Pocong Build Thread

[firdausasri]

Hi Guys,

I just would like to share with you my humble Polo GTI from Kuala Lumpur, Malaysia. Mildly modified and as it comes to fifth year anniversary, the car is currently at workshop undergoing turbo transplant with necessary kits to push the power figures slightly upwards.

Next upgrade would be LSD, stg2 clutch and beefier front and rear brakes. Hopefully..

Engine
Stock VAG BJX 1.8T 20V
FrankenTurbo F21T turbo (new)
FrankenTurbo exhaust manifold (new)
Mitsubishi Lancer Evo3 intercooler (500mmx300mmx65mm) with all new custom piping
VF Engineering Race Bypass Valve (relocated)
Wahle 80deg thermostat
3” MAF (new)
K&N open-pod filter with heat shield

Exhaust System
Custom 2.5” catless downpipe
Custom 2.5” exhaust piping
Blitz Spec Nur muffler with custom silencer

Electronics/Engine Management
Stock Bosch Motronic ME 7.5
Genesis 415cc fuel injectors (new)
VW 4bar fuel regulator (Stock 3bar fuel regulator can be refitted if necessary)
Unitronic Stg 1+ Reflashed
NGK BKR7E (0.028 gap) copper plugs

Transmission & Drivetrains
VAG 02R 5-speed manual
ECS Stg 1 Clutch Kit
ECS Single-mass 14lbs flywheel

Suspension
H&R Monotube Coilovers
Seat Ibiza solid-rubber front bushings
Ford Mondeo’s ARB links
ECS PU rear axle bushing kit

Brakes
Front: VW 312mm x 25mm vented rotors
Front: Single pot ATE 54mm calipers
Front: EBC Red Stuff pads
Rear: VW 232mm x 9mm solid slotted rotors
Rear: Single pot Lucas 38mm calipers
Rear: EBC Red Stuff pads
ECS Steel braided lines

Wheels & Tyres
Wedsport SA70 17x7.5 rims
Federal 595 RSR 215/45/17 tyres

Dyno tests:
178.57whp/253.67nm on DynoJet
174.6whp/288.7nm on DynoDynamics (10/12/2010)
216.40whp/326.97nm on DynoJet (16/07/2011)
205.13whp/304.5nm on DynoJet (19/08/2011)

[firdausasri]

The Car


Sunday Drive with Gojiras


Engine Bay


Idea Behind Custom FMIC


Evo3 Intercooler


Engine Bay (Close-up)


Discreet Front Mount


H&R Monotube Coilovers


With H&R Coilovers


Suspension Setup


Wedsport SA70 Replica (Resprayed)


Custom 2.5” Piping


Blitz Spec Nur



Genesis 415cc Injectors


FrankenTurbo F21T


Compressor Map


Comparison Between K03S with F21T

[team_v]

Looks great!
Might be worth looking into a lightweight battery or a relocation to the boot.

[firdausasri]

Thanks, I'm also looking into possibilities of relocating the battery to the boot. That allows me to have bigger and better induction system

[Deadpool]

Wow, stunning build!

Thanks for sharing.

[Redliner]

Looks good.
Your engine bay is nice and neat.
The wheels suit it. Are they a standard fit or did you have them redrilled?

[h100vw]

Thanks, I'm also looking into possibilities of relocating the battery to the boot. That allows me to have bigger and better induction system

No need to mess about like that, you can fit all manner of smaller batteries in the front. Check my thread and the little red devils for starters.

Gavin

[cylinderhead]

Pocong Build Thread

Good to see a fellow malaysian here.

Polo looks very tidy. Keep it up.

[kaanage]

my humble Polo GTI .... Mildly modified

I beg to differ

Nice car, though I'm surprised it doesn't bottom on the roads over there

[VWindahouse]

Amazing stuff mate! Especially love the Intercooler set up.

But I don't think those fuel injectors are meant for the polo. Could be wrong but I think you'll find the spray pattern all wrong plus I would be surprised if the fit in the intake manifolds injector seats. You need the EV14 style injector I'm pretty sure but check with your installer.

Keep up the great work!

[h100vw]

Amazing stuff mate! Especially love the Intercooler set up.

But I don't think those fuel injectors are meant for the polo. Could be wrong but I think you'll find the spray pattern all wrong plus I would be surprised if the fit in the intake manifolds injector seats. You need the EV14 style injector I'm pretty sure but check with your installer.

Keep up the great work!

They look like AEB stylee ones.

[noone]

Nice toy there... I remember reading your blog years ago.

I'm interested to see quite a few power and brake mods, etc, but minimal handling and suspension bits. Its pretty common in Aus for us to slap on swaybars, braces, etc. Is this something you're not seeing the need for?

I think you'll have fun trying to get that extra power down, although you're running nice tyres which no doubt helps.

Keep it coming...

[firdausasri]

Hi Guys,

Thanks again for the compliment. Most of the mods here are inspired by the works that you guys have done. It is a German car, manufactured in South Africa, aftermarket parts mostly from USA, tuned by Canadian, inspired by Aussies, styled to be Japanese and modded by Malaysians

Hi Redliner,
Although they're replica, it's almost a standard fit provided if you get aftermarket cones. And no redrilling needed if I recall correctly.

Hi Gavin,
Smaller battery is definitely a good idea!

Cylinderhead,
Glad to see you too

VWindahouse/Gavin,
The intercooler was done by couple of Myanmese working for friend of mine. Their welding or artwork is pretty good.

Injectors. Now you get me scared mate
I did went to USRallyTeam.com, basically Genesis provided two options:
415cc for VW 1.8T small port (which is this one): Genesis 415cc - High Impedance (1.8T small port/R32) : USRT, Usually Sideways Rally Team
415cc for VW 1.8T big port (AEB, AGU): Genesis 415cc - High Impedance (16v/AEB & AGU 1.8T) : USRT, Usually Sideways Rally Team
Which one should I go for? Better ring my mechanic asap

Noone,
I crave for handling mods too but I don't find much improvement on chassis braces since the car itself is pretty stiff to begin with. But I'm searching for good sway bars front and rear to get better feel from the steering. The Polo really has weakness in this area in comparison to FD2R, Megane 250 and even my daily workhorse Proton Satria Neo. And electric steering makes things worse

My Satria Neo still in stock standard


Would mind to do something like this provided Honda K20 engine is inside the bonnet

[h100vw]

I'll measure you up a standard one shortly and let you know the dimensions.

Gavin

[VWindahouse]

Hi Guys,

Injectors. Now you get me scared mate
I did went to USRallyTeam.com, basically Genesis provided two options:
415cc for VW 1.8T small port (which is this one): Genesis 415cc - High Impedance (1.8T small port/R32) : USRT, Usually Sideways Rally Team
415cc for VW 1.8T big port (AEB, AGU): Genesis 415cc - High Impedance (16v/AEB & AGU 1.8T) : USRT, Usually Sideways Rally Team
Which one should I go for? Better ring my mechanic asap

The second ones look like the correct shape and length bud.