Front mount options?

[instigator]

on here there are indeed no major horspowerfreaks, a couple maybe.
but i'm also active on a dutch forum from holland, Seat Cupra online.
those people are crazy when it comes to tuning, they are also allowed to do more to an engine as in Belgium.
so i also seek "high power info" elswhere.
if yoy understand dutch, take a look at the forum, verry intresting topics on there.
a 1.8T with 400Hp is no exeption
i have driven once in a friends Ibiza (older model) with 1.8T engine, that day it was on low boost making 380Hp.
ride was pretty extreme, once you get about 3500 - 4000rpm it realy becomes a bullet.
when it's on high boost it becomes just sick and pretty undriveable, 430Hp and limited to 420nM.

but as for power from about 300 - 350Hp i would recommend also a Garret GT28RS.
this is er verry safe turbo wich spools at about 3000-3200Rpm on 1.8T.
but when it spools, it goes strong!

or the IHI VF34 turbo.
wich is about the same as a GT28RS, also making about 350Hp.
but it spools quicker as the Garret, somewhere around 2800-3000rpm it's off.
both turbines will be laggy under 3000RPM but will provide more than enough power al the way to the red line.

personal choise off course.
but i won't go higher in power or getting even bigger in turbo.
the bigger the turbo, the more turbolag you create.
and my experiance has showed me that you are better off with a quick spooling turbo for daily use and rolling start races.
a stage 2 polo will eat a GT28RS polo in a rolling start, for the first hundred meters.
after that, the bigger turbo will fly over it as if it wa standing still.
but, if you want to do dragraces and circuit work youre better of with high end power, such you get from Garret or IHI.
but know that when you have +300Hp, youre 1ste gear will be as good as useless.
so for every day use it might not be the perfect set up...
think before you buy.

a quick story,
a good friend of mine, also with older model Ibiza sport 1.8T, started out with stock K03 turbo.
chipped it to 210Hp.
ride was good and he was quicker as most cars on the road that came along.
after a couple of months he upgraded to a K04s (K04-023 from TT225, Cupra R etc) with exhaust, injectors and other stuff.
made 270Hp, spooled about as quickly as the K03 but with alot more Hp and torque.
did a 13.6sec on the quarter mile (best time)
after that he upgraded to GT28RS, beast of a turbo back in the days (2004-2005, and it still is)
made about 340Hp but it spooled not as quickly as the borg warner turbo's K03/K04 etc.
best 1/4mile was 12.8sec with stripped out interiour and street tyres.
it was extremly fast in higher RPM range.
after that he wanted more, and got a Garret GT30 i think it was.
no nonsens and full boost on the sucker.
it made 455Hp and just over 500nM torques.
on hot dry tarmac with good street tyres: 1ste gear became totally useless, same as 2nd gear.
3th gear he started to get a bit of grip, 4th gear it was off, 5th gear pull was insane.
under 5000rpm there was nothing, absolutly nothing!
did a rolling start against his friend with the same ibiza but with a K04s set up,
they have to do the rolling start against some speed because otherwise it had no grip.
so they started at about 100Km/u in 3the gear.
from 100 to +200Km/u the K04s was faster becaus it spooled much quicker and getting his power down.
did a 5th gear run against a Yamaha R1, it was neck on neck at first, but after a while at about +250km/u the car was getting faster.
he also once tried a top speed run.
maxed out the tacho, and on GPS he just went just over 290Km/u and he had to let off.
car wanted to go faster still but it was to dangerous, car was dancing all over the place.
1/4mile times was low 13's at it's best.
as he could not get his power down from 1st to 3th, so with the GT28RS set up he was faster.
problem with the car was that it eat gearboxes with that much torque.
every week there was something wrong with it, in total he destroyed 4 stock gearboxes and 2 upgraded stronger ones...
in my eyes, this is someone with experiance and knowledge about 1.8T tuning.
and he said, "if i knew in the beginning what i know now at this point, i would probably stick to a K04s set up"
it might not be as spectacular as a GT28RS or even a GT30 (or whatever it was)
but it's more usefull, gives power at the time you need it most, and thats whats makes a car quick.

sorry for the off topic
but when i'm going, i'm going good

[firdausasri]

Hi Guys,

Another option is to go for custom FMIC which is what I did few months back. Basically, the intercooler is coming from Evo 3 (500x300x65) and all new custom piping from from turbo towards IC and IC towards manifold. As for the drives, well, what I can tell though there’s a slight (very slight) lag of 300-500rpm for the turbo to spools but once the revs past 3k all the way to 5.5k, the car pulls with fatter torque figures and more rush feeling at high revs. It registered 216whp & 326wnm on dyno, I'm fitting in 4 bar FPR to fix lean issues at high revs, aside that this mod works like a charm!


