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JT's Polo Building Adventure!

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  • JT's Polo Building Adventure!

    I decided to move from my previous thread and make a new one because it's become a build list. Left that open incase anyone does require ideas/help with FMIC and suspension although there are many good points scattered all over the 9n3 forum.
    Here is link to the previous thread if you're joining just now:




    The very long and overdue build update!


    Car is back in the garage only because of the small stupid sunroof overflows and my neighbors tree... It'll stay there anyway for the next month, will go out for a dyno day on the 20th and after that the last few stage 3 mods will go in!


    What has happened:
    Pretty much everything from my last post!
    Done all the exterior LED lighting, I can see at night now ahaha. Got a chinese auto light switch, which I'm fairly happy with, but it's like anything that comes out of china, EH o.k. ... Updated my AC dash dials to the chrome option, found 2 more sets.
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    Heated seating! Loom arrived 2 months later... Took a day and a half but got it all done. Hardest part was splitting the fusebox open to get the loom and to piggyback another cable to have the 15Amp fuse in slot #24. Rest was fairly straight forward, 1x to the light dial, 2x cables into the control module, 2x to controllers, 2x to the seats and the ground to the airbag grounding point which after more consideration can be a bad idea. All soldered and done properly comparing to the factory manual!


    Picked up Vogtland coilovers, probably best bang to buck for the polo right now from the UK. Whole ordeal this ended up being a good option. Comparing them to the KW Inox V1's, they're super similar but some dimensions and spring wounds look different.
    Finished the rear big brake upgrade with Audi TT mk1 carriers and caliper. I got a set of bora carriers (as I've heard still unsure if they're right) because I'm not happy with the creation motorsport spacers. Need to pull a wheel off and test if they'll be more suitable than the TT ones, then respray them red to match the caliper and throw them in!
    100%, slamming the brakes now, rear end wants to pull itself out from under the car, would recommend
    Have received braided lines so those have to go in too!
    Got a paint correction and it was looking great and then I took the car offroading
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    Other day have finished putting in the R8 coilpacks, bought the billets from the UK, $90 can't go wrong. Threw those in and also got a golf loom case to tidy it up more. N249 won't leave with this turbo, sure the SAI delete yes because racecar, but as it has always been installed and if German engineers put it there, not going to take it out! Maybe for the new turbo, but again I don't want to kill that either.


    What's left to do:
    Tomorrow, and I pray tomorrow that, turbo, injectors, water meth (because was a good deal on a full kit), all strut bracing and also front brakes get sent and arrive sometime this week so I can sit and do all the front end modifications.
    After they arrive I'll wait after dyno day before I start the final transformation.
    Sadly still waiting on my fuel pump even though I've waited more than 20 business days... Should arrive this week too.
    Have some fresh carpets coming from the UK close to the end of the month.
    Catch can install will be done too after the stage 3 stuff. Got all the right bits to do it.


    Another simple service, I didn't do the trans oil before because I was lazy, just checked the level and it looked good.


    Only few things that I think I'll do but over time.
    LSD! Quaife most likely, I have a spare box with a blown diff, so will make sure it can be built before I buy it.
    Bluemotion front lip, and get the side skirt and rear valance sprayed. I really want the cup edition rear spoiler! again it's one of those things, to find and get will be a pain, but well worth it!
    LED rear upgrade, with the VW infinity mirror badge, some guys done it in the UK, looks pretty cool.


    That's about it. Hope this wasn't a stupid long read, but I'm covering everything done/planned to the car, so it'll always be an extensive list.
    Peace, Love and Positivity during these times!

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  • #2
    What turbo, injectors, pump etc are you planning on running mate?

    Comment


    • #3
      Hey Sam!

      Still waiting on them looks like next week.
      Frankenturbo K04 hybrid (typical)
      Bosch 550cc injectors (typical)
      Deatschworks DW65C pump which looks like it'll never arrive from sparesbox, most unreliable Australian retailer. Dealt with them 3 times prior and stuff always arrived a week or two late even before everything went down. I ordered this start of May...

      As soon as my exam is finished on Monday, I'm pretty much digging into the car finishing front suspension and BBK and throwing in the braided lines. Should take a day or two

      Comment


      • #4
        Manifold, MAF, TIP and exhaust manifold from frankenturbo too as a kit, or are you cobbling together parts that you've sourced yourself?

