VT86, Seat Leon4 4wd k03 285hp => GT28R => GTX2867R Gen2 420hp

[VT86]

Slow progress, some minor tweaks for FMIC installation so that I can avoid bumper cutting and it sits nicely.



Also yesterday did some tuning on the road. Car starts to be quite good at gate pressure (0.8-1 bar).




Also I still have problem with oil pressure warning, I have replaced pressure switch but still it randomly makes alarm. Oil pressure sensor on Ignitron read 3.4bar at the same time with oil pressure alarm on cluster. Any ideas where to look problem? I'm assuming wiring or something

Also I started tune my friends Golf MK4 4motion. That's running Ecumaster and have 1.8 20vt 2.0 stroker, with custom H-beam Rods, custom JE-pistons, billet main caps and griddle, CatCams and DQ250 DSG transmission. Full carbon R32 bumper, carbon bonnet, carbon trunk and carbon wings.

 

[VT86]

Some progress with tune up. Had few setbacks though, after trying to get boost nothing seemed to work, so I thought that I have missed some settings and while googling and discussion in Ignitron page. End result was that either Turbo is gone, wastegate actuator is broken or n75 is faulty. Well I tested both my N75 and no luck. More digging in to settings and i couldn't figure out why car is not boosting. Then I remember I have one unused Apex 3-way MAC from our RallyCross supercar.

With Apex it started to boost but didn't hold boost well. After disassembling turbo intake and using blanking plug in throttle body end I did pressure test to whole boost pipeline. Surprise was big piston type diver (bypass) valve started leak as soon pressure did go over 1-1.2Bar. I had one never used diaphragm type adjustable Dump valve so I swapped that in and tightened up so that it didn't leak.

Now car started to boost but I had to go home so tuning will continue later.



Also received my order of titanium nuts for valve cover. Quite unnecessary thing but those looked so cool. Need to buy new valve cover and paint it first. My second unnecessary purchase was short shifter





I had to fix cluster with ori file, to make fuel consumption correction to show some reasonable readings. With ME7.5 i had to scale cluster because ecu was not able to handle big injectors. Now Ignitron can and it was showing crazy readings. Need to rescale temp gauge in some point.



And one pic just for fun. First time this year car is at home, and most likely last one. Hill to yard is too big and bumper is scraping so badly.



ps. I would say that how car feels it must have few extra horsepower already with these modifications and without being tuned properly.

 

[MoToJoJo]

This is such an insane build, love it!

Oh, and like the casual "Yeah, just a part from a rallycross supercar"

 

[VT86]

Some small updates if people are interested in something different.

I have some visible bolts which are quite rusty looking and for example bumper bolts are quite special so I had to figure something out.

Ended playing with copper plating. Warning this includes acids, electric and some experiments. And must to wear protective gears.





And end result was quite ok



Also I wanted to test stainless hose clamp just for fun

 

[VT86]

Did some minor tweaks and every one like to use NLS (shift cut) so I decided to go different route and used "mild" settings for Anti-Lag to ease gear changes
Sound good and works but I think that I can not use that aggressive ALS on track, only if I will go to do some 1/4 mile events.

Enjoy, at least I did

Seat Leon 4 Testing mild ALS

- Seat 4x4 Testing Ignitron ECU mild ALS gear changes

youtube.com

 

[MoToJoJo]

Well, you could use it... at least till they tell you not to

Sounds bloody awesome

 

[VT86]

Short update, car is ready from first tune. Well spend day at hub dynos. These updates have been delayed due some personal **** in life.

But tune was quite nice, still some work with Ignitron boost control to make it more responsive. Did one trackday also with this and some small changes there due over boosting plus one blown intercooler pipe.

Dyno results are what people like (will add later graphs)

With petrol 98e (RON) 383Hp @ 6500rpm and 480Nm @ 4470rpm
With E85 (70% ethanol content) 423Hp @ 6380rpm and 513Nm @ 4420

Seems that I have maxed out GTX2867r GEN2 in this setup

 

[MoToJoJo]

Uh oh, sounds like a new turbo is on the cards

 

[VT86]

I would really like to test g28-660 or even g30, but had to save some money, going to upgrade my Honda CBR900rr sc33 to BMW S1000r, BMW F900r or Kawasaki Z900


Here's the Dyno results

98e5



With E85 (about e70 blend)

 

[MoToJoJo]

Depends what you want from a bike, I ride a Z900 (2020) and it's a bit of a hooligan (OE tyres are numb but grip well in the dry, not so much in the wet).

