I bought my mk4 back in 2009, Jazz blue 2000 Agu. Completely standard apart from it had been lowered on coilovers with 19" multi spokes and a forge 007p dumping to atmosphere!? Soon sorted that.
My plan was never to mod it as was happy with it as it was but soon got bored with the power and after joining the forums started planning what my next mods was going to be.
My first plan was to get a hybrid k03 and just stick with that but then thought im gonna do this once well allowed to do this once(missus) so I better properly, so started looking at big turbos.
I was a welder and fabricator working for my old man a few years back so I thought I could do most of the work myself and make exhaust manifold, downpipes and exhaust to save money. Never really done much engine wise but thought the best way to learn it to do it! and had this workshop at my disposal
So I decided on using a TD05 16G because you can pick them up cheap they spool quicky, give good power and dont break easily. Read qiute a few things on Ihi's going bang and defo didnt want that!!
So I made a list of things I needed and started buying them. Took my car off the road and my parents kindly let me use their garage.
The spec what ive bought so far
TD05 16G with forge actuator
Twin scroll exhaust manifold
3" downpipe and full exhaust with sports cat
RC 500cc injectors
Custom 3" TIP
Silicone vac and coolant hoses
Intergrated Engineering Forged rods with Pec big end bearings
water/meth injection Aquamist
whiteline anti lift and rear eibach anti roll bar
Fmic
Brembo lcr front brake setup with fedro pads, braided hoses and Ate superblue
256mm rear brake setup
Walbro intank 255 fuel pump
Hks Evc 6 electronic boost controller
THS FR3 engine mounts
So I started stripping the exhaust, downpipe and K03 off and found myself a turbo.
Td05 next to the K03
Got a new clutch and flywheel the VR6/G60 combo and fitted that. As well as silicone vac and coolant hoses.
Then ordered flanges and SS bends and straights to make the manifold.
This took a while to get right but finally did so I could top mount the turbo.
I then got a Forge actuator and made a mounting bracket and fitted that on the turbo so it would all fit in the bay.
My brakes and Ths engine mounts arrived and got fitted
Aquamist 1s came and I fitted it in the bumper bar and will be using the washer bottle for now.
More bits and pieces arrived so I got a new oil pump, water pump, cam/aux belt kit, piston rings, Pec big end bearings, gaskets and plenty of lubes and oils.
Then I started taking the head off ready to put the rods in.
So I cleaned the gasket off and started cleaning the pistons and fitted the rods.
I kept the standard forged pistons so I just cleaned them and put them back in with new rings after honing the cylinder.
Put the head back on with new gasket, timing belt, water pump. Removed AC and put the smaller belt on. Thought id spay the rocket cover and polish up the inlet manifold.
Fitted new fuel pump and modifed swirl pot (thanks Jamie16v for your guide and help).
Put the inlet manifold back on and trial fitted the catch can and started making up the TIP ready to weld the pipes on.
Thats as far as I have got so far hopefully this wkend I should finish making the TIP then ill start on the turbo downpipe.
Fingers crossed it will be ready for mapping in the new year.