        Comment


        • #5
          Everything should be coming as the kit, but again, I've been kept in the dark about all the details even though I've asked multiple times :|

          BAM intake manifold, doubt will change this. I've got the welly setup, holding strong 20psi right now. Might beef it up from 2" to 2.5" and get a thicker intercooler to comfort the K04, but again, unsure about it right this moment.
          Completely unsure if the exhaust manifold will come with the turbo. I want to port the exhaust ports and manifold, but it's one of those things that'll have to come later because I don't want to risk rushing and stuffing it up right now. When I'm done with uni and have a spare engine to build with forged internals, then sure, will get it done!
          MAF, 3" also coming in the package hopefully, otherwise I'll go grab the housing from an Audi at the wreckers
          TIP, again should be coming because I've asked for it and when I was placing my order at creation motorsport earlier last month, was comforted that it'll come with the turbo so I wouldn't have to worry about it :/

          Everything is meant to be sent from this Saturday (Monday processed from Sydney), so hopefully it arrives by the end of next week. It's been 4 months that I've waited for these bits to be taken off this car and get sent to me... Has slightly gotten frustrating but I'm patient

          Comment


          • #6
            Hadn't ever heard of FrankenTurbo, very interested to see how all this turns out. Was looking at getting a BBT K300 but if the FrankenTurbo option is only a little bit more for a whole kit it sounds like a fantastic option.

            Comment


            • #7
              AET Turbos | 1.8T 20V Hybrid K03 Turbo

              can check out these guys too. I may be wrong but I think despite BBT having a BBT280 on their site, they don't actually do it anymore. AET was sort of formed out of BBT and they do the smaller K03 hybrids for 1.8T's. Apparently a ported K03 exhaust mani can flow very well compared to a factory K04 one so there is that to consider too. I never researched the K04 hybrids really so cant help you there.
              If you ever go down the K03 hybrid route let me know as I have one spare that you could get ported ready for a K280 or 300 conversion.

              Comment


              • #8
                Littco do a 280. I had one make 177kw are at UGP. Stick manifold, not ported. With Littco TIP, alloy MAF, Airtec twin pass and 550cc
                optimumcode@gmail.com | https://www.vwwatercooled.com.au/for...i-;-79012.html | https://www.facebook.com/TTY-Euro-107982291992533

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                • #9
                  Originally posted by sambb View Post
                  AET Turbos | 1.8T 20V Hybrid K03 Turbo

                  can check out these guys too. I may be wrong but I think despite BBT having a BBT280 on their site, they don't actually do it anymore. AET was sort of formed out of BBT and they do the smaller K03 hybrids for 1.8T's. Apparently a ported K03 exhaust mani can flow very well compared to a factory K04 one so there is that to consider too. I never researched the K04 hybrids really so cant help you there.
                  If you ever go down the K03 hybrid route let me know as I have one spare that you could get ported ready for a K280 or 300 conversion.
                  Not to derail the thread but if the AET is rated for between 260 and 280HP what would you say are the advantages over the cheaper BBT K300?

                  Originally posted by h100vw View Post
                  Littco do a 280. I had one make 177kw are at UGP. Stick manifold, not ported. With Littco TIP, alloy MAF, Airtec twin pass and 550cc
                  That's cheap, might as well the same price as the K300 was in 2019. I'd imagine its quite a bit better than the OEM units but do you know how that turbo is doing now?
                  Last edited by Stein; 15-06-2020, 09:04 PM.

                  Comment


                  • #10
                    Littco and TIP delivered was $1700. Dont need to fit Rods which saves a pile of money.

                    Not a cheap upgrade but then....... I have had 3 different hybrids on mine in its time.

                    The main advantage of the AET over the K300 is the chances of actually getting one.
                    optimumcode@gmail.com | https://www.vwwatercooled.com.au/for...i-;-79012.html | https://www.facebook.com/TTY-Euro-107982291992533

                    Comment


                    • #11
                      argh dumb ass. Sorry Stein, when I chucked that up I had Littco in mind. Linked the wrong site. I realised I'd stuffed up when I just went to close the page down and saw the price because I remember that the Littco was very very reasonable.

                      Jeez 177kw aint bad Gav.

                      Comment


                      • #12
                        Originally posted by Stein View Post
                        Not to derail the thread but if the AET is rated for between 260 and 280HP what would you say are the advantages over the cheaper BBT K300?
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                        From what I've seen, the only thing different is the charge pipe muffler? (not sure if that is the correct term) and housing difference? Specs are so hard to find nowadays. The one Sam posted doesn't have a dimension specification, the BBT K300 has 51mm from what I read on this website
                        BBT K300

                        Originally posted by h100vw View Post
                        Littco do a 280. I had one make 177kw are(atw) at UGP. Stock manifold, not ported. With Littco TIP, alloy MAF, Airtec twin pass and 550cc
                        I've touched his TIP a few times ahahaha
                        Done the gentleman's lowering springs and had advised for uh, upgrading those dead front stock shocks. What's good to have power and then the car can't go around corners. These cars are to go left right, ciaos.

