davegolfturbo - "GT2X hybrid build thread"

[davegolfturbo]

After seeing a few cars this year at the shows I decided I wanted to buy the window deflectors which I think set the car off really nicely!

The next mod which I decided to do was to lower the front end of the car.

Lucky when I went to a one of the shows a lad was selling a set of front coilovers for the 1.8t golf. To my look these were the exact same match for my rear ones so for £40 I snapped them up…what a bargain!!!!

Before I could put them on I needed to get the threads re done, but with knowing someone who works for BNFL (engineering) it wasn’t so hard to achieve!

So I was now a lot happier with how my car looked!

later on in they year I decided to get some brand new 19” rs6 replica alloy wheels with new tyres, I was going to go for the BBS LM’s  but with so many people having them I decided against it, presides I think mine really suit the car, especially with the new drop and spacers!

[davegolfturbo]

Stage 4 - INJECTORS

Originally I thought the turbo that was in the car was the GT28rs eliminator, for that turbo you need to run the big injectors revo recommend the genesis 550cc ……after looking everywhere for a set of these I had to bite the bullet and buy some brand new ones with adaptors from ‘Backdraft motorsport‘. These cost me £365 at the time inc P+P

Later on did I find out that my turbo was not the gt28rs but it was the GT2X. This meant that the injectors were incorrect for the turbo that was on my car!

To cut a long story short again I sold the genesis 550cc ones and bought some 390 bosch ones from the 225 leon cupra r! these were now the right injectors for my turbo!

[davegolfturbo]

Stage 5 - 3” MAF

Next I bought the 3” MAF sensor, I managed to source this second hand from one of the forum members.

The only thing left to do now was the induction kit and then I could finally go and get the car  mapped.

[davegolfturbo]

Stage 6 - FORGE INDUCTION KIT

I sourced myself a forge induction kit

finally the map is comin...

[davegolfturbo]

TIME FOR THE MAP.

As it had been a long time since I spoke with ADS (revo) id been speaking to a few various people  at shows and a guy called Wayne Schoffiled kept coming up. He is very well known for tuning some of the fastest Porsche cars and specialises in custom mapping. So I decided before I take my car back to ADS I will look into it a little bit more.

I rang Wayne at chip wizards in Rochdale, and spoke to him about what he could do. It was quite obvious following the conversation that he knew exactly what he was on about  and I decided to go for a ‘custom map’ not a ‘generic map’ which is what I would of got from ADS!

Before the map, I decided I have spent so much money on the car I would rather take the turbo off and get it re conditioned so I know it is perfectly up to the job and it wont give up on me a week after having the map!

I knew a few people on the seatcupra forum and one of the lads had done the exact same conversion that I was doing. He recommended me to go to CR turbos and see what they could do for me.

After the phone call to CR turbos I decided for the extra £150 I was going to hybrid the turbo!!!!! :D

So I had a month until the car was due for the custom mapping session with Wayne and I had to get my turbo of recondition it and get it hybrid’d!!!!

First thing was cleaning out our old garage which was full of gardening equipment and all sorts of rubbish that was no longer needed. And turned it into my ‘Golf workshop’ !!!

[davegolfturbo]

Stage 7 - GT2X hybrid

First thing first was getting the old turbo off the car! This was a task in itself but after a lot of hard work the turbo was off!
Whilst taking the turbo off, I could see that who had ever put it on in the past had not done a very good job at all, all the hose clamps were loose the TIP was not securely fastened to the inlet of the turbo itself. And there was a few boost leaks around the fittings.

I boxed the turbo up and off it went to CR turbos. They told me it will be back to me within 3 days.

Came home from work and there it was in a box with ‘CR turbo’ stamped all over it!!!

The guy on the phone said that the turbo come from ATP and they don’t design or make it very well! He told me that he has now reconditioned it to a garrett turbo and it is much better,

The work he did on the turbo was;

- 360 thrust bearings
- polish internal housing
- New improved compressor wheel
-New internals
-New seals
-Uprated actuator arm

Whilst the turbo was off I got recommended to buy a new manifold that was a lot more free flowing that the original one! So I unbolted the original and got an ATP one on order! (my god that was hard to fit required bent spanners, a  mirror, and a lot of time!!!

I then spent that night getting the tutbo all bolted on! Obviously I bought new gaskets, bolts, studs etc which was needed and some new oil for the engine!

Primed the turbo up and went for a drive I covered at least 250 miles before taking the car to be mapped

[davegolfturbo]

some pics of the vw garage, manifold and turbo bfore it got sent in!..

[davegolfturbo]

here are also some pictures of when i got my 'hybrid gt2x' back! 

[davegolfturbo]

FIRST SESSION - CUSTOM MAP

I arrived at chip wizards with my car all ready to go…or should I say what I thought was ready to go!

I asked wayne to do a power run before mapping it so I could see what it was running! The car reached 284bhp which I was very surprised with! But was running very lean towards the top end and rich in the middle!

When the previous owner chipped my car they used a chip instead of  just mapping the ECU this meant that it was anti tamper proof and Wayne could not get into the ECU to write over it! He said he had to do it the old fashioned way which meant splitting the taking the chip out and doing it that way!

So off he went into the backroom to start modifying a few base files to run with the larger injectors and 3” MAF once he did that he was then able to start the power runs and start adjusting the parameters!

I must say watching you car reach 164mph on the rollers is not a nice thing. Anyway he kept trying to make the turbo come in sooner but for some reason it was not acting as it should he seemed to think it was something to do with the actuator ( if it was opening and closing properly) after a few more runs he managed to get the car running 194bhp with 1.5bar boost! But he said it still isn’t acting how it should. He also seemed to think that the car was not supplying the correct fuel pressure high up in the revs. It was getting late now and we had already been there for hours!

Wayne suggested that we put a fuel pressure gauge and see what was happening to the pressure as he gave it another power run…the results were that my car could not be mapped and I needed to get an uprated fuel pump! Not only that but the something was not right with the turbo!!! I was so angry and disappointed as id been waiting so long for this day and it all went wrong! (what can you do it’s a tuned car !) lol

So I rang the turbo place and explained what had happened, they said if I take the tubro off they will re look at it and make sure everything was right from there end. Obviously it was a pain for me to have to do this…but again to cut a long story short it was time to take the turbo off……..

Took the turbo off and noticed a main thing…..the exhaust wheel was much smaller than the exhaust housing! This would explain the ‘slow spool’

After speaking with CR turbos for the next 2 weeks they were very helpful, fixed the problem and sent me the turbo back with a brand new style actuator, which worked a lot smoother and  better , fully reconditioned it again and bored it out putting larger internals in it meaning there was no longer a gap between the housing and the wheel for pressure to excape…now it was an even bigger turbo!!!

[davegolfturbo]

some pics from the session

the morning before the big day!