Sam's build thread

[Stuwey]

Eddy's old bus? Nice place to start! It'll be interesting to see how it compares in performance to your previous.

[sambb]

Yep. I'm so lucky he was ready to sell it at the time of the crash. Honestly if I hadn't had that offer I wouldn't have kept on with a Polo. If I was going to have to more or less start over on a stock road car then there was no real reason to stay in the VW camp. Like any write off on a modified car you are well and truly out of pocket even if its not your fault so Eddys car was the only way I could get back out on the track and also be able to recover dollars lost from the old cars wreck. His car is pretty much complete. There are a few bits and pieces that will find their way across to the new car because they are either newer on better spec and a few setup changes and service things to be done but really I could do an event tomorrow.
Setup is such a personal thing and the car due to its suspension spec and particularly the diff is completely different to drive. I'll take the time to get used to it because I think its fair to say that with the clutch LSD the car will tolerate more front end roll stiffness than my wavetrac setup did. The diff locks up much more abruptly than the wavetrac and I need to take the time to work out if thats a service issue ie oil, friction modifier, a legacy of having had Shockproof in it or if thats just how it behaves. It honestly feels like how I imagined running a welded diff in a FWD would be when it is locked up. Civil as anything when not locked but pretty mutant when it is. If thats how its intended to behave though I'd probably need to think about just how much caster and rim offset is appropriate because it'll be much harder to hang onto than the wavetrac diff in the tight stuff with as much as before. Its going to be weird when all the power under your foot can actually make it into the road!

[sambb]

APR intercooler vertical single pass. Still a tube and fin design. A lot of the airflow to it is obscured by the crash structure though. I'll have the SEAT Sport one on hand in case its temps look to have been better than the APR one.
The brake ducting. When you look under the car there's probably more than enough air feed just from air running under the undertray, but they are also fed by fog facia ducts that conduct air through the engine bay and then out into the wheel well through the convoluted tube you can see there. Like I said RE tweaks - I'd probably look at making these removable just so that every piece of crap off the road doesnt squirt directly into the brakes and I wouldnt want a good puddle to damage them.

Compomotive MO1681's 8Jx16 ET35 with 225/45/16 A050's (18kg total) which is same as a stock rim/wheel. Need to switch to 225's now as my 15's wont fit over the TT Mk1 brakes. Any 225's kicking around Gary? I'll swap you some 215 and 205/50's!
RE tweaks again - while the front brakes will be awesome I'm not sure if vented TT discs with the bigger calipers are needed on the back of a Polo. They'd add a lot of unsprung mass to the rear suspension and on a 64:36 weight split FWD car (well different to a 4WD TT and much lighter overall) I'm not sure they'd be needed. I think I remember people saying that the addition of the TT rears with the Polo master cylinder starts to make the pedal get a bit long too. Easiest way to remedy all of the above if its an issue would be to just swap in my entire complete rear beam including all the toe shimming I'd done, with the brand new T2 discs and rebuilt stock calipers but again I want to drive it in anger first and get a feel for whats going on before I make any decisions like that. It would all be fully reversible though even if I did do that.
This is Eddys brace. I think the flange is cut off the base of a stock engine mount and then the bracket welded to it extends to the master cylinders snout and has adjustment in it. The flange I think is mounted vertically onto the inside of the strut tower but how I don't know. Could be Riv-nuts or through bolted with a backing plate - don't know yet. Its the kind of thing thats effects wont really be felt till I'm on the track.
Eddy should have this up on his wall. Great Pic! My old car was definitely not quicker when going over the kerbs to that extent as the diff would have just opened and then had a little wobbly when it landed again. Would have to be one of the main reasons why I'm 7/10ths off his best Wakefield time. Also I was on 205 A050's when I did my time. So pretty excited to see where i'll get it to!!!!

