mk3 ibiza cupra......ko3 to ko3s to BT now HYBRID ko3

[turboholic]

been a while since i've updated this so better do it:

well the car is now back on all 4 wheels! 99.9% of the boost pipes is now finished. all routed nicely but too many joins so once its all up and running gonna get some custom pipes made with less joins. just got to get some hose for the dump valve recirculation back into the intake and some jubilee clips of the intake side of the turbo. all turbo oil/coolant pipes/connections are now all tight. made up a tempory oil breather for now just venting behind the bumper until i can afford a catch tank. its all filled up with fluids....oil, coolant, p/s fluid etc. left the front top and bottom strut braces and o/s driveshaft off for now as it will be easier to access the downpipe for when it gets made. think i will take it to Infinity Exhausts for the downpipe to be made! started wiring up the external fuel pump. routed the wiring inside to find a live and will run it off a separate switch which will be hidden. brakes have been bled. manual boost controller is fitted under the bonnet but will move to the dash once its been mapped.

so with all this done it was time to crank it over and circulate the oil. i connected the battery and gave the car power and then realised i didnt have the key with me!!! so will grab the key and do it tomorrow!

still to do: need the downpipe made, heat shield around the brake fluid reservoir and bonnet, dump valve recirc hose, and mapping!

 

[turboholic]

can anyone recommend anywhere in the south-west region to get a downpipe made??

 

[4wdibiza]

prospeed exhausts, cardiff

 

[P1N3R]

Very nice and great that you've done the work yourself! I'm just moving onwards to a K03s at the moment but it's great to see so many people doing big turbo conversions themselves. I'm sure one will be on the cards for mine at some point!

 

[turboholic]

cheers mate. yeah saves alot of pennies doing it yourself! and more exciting aswell! just beware of the cost when going big turbo! lol

 

[P1N3R]

cheers mate. yeah saves alot of pennies doing it yourself! and more exciting aswell! just beware of the cost when going big turbo! lol

I do everything myself normally but I haven't got the confidence to tackle a cambelt, for example, myself, it's something I've never ventured in to. It looks easy though?

I bet the costs are incredible - there's a lot of custom fab to do right?

 

[turboholic]

when you see how it all comes apart it is easier to see how it all works and is much simpler. not too much fabrication is needed. main thing is the downpipe really......which is whats next on my list and hopefully this weekend!

 

[turboholic]

LONG OVERDUE UPDATE!!!!!!

well all the boost pipework is now finished. too many joints for my liking so once its all up and running i will get some custom alloy pipes made up. power steering fluid seems to be leaking under the reservoir so need to sort that out at the weekend. external fuel pump is now wired up and working fine. i have turned it over with the injectors unplugged a few times in the week to get the oil circulated round the engine and turbo.

i took it to infinity exhausts on saturday morning for the custom downpipe to be made so i left it with them for a couple of days. went and picked it up today and have to say they have done a great job! custom downpipe has been made into 2 sections and heat wrapped. also got a exhaust temp sensor boss welded in so that i can keep an eye on it. roughly heat shielded the brake reservoir and servo, fitted the o/s driveshaft and also the front bottom strut brace today. its all there and ready to be started for the first time in about 3-4months! will do this at the weekend as the battery is flat and needs charging.

then its ready for mapping but will need to save for a bit as insurance is due for renewal on the golf! not many pics but heres a couple:

 

[Mo Arif]

Very nice, quick question mate, what route has the fabricator taken for the custom down-pipe? if you could PM me with some more pictures that would be very helpful

 

[turboholic]

Wow this hasnt been updated for over a year! Lmao! i had a 3"elbow to a 2.5" downpipe and decat. I've still got it actually! The gt28rs came off last sept and i now have a ko3 hybrid setup. Will update properly soon with pictures

Sent from my GT-I9305 using Tapatalk 2

 

[Mo Arif]

Wow this hasnt been updated for over a year! Lmao! i had a 3"elbow to a 2.5" downpipe and decat. I've still got it actually! The gt28rs came off last sept and i now have a ko3 hybrid setup. Will update properly soon with pictures

Sent from my GT-I9305 using Tapatalk 2

Lol yeah I thought i'd take the gamble and ask, it would be very helpful if you could get me some snaps, possibly from underneath (if you have any) of what route the big turbo down-pipe took.

 

[turboholic]

had a look through my pics and cant seem to find any of the downpipe mate. all i have are these:

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[turboholic]

right..............its been too long! lots has changed

first of all, didn't have much luck with the gt28rs. ran it for about 6 months and all i had was trouble. i used an AGU head which was constantly leaking oil. this resulted in mapping problems so was only mapped to 250bhp. also boost piping was a bodge so any more boost and the pipes would have been blowing off. so i had the head off a few times and turned out to be the valve stem oil seals every time! im guessing it was worn and not holding the seals on properly?? i dont know so i put the smallport head back on then only used it for one track session (Forge Summer Performance Action Day at Castle Combe). i upped the boost slightly using the unos and the turbo started to squeal like a pig. (at about 22psi). also doing 120mph coming into quarry corner (very tight right hand corner) my brake pedal went solid! had no time to shift down so onto the infield i went, ripped uo the handbrake, span, bounced across the track and stopped about 3 inches from the barriers!!! i sh*t myself! came into the pits and found my turbo had come loose off the manifold and was blowing onto the brake servo hose and melted it!



quick one on track shooting flames


how it looked with the gt28rs


so i thought all these problems and got myself into debt it was either sell, break the car or sell the big turbo stuff. i advertised the car for a couple of weeks but didnt get much interest and i love the car so i decided to get rid of the big turbo setup and save for a ko3 hybrid! selling the kit got me out of debt so i got on with the hybrid.



decided to take the engine out as i had the flywheel lightened and balanced as well. plus its 10 times easier to fit the hybrid turbo with the engine out. also cleaned up the engine bay and gave it a bit of paint


dan (beachbuggy) from the audi forums sorted me a ko3 hybrid for a very good price with an uprated actuator. had my manifold ported by bill and bought a 3" downpipe/decat off a guy on another forum. put it all together and refitted the engine along with my solid front engine mount i had lying around for months.


also picked up a set of leon cupra r brembo calipers off the bay and had the carriers machined down so the 323mm setup bolts straight on perfectly. excuse the temporary wheels!






decided to refit the standard wheels and brakes for the time being as temporary wheels needed tyres.

its all back together now and currently at badger 5 for a wideband conversion and mapping!



how it looks atm

 

[turboholic]

also fitted a suede steering wheel i got for free after mapping, i will be getting wmi and looking into wide track conversion.

dont know what to do with front brakes and wheels. do i keep the standard alloys and run 312mm discs? or use the lcr brembos and go for 17" wheels with very low offset? opinions needed!!

 

[Chambers_CUPRA]

Glad to see tge car getting some tlc. Interested to see how the wideband conversion gets on

 

[turboholic]

yeah me too lol was chatting to bill and sounds like it not actually too bad. small bit of wiring needed and then map i think. fingers crossed will get it back this weekend

 

[Chambers_CUPRA]

Thats good to news then. What else you planning?

Need to get on with mine lol

 

[turboholic]

Debating whether to strip it out or not. Or flock the dash and a, b, and c pillar trims.....

Sent from my GT-I9305 using Tapatalk 2

 

[Chambers_CUPRA]

Defo. ive stripped the rear out of mine and painted it imp blue. Flocking is on my list eventually lol

 

[yellonvi-R]

Oohh this is yours then