Some adjustment on the inlet/outlet needed, if Evo 7/8 intercooler of the same size, it would be ideal


The old Evo 3 intercooler seems to be working well which defies its age


The guy managed to make a hole when I didn't think it can be done


Got to love the welds done by the Myanmar national staff, reminding me of seeing these things in the US




Pretty stealthy too

[instigator]

verry good set up there!
nice work done!!

must be the nicest self made IC set up i've seen on a polo

[vwthunder]

The thing with a custom intercooler is that I would be worried about getting a good core, so much stuff out there, hard to know what works and flows well and what dosent, unless it has been tried and tested.

I would think about doing the Seat Intercooler as I am chasing 300hp (at flywheel). Remembering that at around 300 or over 300hp, you need to do rods to be safe.
That will involve a Hybrid K03/04, Jbs manifold, good intercooler, custom tune and maybe even water meth, I think it would be a realistic goal

[instigator]

i'm currious if there is any hybrid K series that will give you 300Hp...
if you do get another turbo, just put a GT28RS or IHI like i said above.
let it get custom tuned and set it safe at about 300Hp.
turbo won't run at his maximum and you have youre HP goal.
if you want a K series make 300Hp (i wanna see that happen ) it will probably be at his ultimate limit.
wich can be dangarous at track days...

they say 300Hp is safe with the 1.8T engine without changing internals.
they can easy handle that power.
my mate with the 455Hp ibiza i was telling about has drivin the GT28RS with 340Hp on stock internals without any problems.
but, it's absolutly safer to change internals @ +300Hp.
but it's not the Hp, but the Torque that destroys everything.
specialy high torque at low RPM, so i guess you will run more danger with a K04 as with a GT28RS.

[vwthunder]

I am trying the Frankenturbo

Most of the guys on Vortex are making 250whp, one guy with water meth is making around 285whp.

I guess it is not all about the turbo, it is about the supporting mods, seeing as people have quite high numbers even just with a K03s

[blitDz]

I really do enjoy reading a good yarn instigator. Always have great insightful things to say. At this stage 180-220kw is a goal. My initial thoughts were that this was still going to be a level where the car will be driveable "everyday" so to speak. I was definently thinking of changing turbo but that was later date once i was happy with the essential mods that come before that sort of jump. At least i know that if i wanted to go as high as VF34 i could just ring a couple of my mates from my WRX days. They always have these things laying around. As for IC my cousin is currently setting up his S13 drift car with a RB25 in it with custom IC etc. So im more than happy to go with the company he went with for his cooler as im very impressed at the cooling power he has from his core. The main thing for me is getting my head around everything before i start so i know what i want. My poor father tries to help me as much as he can but hes not all that interested as its not a V8 RWD with a ****load of power. hahaha

[noone]

I'd love to see another quality build, but worth while measuring up the costs before you go too far.

If you are going to put down that sort of power, I'd suggest you will want to work on the suspension and drive-train.
Coilovers, swaybars, diff, bushes, etc. Just that part is going to set you back around 3 grand to do it well (can certainly do it for less).

By the time you drop in a decent turbo (Franken turbo is the best I've seen for the $$$), otherwise a Garrett kit is going to be quite a chunk more.

I don't want to put you off, but chucking a turbo and retune in will not give you all that without working on all the other parts to make it work well.

At a high level, I'd think you're up for:
Bigger Turbo
Exhaust Manifold and piping
FMIC
Intake (like pod), maybe larger MAF
TIP to suit Turbo
MBC or EBC
Suspension
LSD

This does not touch on some of the other things that should be done along the way, exhaust (or Cat and dump at least), catch can, bypass SAI, Intake manifold, etc etc.

Lots of reading on here, Polo UK and Cupra Forums. Were here to help.