Interesting curves on those graphs, looks like it's slamming into a wall at about 4500. I'm guessing that's boost control cutting in

 

[VT86]

Depends what you want from a bike, I ride a Z900 (2020) and it's a bit of a hooligan (OE tyres are numb but grip well in the dry, not so much in the wet).

Interesting curves on those graphs, looks like it's slamming into a wall at about 4500. I'm guessing that's boost control cutting in

I'm limiting max torque around 4500 due that turbo ain't capable push more at top end so feels nicer on track and also saving gearbox little bit. And some reason my setup is limiting itself at top end. Can not get more controllable boost there, gate closed boost like hell and duty cycle 87-94% is around 2 bar of boost.

I'm quite pleased with the results even I was hoping to achive 450hp. Any way, I need to do some work with boost PID and make it build boost little faster. That should compensate lack of power.

 

[VT86]

Finally some motivation, so I started to change shifter mechanism to Cooler works one. Pulled out center console and dropped exhaust off. Prop shaft is still on place but next time I'll drop that out also.

Also wanted something "nice" and unnecessary for the car so order from my mate powder coated valve cover.

 

[VT86]

Some slow progress again if people are still interested.

Shifter found it place and also notice that 4x4 Leon has different style mechanism than all other, so Plug and play shifter wasn't plug and play. Well some drilling and filing and all good.

 

[VT86]

Some slow progress, new handbrake cables and modified center console to fit with new short shifter.


Also decided to do some modifications to boost pipes and add better BOV, old forge bypass is working as BOV at the moment. I haven't weld anything with TIG for long time and i could tell it. Pity that Argon run out during welding so need to fix end of the weld due that and there's also approx 1cm to weld to do.






Next steps are fix mag-valve (N75) hoses to PTFE with AN4 fittings and do timing belt service, changes step cooler thermostat and "highflow" waterpump

 

[VT86]

Had again free evening, decided to modify original coolant line which was hangin under intake manifold. I had from my brother some aeroplane grade stainless/titanium how knows what hyrdaulic piping which was quite perfect size for that. After some bending it was quite close what i wanted.



Then some love with TIG and hopefully hoses stays on the pipe, Pity I didn't have any stainless washers but luckly that one also stays under manifold so no one sees it if it get some rust on the washers. Had to say that such tiny pipe is quite difficult to weld.








This one is for remainder for me. Ordered bigger DBW throttle body, for testing. There's some measurements that stock one will cause choke point which could explain power drops and difficulties with boost control.




sorry lots of pics and less progress...

 

[VT86]

New throttle body arrived, need to build some kind spacer between manifold and throttle body. I have to say that that is way overkill, but lets see what happens.

 

[VT86]

Non Leon related update. Garage starts to be quite full, I picked up my new summer toy aka. bike.

F900R '22




And of course I had to order few bits and pieces. Crash pads, seat cover, axle protectors, mask and wheel stickers.





Mine and Hers, can't wait our summer vacation trip to Norway


Leon is waiting more parts for bigger throttle body and. Need to do timing belt and water pump before going to MOT then I can take it back to road again.

 

[VT86]

Have been time and motivation issues lately so Leon has been sitting in garage. Now I decided to buy some motivation hopefully

Mystery Box arrived


Unboxing



toys out for a while


Lifting motivation?

 

[VT86]

Some upgrades to test with






Then need to try can I manage welding quick connector to bigger throttle body



Not the best welds and was quite difficult one for me.



next step is to make some changes to boost pipes and FMIC brackets. And have to admit throttle body looks quite overkill but didn't find 70mm nor 75mm throttle body so now it's 83mm one.

 

[Wyld Stallyn]

Some upgrades to test with






Then need to try can I manage welding quick connector to bigger throttle body


Not the best welds and was quite difficult one for me.



next step is to make some changes to boost pipes and FMIC brackets. And have to admit throttle body looks quite overkill but didn't find 70mm nor 75mm throttle body so now it's 83mm one.

What's a few mm between friends..?