[HaydEn]

Attachments no good


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[metalhead]

Yeh, attachments not working for some reason? But yeh, sounds great. The clutch diff if setup aggressively will lock up solid under power. Might take some driving adjustments, but as you say is likely to ultimately be faster. Look forward to seeing it!

[sambb]

[sambb]

Can anyone tell me what the hell an original K04-001 actually is. I've read everything from a K03 comp wheel/K04-023 turbine to K03s comp wheel/K04-015 turbine. Also read that the wastegate port is bigger than a K03 and that they have a stiffer wastegate spring because of that, but who knows. The problem is once upon a time K04-001's only came out of APR and then a bit later there were ED05's. Now though after the chinese got into them, the word K04-001 has come to mean just about anything. Pretty sure this is a genuine APR K04-001 with the APR K04-001 4 bar fpr tune. I think it was referred to as their Stage 3 kit back then but by todays standards its about as far away from Stg 3 as you could get.

[HaydEn]

K04-001 came factory on the 20th/337 anniversary MK4 GTI’s


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[sambb]

did it really. ok. I had seen it referred to as a Borg Warner but I thought when I read that, that it was someone talking about the K04-023.
I always thought The K04-001 was just APR or ECS or someone like that doing there own machining and bunging some bigger wheels into a K03 frame. Stoked that its a BW then. So mine should have a BW placard on it then - i'll have to get in there with a mirror and see what the go is.
Any idea on what the wheels sizes in it are?

[HaydEn]

No idea on wheel sizes. Small!

They aren’t much more chop than a K03, just ‘easy’ as they use all K03 plumbing.


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[sambb]

From what I can gather they are a K04-023 turbine (audi S3/TT) but they use a compressor that is
inducer 35
exducer 50
tip height 3.7mm (same tip height as the oldest K03)
12 blade (2 pairs of 6)

This compressor is even smaller than the Polos K03s which is
inducer 38mm
exducer 51mm
tip height 4.4mm
blades 4/4 (4 long 4 short - 8 total)

Seems you can take a K04-001 with its bigger hotside and put the bigger K03s compressor wheel straight onto the shaft (balanced of course) inside the K03s compressor housing that it came with on the Polo - all lego. No idea if that slightly bigger compressor being driven by the K04 hotside will surge but theoretically a K03s/K04-001 should push slightly more air. I have all the bits to do it and it would be nil cost except for balancing. No idea where to get a shaft balanced though. anyone?

[h100vw]

Buy a known turbo Sam. Swapping out one that didn't perform after putting time and effort into it. Plus tuning. Then doing it again. Even without labour it's a painful experience. I dont even like doing it and getting paid for it��.
I have ported 3 manifolds and sold them all. Still not done my own car yet. Even after seeing what an improvement it can make over a stock one. #toohardbasket

[Sydneykid]

That's a nice Polo Sam, sounds like it will be really good with some of your bits on it.

No idea where to get a shaft balanced though. anyone?

GCG Turbos at Condell Park.

We have some 225/45/16's, I'll put them aside for you. They are about half worn, long story for another day, but the current set up is fast (SMSP = 1.42's & WP = 65's) but hard on the tyres, so we will be moving to new tyres more regularly.

Cheers
Gary

[sambb]

PM'd you RE tyres Gary!

[sambb]

so parts to come are:

- 4 x enkei RP01's (not RPF01) 15 inch x 7 inch 7kg
- 4 x Yoko A050 medium compound 205/50/15 used but still enough for a couple of track days
- 4 x Yoko A050 soft compound 195/55/15 well used but great for hillclimbs on ......
- set of VR6 15inch x 6.5 inch OEM rims
- 1 x 160,000km engine
- DBA T2 slotted front discs & ferodo DS2500 pads
- OE exhaust manifold
- dogbone with superpro big end bush
- most likely a full 2.5inch exhaust system (dump + cat + cat back)

so PM me to let me know if you're up for any of those bits and we'll work out a price. There'll be more to come as I get deeper into it and change from just wrecking the old car to actually starting to build onto the new one.