[instigator]

my best friend did a frankenturbo upgrade.
that why i'm telling it, verry currious to see 300Hp happen
i do have to say, it's not tuned at his max, running about 250Hp and being equally fast as my GTI.
it's set a bit safe because he does alot of trackdays.
in the states they do make 300Hp with a hybrid, but never believe the states, they allways will have more, but irl it's less.
but it's a verry good set up for the money, he paid the frankenturbo kit with injectors, bigger MAF, hybrid turbo, manifold etc as much as he would pay a K03s turbo.
but don't expect TO much of the hybrid. it gives good power and torque but higher as 265Hp... don't think it's possible.
we have tested the characteristic levels of the Frankenturbo hybrid against my K03s.
both having about the same power and torque i guess, we still need to do a dyno to be sure.
in 2nd gear, 50 - 220Km/u we are equally as fast al the way.
3the gear you see start to see the charactistics. low rpm K03s spools slightly better and polo takes the lead.
but once above 3500 - 4000rpm the ibiza start to crawl back and gets besides me again.
4the gear the ibiza is a bit stronger.
K03s would take the lead but not by much, a hoodlength in frond or so.
but the ibiza is def. stronger in higher RPM and crawls over me, taking also a hoodlenght.
5th gear polo is stronger, slowly getting away to a point where it stops.
after that still going equally as fast.
do note that my K03s in my polo is at his max making 1.5bar at some points.
his Hybrid is not at it's max but also making 1.5bar but it's capable of doing 1.6bar easy.
but the powerband is totally different between each other, almost not compareable.
i'll try and make a movie when we are going to test again.
but if you want to know something about the frankenturbo just ask me, i can ask my friend or the guy who installed it.
both pro guys who know what they are talking about.
i do think a good K04-001 set up would be as powerfull as the hybrid version.
only thing is, the hybrid will be a safer set up and would probably cost less.

another short thing,
you can't compare the hybrid k series with a IHI or Garret GT28.
the hybrid is a much smaller turbo wich spools quickly still.
the IHI or GT28RS etc are "big"(er) turbo's wich give power in high RPM.
example, hybrid start to pull at around 2500rpm and gives his full power @ 2700rpm,
but it builds his power down to 1.3bar near 6500rpm
K03s builds up at about 2300rpm and gives full power shortly after at 2500/2600
but it gets out of breath at 5500RPM, making 1.1bar at 6000rpm (wich is pretty good for small turbo)
and then there is the garret or IHI, they start pushing at about 2700rpm and gives full boost at +-3000rpm.
but when they spool, the will hold power all the way to the red line @7000rpm.
so the powerband is not just different, but completly off the scale of a K series.

a turbo has its "working field"
and you have to make youre own descision about where you want this working field to be.
depending on what youre goal is and where you want to use the car for.
good thing is, for 1.8T they have made manifolds for about every avaiable turbo on the market

[vwthunder]

Got the Frankenturbo on, and a GIAC program loaded, I dont think I will make the power i was after lol.
Still have to play around with the tuning and get more logging, as the roads were wet last night and it was wheel spinning at 120km/h.

Yeah it feels ok, pulls harder higher up, which a K04 is supposed to do, more smooth powerband, more like a N/A car.

I did notice more heat soak, with the scan gauge temps on my dash

More updated as we progress

[minifreak]

hmm 120km/h on an open road....lol...be carefull police might read this like you once told me..lol..

[firdausasri]

Instigator,

Thanks, it's not really fancy stuff but the rest is pretty good and on the money. For me, I'll be sticking to K03S as I find the only different with K04 is quite marginal at high revs, the K03S's compressor is bigger anyways.

[vwthunder]

Haha maybe, it was on the freeway, looked like 120, i was in passenger seat, so it might have been 100 lol
Wasnt me driving anyway

[instigator]

NP

VWThunder, you haven't got a intercooler yet on youre car??
do that asap and you will have more fun with the frankenturbo hybrid, it will hold its power wich you do need with that sort of set up.
i do know what you mean, also noticed it that the hybrid comes in more smooth as where a K03s realy burst in at low revs.

btw, wich hybrid version you have, F4 or F23?

[vwthunder]

Yes it has a Forge Intercooler

It was fine on the K03 but now I really noticed it not standing up to the job

Might get a custom one and some water meth are on the cards