PhilW's Mk3 Ibiza Project Thread - 3071 - Now Breaking!

[PhilW]

Spec List

Engine

Garret GT3071 0.63 A/R, T3 hotside and 3" V-Band housing
Revo Stage 3
Walbro 255lph in line pump and wiring/relay setup
630cc Siemens injectors with fuel rail spacers and 3 bar fpr
S3 in tank fuel pump and modified ibiza float
Scat rods
JE pistons (standard bore)
RS Fabrications T3 top mount mani, 3" vband turbo back exhaust and wastegate pipe.
Custom oil and coolant lines
Modified ABS bracket to give more clearance for WG
38mm Tial wastegate
3" inlet
S4 MAF with Ibiza element
Forge Supersize DV and pipework, 35mm hoses and custom made Forge MAP pipe
S4 throttle body and custom made adaptor
Greddy Profec B2 EBC
Massive FMIC and t-bolted 2.5" pipework
SPEC Stage 3 clutch
Custom Lightened and balanced flywheel
Refreshed box with 3.6 final drive and Quaife ATB diff - box work and flywheel done by hotgolf on Club Gti
TT shifter and B+M copy short shifter and Richbrook gear knob
Blackforest stage 1 mounts
Wrinkle painted inlet and rocker cover
Gloss black cam belt cover
Chrome plated SEAT upper strut brace

Wheels, Suspension and Braking

17x7 OZ Supperleggeras with 215/40/17 Yokohama Parada Spec 2's, pretty much new.
310mm Wilwood 4 pots with Ferrodo DS2500 pads
FK Silverline coilovers
H+R Rear ARB
Custom grooved rear discs

Interior, Exterior and Other Bits

Battery in boot in a ally tray
Sound deadening removed along with excess interior parts
AEM wideband sensor and gauge
Autometer Ultralite boost, oil temp and oil pressure
Flocked interior parts including nomad pillar
Custom made suede roof lining
Wot Box
Snap off steering wheel boss and OMP wheel
Corbeau Sprint seats in black, one XL one normal size
FIA approved 3" Rocco harnesses
OMP side mounts
Sparco seat mounts
Colour coded bump strips
Lupo Gti Aero wiper conversion
H7 HID's and LED sidelights
Number plate holders
Scangauge 2 and holder where cigarette lighter used to be, cigarette lighter now in glove box

Current photos...

Thanks to:

Peter and all @ Forge Motorsports
Bill @ Badger 5
Craig @ GotBoost
Pete @ Gripztyres.co.uk
Jonzy
Byron @ OldSchoolEngineering.co.uk
Dai @ C A M Sport
Kev @ Revo
Neil & Rhian @ Samco/Silflex
Martin aka Hotgolf

 

[PhilW]

As i bought it...

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Pretty much as soon as i got the car i was changing it. lol. Debadged and my private plate was on straight away.

 

[Deleted member 13581]

What a transformation.

Spec list is mighty impressive aswell.

 

[PhilW]

Thanks.

I'll be posting all the bits in between when i get chance.

 

[DPJ]

 

[BigWill]

That car is gorgeous! A damn lot of effort put into it, nicely done!

 

[PhilW]

After joining this wonderful website, lol, and posting a Newbie thread someone sent me a message asking me if i wanted to buy some bits from him.

So my first mods were had, a Green Dynatwist air filter and a Seat/MOMO strut brace, both for 90 quid. Bargain, and he lived in Bridgend which is about 30 mins away.

and

 

[PhilW]

When i first put the Dynatwist on i could hear massive amounts of wastegate chatter, not good, which means the DV was knackered, so it was time to replace it. So up pops one of the boys saying he's got one 'kicking about', 40 quid later and i have a lovely, almost knew Forge 007p re-cirv valve.

Now i can hear a little bit of the air venting from the turbo, which sounds a little like a blow off valve but not too loud. But running only 7psi i wasnt going to hear much. Throttle response was up and it seemed to hold boost a little longer as the old one was probably leaking boost.

 

[PhilW]

Next mod up was some gauges in a lovely Nomad Racing A Pilar. This again came courtesy of Mike who used to run AM motorsport in cardiff. The gauges are also made by nomad, 30psi boost and oil pressure and are back lit blue.