                        My 2nd gear is this car's 3rd gear and it just keeps on going and then explodes, crackles and damages all hearing. Everything I wish to not do, unless I genuinely plant my foot.
                        I looked at the Littco one, but at the time when I decided on the Frankenturbo, it was out of stock and delayed so
                        Can't compare the price difference though

                        So Yeah, that's the turbo coming this week, got 60kg of stuff sent to me TODAY and I don't think that was everything.
                        I've got a big Aluminium/silicone combo TIP happening with the CreationMotorsport 3" MAF housing

                        No Exhaust manifold is being sent so...
                        Originally posted by sambb View Post
                        Apparently a ported K03 exhaust mani can flow very well compared to a factory K04 one so there is that to consider too
                        Yeah I keep considering this, but I've got to ask the UK boys how they do them, or Gavin??
                        Will send you a PM later, need to sort the tune out Da he ve he he

                        Everything will be anyway delayed because Sparesbox is holding my money and not confirming my order after a whole month and a half... WTF, who pauses someone's order... That's pretty much what they told me... They deleted all my comments off their insta, and if I did on FB would be the same so I can't be bothered... 1/5 on google as soon as I get it, whether I get it or my money...

                        I'm starting tomorrow to do a few bits, Wednesday should be back in the garage to get the final suspension upgrades and then
                        Car's going on the Dyno this Saturday!
                        See what it currently makes, then it'll go back into the garage and dig into it, get it done and be finished lol
                        Nothing more on the performance side, just keep everything maintained and yeah, enjoy the car finally.
                        Last edited by JTop; 15-06-2020, 11:07 PM. Reason: and i ooped lol, everyone posted whilst I was writing this up

                        Comment


                        • #13
                          Alrighty update


                          Car got a few bits done to it over Thursday and Friday
                          Got the Bora carriers sprayed red and replaced the TT carriers, fixing how the pads sat on the rotors. Fixed the rear muffler as the hangers were travelling in the same direction so it would bang onto the rear spring. Flipped the rear one, solving the banging problem
                          I was going to put in the braided brake lines in the back and then realised it's not a straight swap... Fronts are, but rears aren't... That was silly that I thought it'd work... SO got to pull another set off another polo and then have those remade to fit the braided line, If anyone has an idea how to do this, would be appreciated.

                          Got all the undercarriage plastics, fender liners and wheels cleaned and thrown in the UR rear strut bar, as well as the UR mid bar, was going to fit the undercarrage front one but I got tired and didn't have time. Fitted the top mount one, and can say, that actually made a massive difference for the handling of the car on the stock setup. Would recommend that as an upgrade without doing anything else to the car.
                          Was going to fit the front coilovers and the big brakes but again I was super tired by Friday evening.


                          Saturday was great, had quite a bit of fun and discovered a few things
                          Dyno at Peerless Automotive in Lynbrook Victoria outputted a maximum of 134kW atw with 271Nm, which was really and I mean REALLY surprising when the gentleman tells me it's a stage 1 tune... My friend, also running a 9n3 gti. who pulls about equally against my other polo (UGP 120kw) hit 112kw... that's what the stage 1 tune would be doing on this dyno... And I was pulling 20kW from thin air...
                          I'm in stage 2 territory so something doesn't make much sense. Oh well


                          This week is build week, everything else that needs to go in will go in, except for the fuel pump and one other thing as I haven't received them yet...
                          I'm at that stage where I want to get everything done in the instance and enjoy it, but there is a road to get to that point, and I'm yet to get there. Goal at the moment is to get everything done, safe tune it and enjoy for a few months before going any further.
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                          Will keep this updated as I go!
                          Cheers

                          Comment


                          • #14
                            134kw is 180hp. If you assume 30% driveline loss then that 234 hp crank. I remember my stg1 custom code tune had enough maf flow to put it at around the 240 mark. Having said all that all dynos are different. My mates Clio in an earlier state of tune made 165hp atw on the next door workshops dyno. It then ‘found’ 20hp the next day on a different dyno. As long as you just use the same dyno so your numbers are apples vs apples then that’s the best way to chart your progress. I must admit stg 1 was very strong vs stg2 on my car. I don’t think peak power changes too much. But the stg2 dump reduces back pressure and allows more timing advance in the mid range which really boosts the torque there. Stg 1 due that extra back pressure and more retarded timing runs really hot , like cherry red turbo kind of hot. Fine fir the odd squirt around the street but a worry fir sustained running or on the track. That’s stg2’s advantage. Actually kinder on the engine.

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                            • #15
                              Keen to see how the K04 hybrid goes they’ll be a step up.

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