok i postponed my big turbo setup date for early April as i will have a bit more free time...

So Wiseco 9.1 pistons have been ordered , calico bearings, Scat rods, Goetze gaskets, blah blah blah.

So engine internals will also be upgraded...

Full boost madness coming soon that means...

clutch-flywheel etc will be upgraded as soon as the stock ones are worn out

nice project

 

[brwmogazos]

Due to the slipping under load you mean?

Well i dont plan to use full boost tbh till the engine breaks in.

so during that time i think ill get myself a clutch masters FX300 clutch and a vr6 flywheel and some stronger bolts so that i can upgrade them too when i have a few more days off work

thanks.

 

[CluneZ]

Love the build your doing pal.

What sort or RPM is the new turbo likely to come in at and have you got any ideas as to what sort of power you would expect afterwards.

I've read the whole thread so if I have missed the info I apologise