Petes Polo goes big

[vwthunder]

Wow that is awesome, thinking of all the things that could be made, hmmmmmmmm

[noone]

Re: Petes Polo goes big

Wow. Very impressive

[AntiFun]

Objet Connex printer for more info on the machine.

I knew this looked like a 3d printer job, that's so awesome! I never even considered 3d printing in automotive applications..... This might be a good work around here in vic for those who need a stock filter box for RWC.... How much did the plastic cost you all up if you don't mind me asking...

[VWindahouse]

Next level Pete

[Bullet Fast]

Sorry mate, too much to publicly disclose.

Sent from my GT-I9505 using Tapatalk 4 Beta

[Bullet Fast]

So everything is done. Minus a final tune and a dyno for fun. Essentially stage 3 custom code with all the regular upgrades and a FT21t.

Long story short it's fairly exhilarating. Very point and shoot. But it does needs better brakes, bigger wheels and more suspension. More to follow.

Sent from my GT-I9505 using Tapatalk 4

[Bullet Fast]

And more to follow now.

So Gav has come by, fixed a niggly adaption issue and do some logs and the car runs like a champ. What'd we say Gav about 280 peak crank hp? I'm not sure how much a reflash will tidy up the tune, but boost could probably be throttled back a bit. Peak manifold boost is showing up to 26psi... I've got two 'helper' extension springs on the waste gate actuator that about 2psi to the crack pressure each. FWIW I ditched the FT waste gate it looked and worked like rubbish.

I tested the stock waste gate on the turbo with a boost gauge and hand pump, cranking the rod didn't change stock waste gate opening pressure beyond 1psi. Barely wound up the waste gate opens at 6psi with about 25mm of lift but cranked up it lifts about 5mm at 7psi. At least in my mind that myth is busted. Strapping a couple of springs on the outside adds 2psi crack pressure each. Two springs nets about 22-24psi of boost, if I take one off it pulls only 18psi and runs like a slug. Comparatively speaking anyway.

Stuck a New South boost gauge in the drivers side aircon vent, breaking 3 out of 4 plastic clips in the process. Running the wires was a nightmare but the pressure line off the inlet manifold went straight in.

I've got some tt front calipers and carriers getting tidied up now. They'll get some vht red paint and seals. Tossing up solid bushes... Not sure if they're available; they can always be made! But no rush. These will get some braided lines, I've been quoted $100 per line for ADR compliant jobs which are the labelled, swaged type, not sure if this is reasonable or not just yet. Pads too, EBC green stuff is a personal thing but whatever comes. Rotors are annoying me though. Discs aren't cheap. DBA have a few sport discs left over at like $200ea! Can save about $50 through ebay. Yeehaw! Id be happy to machine some second hand ones if there's any lying around...

The front really needs a bit more anti roll too. Either the pedders or Ultraracing. At least the pedders are a little adjustable. I'm dreading putting it in. Really thinking about paying someone to do it for me! Engine cross brace too, I'm hoping the Ultraracing one will fit over the airbox as per the other thread. Me and another guy at work are talking cro-mo bar running straight across the top. There room for a 30mm bar/tube going barely in front of the ecu, and turning to meet the inner wings flat, nailing the two closest bolts together. There's probably $75 bucks worth of cro-mo bar and 5-6mm plate, and the pain in the arse of bending alloy steel and welding... I'd guess four hours and then it needs paint... Makes the Ultraracing brace a bargain!

What else? The shift plate bushes and cable end plates. I'm keen on a set of those two. I've got brass and bronze off cuts at works which would be sweet for the cable ends!

And that's about it! Missus goes away Friday night for the weekend so it'll be a mountain biking and machine shop weekend! Yeeeew!

PS same guy with the engine cross brace suggested we replace the entire middle section of the front bumper with a massive machined infill plate to help the intercooler breath, complete with hexagonal holes! In his own words he hears voices at night that tell him to make things!

[Bullet Fast]

I'm trying this at the moment with mixed success. I'm finding the caliper binds on brass bushes fairly easily. It might be fit related, ill try and get it a little tighter but I think ill end up with regular bushes instead.

[Stuwey]

Tyrolsport kit?

[seangti]

I'm trying this at the moment with mixed success. I'm finding the caliper binds on brass bushes fairly easily. It might be fit related, ill try and get it a little tighter but I think ill end up with regular bushes instead.

What's the compressive and tensile strength of brass like? I can't quite understand which part of the car I'm looking at in your photo (guess brakes given your reference to caliper) and what sort of force is being applied to the brass bushing, though I'd have thought brass would be too soft for many automotive applications. I'd also consider it's fatigue rate. I'm no metallurgist and really only drawing on 1st/2nd year engineering principles.

My internet at work is playing up, otherwise I'd have checked compressive and tensile strength before commenting. Better to be safe than sorry.

RE braided lines, I looked at getting some directly from HEL in the UK, worked out about the price of sourcing the same gear locally.

[h100vw]

Tyrolsport kit?

Pete is making this stuff at work. Too much spare time on his hands.

[Bullet Fast]

I wish I had more time, I do all this after hours. I need to get a bit more back from the man.

Sean these were done up in brass. Tyrolsport are using bronze, probably an alloy. I've got to some sizes and clearances I'm reasonably happy with. Next step is to try bronze, on one caliper and see if its noticeably less draggy. The last set I made this afternoon move quite nicely. Compressive strength shouldn't be a problem. Grease might be though.

[Eddy]

Tyrolsport kit?

Hoyhoy.

Stu, only for when ya upgrade to the 312mm front rotors using Audi TTMk1 calipers.


Tyrolsport brake caliper stiffening kit