Bocanegra Stage 3 Hybrid

[BocaBill]

Hi All, Hope your all well

Not posted on here in a long time, I think the last time I did I was considering going Hybrid with my Boc, Thread title kind of gives away what's happened since....

So the ol girl is still heathy and running sweet while the remaining few hundred other's keep dropping like flies with the usual problems, mid last year I bought a very nice k03 Hybrid from Venom Turbo's, once fitted and ran in I had it tuned back at the tuners.

It made 261hp/361nm on safe mapping for timing and stock fuelling being close to 100% duty, Revised CAVE engine & Clutch pack still stock also with no extra mods other than the turbo and tune from my previous, The Boc is now an absolute beast and pulls so hard all the way through the rev range!!


Here are some some shots from a recent photo shoot also my updated StanceAuto magazine feature if anyone fancies a read

StanceAuto Bocanegra

http://imgur.com/a/6dIz8v5

http://imgur.com/6Rw2yku

http://imgur.com/qamo61N

http://imgur.com/lEMsBEB

http://imgur.com/aC3NoZj

 

[CW92]

Those bonnet vents look lovely and with the improved spoiler it looks nice and appears like it would fly.

 

[BocaBill]

Those bonnet vents look lovely and with the improved spoiler it looks nice and appears like it would fly.

Thanks, Appearance matches the performance

 

[CupraJohnQ]

quality this, nice work sir

 

[BocaBill]

quality this, nice work sir

Thanks mate

 

[BocaBill]

Quick update, I finally got around to getting the wheels I've always wanted to run on the Boc....
Always had a thing for the Audi S-Lines and picked these up cheap, needed a refurb and tyres.

The result.....

Fitment is spot on

 

[CupraJohnQ]

Quick update, I finally got around to getting the wheels I've always wanted to run on the Boc....
Always had a thing for the Audi S-Lines and picked these up cheap, needed a refurb and tyres.

The result.....

Fitment is spot on
View attachment 30732

View attachment 30733
View attachment 30731

Yeah nice, are they 17" ?

 

[BocaBill]

Yes, 17's, ET 36.

I was surprised I havn't needed to roll the front arch lips

 

[BocaBill]

Couple of updates, Recently went upto Trac Mon in Anglesey, Bit of a wet one but no problems for the Boc.
Also been to a couple of local show's over the last few months

Best of both worlds Track/Show builds

 

[CupraJohnQ]

Love it man, good to see it’s still very healthy

 

[BocaBill]

Love it man, good to see it’s still very healthy

Cheers, Yep all good, No issue's to the annoyance of many "greek tuner" fanboys on the socials as they all told me it would be dead by now if I didn't "go to the greek"
Just show's how well informed they are!!

How's your's keeping? Many changes?

 

[CupraJohnQ]

Cheers, Yep all good, No issue's to the annoyance of many "greek tuner" fanboys on the socials as they all told me it would be dead by now if I didn't "go to the greek"
Just show's how well informed they are!!

How's your's keeping? Many changes?

Haha, I’ve had it too mate.

Yeah all good here, just about to tick over to 90k miles and it’s running sweet as ever on a Stage 1. Going to take her in for a service soon as it’s been a year since the last one.

No changes yet, funds have been tight to be honest, but I have plans to get a sports cat and Airtech cooler on next then stage 2 map to tie it all together.

 

[BocaBill]

Haha, I’ve had it too mate.

Yeah all good here, just about to tick over to 90k miles and it’s running sweet as ever on a Stage 1. Going to take her in for a service soon as it’s been a year since the last one.

No changes yet, funds have been tight to be honest, but I have plans to get a sports cat and Airtech cooler on next then stage 2 map to tie it all together.

Good to hear, I've had to do discs and pads as leaving ESP on round the wet track burnt through my pads, but I was ready for changing them anyway, Other than that MOT next month then look at booking another track day

 

[BocaBill]

Another track day complete.... First time around Oulton Park, Loved it!! Definitely booking again in the summer The car boosting like a champ, No errors, no burning oil, no misfires. Hashtag NOT BROKE!!

 

[mydavestrong]

good to see it’s still very healthy

192.168.100.1 192.168.1.1​

 

[BocaBill]

good to see it’s still very healthy

192.168.100.1 192.168.1.1​

Yes, Still going strong, Just got all the parts together for a top end rebuild to fix the valve float with uprated OEM exhaust springs and the usual water pump/timing chain etc etc, Should be able to up the boost a make a little more peak HP but overall for stock CAVE engine it's a good egg

 

[BocaBill]

Build update part 1....

As mentioned in the post above I have been collecting all parts for a partial engine rebuild/refresh as long story short going stage3/Hybrid turbo on factory exhaust springs and running too much boost pressure above 6.5k will cause valve float misfires which I have had for 12 months, Having read through many builds from years gone by I found a few had ran into the same problem around 10 years ago to which the fix was stiffer OEM exhaust springs.

So work completed....

Carbon cleaned head


Valves lapped & Seated, Replaced Exhaust Springs with OEM 036109623AC

Replaced Intake Springs & Valve Stem Seals with OEM Stock 036109623R/036109675A


While the head was off I also did the 2 major items Timing Chain & Water Pump/Supercharger Pulley
(side note VAG actually revised the timing chain and sprockets at some point post CTH manufacture to a chain with fewer but longer links and sprockets with fewer teeth to accommodate the new chain, THIS is something I have not seen mentioned across any forums, what this means is if anyone is having a timing chain done for the 1st time will most likely need the COMPLETE kit incl sprockets, not a partial kit of chain, guides and tensioner (which is what most threads mention) Also threw in a DSG Mech fluid and oil change for good measure.