 

[PhilW]

After looking at the car up on the ramps i knew i needed a knew exhaust sooner or later, from seeing some rust build up to how bad the actual design was, narrowing loads to get over the rear beam etc...


So i got on the phone and ordered a 2.5" stainless steel cat back system from Supersprint. After waiting a month for it to arrive i got myself up to my mates garage to fit it on the ramps.

Lovely build quality and looks, sounds pretty good too.

 

[PhilW]

Remap time.

I chose to go for Revo, which Westec offered the. With revo they also offer a 5 hour driving time trial, upload the softrware and basically go rag your car for 5 hours. Brilliant. After having a go at the trial whilst having a service done, i'd made up my mind, so it took me a grand total of 4 weeks to get the full software. lol.

The differance is unreal. Boosts on anything up to 23 psi and keep pulling and pulling in all gears.


This is a graph of the remapped cupra, remember this was when Westec had only just had the rollers and my car hadnt fully adapted to the map(and was run in 3rd)...


BHP
http://img.photobucket.com/albums/v147/phi...lingRoadBHP.jpg


Torque
http://img.photobucket.com/albums/v147/phi...gRoadTorque.jpg


After the rolling road results it became clear to what the next mod would have to be, a FMIC. On the ibiza it has a notriously small side mounted intercooler so decent FMIC would mean it would stay cool and run to its full potential.

Below is a pic of a comparison of intercoolers...

 

[PhilW]

Some samcos next up coz i know people who work there.

Also decided to ditch the engine cover.

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[ChrisCurzon]

Very nice Phil you have done loads to it as people said good spec list. I seen your progress thread on that other forum ones was good to see everything step by step.

 

[PhilW]

Thanks chris, i think its gonna take me a while to get up to where i am right now but hopefully it'll make for a decent read, if not at least you can tell me its ****. lol.

Next up was wheels.

17" Oz Superleggeras...

After 4 weeks of waiting as it was the first batch of Forge FMIC's, my cooler turned up...


Here are the pics...

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And then later that weekend @ Trax with also the OZ wheels on...

 

[PhilW]

Forge caps and dv servicing cap added.

You can see the caps on in this pic...

I also ditched the nasty fried egg indicator bulbs for some silvatec ones and replaced all standard bulbs ready for the winter with Philips Bluevision sidelights and headlights and Bosch Super full beam.

Also added a Samco mk4 golf TIP as the Forge version wasnt about at this time, which later i found had been ****ed up by Westec as they cut the bottom hose too short...

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[PhilW]

Originall i wanted forge to put an extra 25mm take off on the pipework leading to the throttle body, but as it hadnt been done i decided to make my own kit...

Schematic of the kit...

http://img.photobucket.com/albums/v147/philwarren11/dvreloaction.jpg

So i got all the parts from forge.

At the same time i replaced any red vacuum hoses with blue ones, i will completely replace all braided vacuum lines with silicone ones at some point.

 

[PhilW]

RR day next up, wanted to see how the car pulled with the fmic and other mods i'd added, N75J, etc...

Below is a photo of the BHP and Torque, the lower two lines on each graph being the previous rolling road day so you can see the increase.




BHP
http://img.photobucket.com/albums/v147/phi...pra/power-2.jpg


Torque
http://img.photobucket.com/albums/v147/phi...ra/torque

 

[PhilW]

Got round to fitting my Leon Cupra R splitter yesterday. Also replaced all braided vacuum lines with nice 3mm blue silicone ones.

Changed the spring in the re-circ valve as well to a green one.

Also fitted more samco hoses...

Elbow for Dynatwist filter - 70mm
All hoses to N75 - 8mm
Hose to coolant tank - 8mm
Oil breather hose to mushroom thing - 19mm
And small elbow which you can hardly see under the charge pipe - 19mm elbow.


Before today...

http://img.photobucket.com/albums/v147/phi...ra/DSC03735.jpg

Finished...

 

[Myki da Pyki]

Its come soo far mate. Definatly the best looking engine bay out of all us MK3 boys (that ive seen anyway)

 

[ForgeMotorsport]

nice