Author Topic: k04 hybrid finished - 350bhp and not a big turbo in sight!  (Read 11005 times)

Offline jamie1989

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #30 on: 22 November 2012, 16:45 »
This thread makes me want another  :cry:
1.6-1.8t AGU K03s, Forge actuator, Forge 007p, turbo back exhuast, Ths front mount, Catch can, 5 piece silicone boost pipes and creation sports tip. Stage 2 atm 232bhp 270lbs. Waiting for custom mapping :-)

Offline Chris.

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #31 on: 22 November 2012, 16:46 »
Shouldnt have sold up!

I need more boost in my life, but seriously trying to hold off the idea, until new one is done,

Click For Build Thread

248bhp  278lbft R - Tech Powered 1.8T!!  - Gone but NOT forgotton

Offline ReadieeVTS

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #32 on: 23 November 2012, 20:53 »
Hey mate did you say littco down the hybrid for you? whatK04 turbo is it and what internals did he use also how much did he charge. Sorry for the questions just love the build you've got!

Offline Prawny

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #33 on: 23 November 2012, 21:51 »
Dan (Littco) rebuilt the turbo for me yes mate, although it's originally built by CR turbos

It's a ko4 frame, with a RS6 turbine wheel with 7 degree clip, and a 2283 billet compressor wheel. B5/Littco ported hotside, and a 1 bar actuator. Price wise I couldn't say, as Dan just rebuild this one. The original unit from CR was around £950, but I believe Dan can do them for much less.

I havn't got my own build thread, so I'll add todays excitment in here instead:

I bought a VW Motorsport Billet alloy shifter :)


It won't make the car any faster, or lighter, but it will make me smile every single time I use it, because it's just so damn cool. It's something I have wanted for YEARS since I first saw one on a race car many years ago.









The unit seems really nicely made, both the pivots are on bearings, and it has an awesome little lift collar to engage reverse.



The only complaint I could find about these, was the lack of self centring on the lever from left to right, so I decided to try and come up with a solution.

That's where a tractor brake pedal return spring comes in.

it'll be fitted over the main shaft like this:



But in between the unit body, and the main left-right pivot body, with 2 small dowel holes drilled for the tangs:



With careful placement, that should see the lever springing back to centre nicely.

The reverse lock out is also really cool. In normal operation, you push left for first, the these adjustable stops hit this pin like so:



Then you pull this little lift collar:



Which pulls this bike gear cable:



And the pin slides back, allowing you to move further left for reverse!



The welding on the alloy tower supplied seems strong enough, but it's not very pretty, so I'm going to attack it with a flap disc and some wet n dry, and paint the tower Porsche 8C6 orange to match the cage and things.

Cable wise, I've got a set of shift cables from a volvo S40 which are longer to allow me to position the lever where I want it, and I'll be making up custom cable stays from 3mm plate, and of course, painting them orange too.

The ball joints I showed earlier, will go on each end of the new cables, so it'll be solidly mounted at each end of the cables for a really tight shift without any rubber in there.

Taking the volvo cables, and cutting the ends off, you can run an M6 die down the rod end and cut on an M6 thread like so:



Then with the aid of an M6-M8 adapter, I can convert the cable ends to an M8 thread:



Then screw on my ball joints:



Sorted! If I need to extend the cables ends at all due to stay placement or anything like that, I also have some M8 threaded sleeves, so I can fit a sleeve to the M8 male end on the cable end, then use some M8 stainless thread bar to get the ball joint exactly where I want it and lock it out with lock nuts.

It's a complete experiment, and I'm sure it'll feel rubbish at first, and take considerable setting up to get it right, but I just love these shifters so much, so here goes!

Offline Wazzzer

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #34 on: 24 November 2012, 12:21 »
Shotgun a ride out at JKM :afro:


1999 1.8T: R-Tech remap - 225bhp/256lb/ft : K03s : THS FMIC : THS PCR pipe : 2.5" stainless exhaust : THS FR3 Engine mounts : G60/VR6 clutch : Calibra Yellow injectors : VR6 MAF : Devils Own WMI : Forge 007p : Carbonio CAI : Leon Cupra R Brembos : FK AK Street coilovers : Votex skirts : Anniversary front : click ---> http://www.golfgtiforum.co.uk/index.php?topic=92175

Offline Prawny

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #35 on: 24 November 2012, 14:43 »
Sure man. Have been working on bits for the shifter today. Wanted to try and fit but weather is horrific here!

Offline Wazzzer

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #36 on: 24 November 2012, 15:19 »
Same here mate, it's been raining non stop


1999 1.8T: R-Tech remap - 225bhp/256lb/ft : K03s : THS FMIC : THS PCR pipe : 2.5" stainless exhaust : THS FR3 Engine mounts : G60/VR6 clutch : Calibra Yellow injectors : VR6 MAF : Devils Own WMI : Forge 007p : Carbonio CAI : Leon Cupra R Brembos : FK AK Street coilovers : Votex skirts : Anniversary front : click ---> http://www.golfgtiforum.co.uk/index.php?topic=92175

Offline mar_k

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #37 on: 25 November 2012, 18:23 »
Prawny, What spec is the rest of the engine?
I take it your running steel rods and forged pistons?

Offline Prawny

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #38 on: 26 November 2012, 04:58 »
Interally, it's pretty much a stock engine aside from the rods. AGU block/crank/pistons

All rebuilt, new rings/shells etc etc, with DM forged Rifle drilled rods, and a baffled sump, but otherwise it's standard on the inside.

Next weak point would be the exhaust valves, but they're not a worry if you're keeping the revs down, and my limiter is set at 7400 :)

http://www.youtube.com/watch?v=V8tnV2L7Dew

Offline xtetx

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Re: k04 hybrid finished - 350bhp and not a big turbo in sight!
« Reply #39 on: 26 November 2012, 08:49 »
Sure man. Have been working on bits for the shifter today. Wanted to try and fit but weather is horrific here!
+1 its minging, non stop rain, cant get anything done