After a week in my mates workshop I collected the car this morning which included a little bonus of information that a some point before
my ownership the car had a short block CTH replacement under recall work (something I always suspected) plus pistons were checked and all looking in top condition along with the bores while in the workshop (Happy Days) so now I'm pretty running a full CTH Engine minus the ECU

Engine ticking over quietly, DSG silky smooth and with a quick venture into redline to check all the work was worth the effort.........

YES, 0 Misfire 0 Valve Float

Happy, Healthy Stage 3 BOC on stock internals!!

Part 2 coming soon with a revisit the tuners to tweak the map......

 

[BocaBill]

Jeez.....not updated this for a good while, I still have the Boc, She's still healthy and pulling like a freight train!!

so what's happened in 18 months....

Build part 2...

Last update I was waiting on getting back into my original tuners to tweak the tune after all my head and refresh work however after all the messing about previously I just didn't think he was the right person for the final tune, so I set about looking elsewhere.

In the meantime a few more mods were added......
Firstly I swapped out the modded actuator from Venom to a Forge Unit with a blue (13psi) spring.
Installed a VIS HPFP piston upgrade to help with final tuning.

I had the wheels redone in a gold colour from Kia

Lastly I took the front bumper & splitter for a repaint plus did a kind of Gloss Black on Satin Black BOCANEGRA lettering on the front (which sort of works)

12 months of attending shows, track days and just general driving later the gearbox developed a squeal on cold starts ,I later found this to be a dry clutch release bearing, so tuning on hold and a new LUK clutch pack & flywheel installed by Lancashire Transmissions (quick turn around, highly recommended)

Having left the clutch to bed and settle in for a month I made the best decision of my build to date.
Being a member of this forum and seeing the great tuning work done over the last 15/20 years on BAM engines and alike plus having been involved in the tuning development work for many Venom hybrid's it dawned on me to ask Rick @ Unicorn if he would be willing to finalise my tune
although being aware the EA111 1.4 Twincharger isn't a platform Rick would generally take on due to it's reputation (understandably so).

So where did I differ?? As above really, being the ONLY UK Bocanegra (Possibly ONLY UK Twincharger) to be running a Venom K03 Hybrid (who unfortunately are no longer trading) and I think Rick showing some sympathy for me and my 2 year plight to complete my setup
Plus the fact I have taken VERY good care of my engine/gearbox which was evident when data logged by Rick he agreed to retune the BOC

After an initial base run, to completely rewriting the tune and then fine tuning.... 5 hour's later she was off the rollers with a 1 off tune and honestly can't thank the Rick, Mario & Chloe @ Unicorn Motor Developments enough, Absolute night and day difference from the previous tune,
Rick has maxed out the stock injectors and running close the maximum fuel pressure with the VIS HPFP for a HUGE torque mountain in the mid range just as the Venom K03 is on full chat making 1.7bar @3.4K, Holding 1.6bar with a steady taper down in the redline with perfect boost control from the stock N75 and Forge actuator.

I know there are higher figures (few proven, many not) all over the internet AND I have made higher figures on a previous tune however peak numbers are not the be all and end all, Delta under the curves IS, To be hitting peak torque of 273ft lb @3.7K and peak hp of 237 @5.4K all within everyday engine rev ranges is Useable Power!!
Strangling the engine to death to hit some 7k+ hp peak figure pushing a turbo out of it's efficiency zone and making hot air just isn't practical....it's NOT a VTEC!!

So YES...A Quicker, Happy, Healthy 'stock internal' Boc running a hybrid no less!!

Post tuning I had a few upgrades and maintenance bits still on the list to sort.....
New Goodyear Eagle Asymmetric 6's all round
New Bilstein B12 Pro Kit (B8's with Eibach pro springs) after 3 years finally removing the awfully harsh Stance Street+
New Control Arms with Powerflex Bushes
New Vagbremtechnic J Hook discs & EBC Yellow stuff pads
All Calipers sent off for a full refurb and recolour in black

Drives, Handles, Boost's and Stops like a little go kart which still surprises those who fancy themselves at a set of lights or round a few bends on the A roads!! (legal limits adhered to obvs).


Full Engine Spec
Pipercross TriFlo Filter, Modified stock intake scoop/airbox
2.5" Custom downpipe with 200 cell sports cat into Cobra 2.5" non res catback.
Airtec Intercooler
Forge Silicone Boost Pipes
Forge Actuator (Blue Spring)
Venom K03 Hybrid Turbo
VIS HPFP internal piston
NGK U5002 Coils
Denso SKJ20-A8 plugs
Revised OEM exhaust valve springs
Unicorn Motorsport Developments custom stage 3 software
TVS Stage 2+ DSG Software

Track it, Send it, Enjoy it!! Oulton park again in Nov and more booked for next year


Almost forgot...also had my steering wheel retrimmed in Perforated Napia Leather and Alcantara, red stich and 12 O'clock ring by Steering Kingz in southport!! Top job!!