MK5 Golf GTI
All Things Mk5 => Members Rides => Topic started by: Chipmunk on April 26, 2012, 06:00:05 am
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Hi guys and girls, on my K03 setup the most power I ever made was 204 kW/274BHP, mods : Software, 76mm Evolution Downpipe, Devils Own WMI, Forge DV,BSH PCV Fix. I then broke the engine :confused: and decided that its a good time for a turbo upgrade aswell, wanted to go K04 but its so common these days :grin: went a little bit bigger with a Garrett GT2860RS :happy2: ball bearing turbo as I still drive my car everyday.
Here is the list of parts for the repair and turbo upgrade :
Pistons
Intergrated Engineering Conrods
ARP Conrod Bolts
Rings
Bigends
Mains
Valve stem seals
Bush
Sleaves
Garrett GT2860RS Turbo + Manifold
Injectors
DV Relocate Kit
Custom 76mm Cold Air Intake
GIAC ECU Software
GIAC DSG Software
GIAC Handheld controler
76mm Exhaust
Bigger Intercooler
Eibach Lowering Springs
Then theres still some small things like gaskets and so on that I didnt mention.
We estimate around 270 kW/360 BHP.
Build started on monday 19 March 2012, completion date hopefully 30 April 2012.
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Pics of my ride
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg545.imageshack.us%2Fimg545%2F9185%2Fdsc00668nt.th.jpg&hash=2a90e95bd9781582b94d521b54c6d8fe2075239a) (http://imageshack.us/photo/my-images/545/dsc00668nt.jpg/)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg9.imageshack.us%2Fimg9%2F1305%2F011020117201.th.jpg&hash=abef54697730e503d78d63cd0ec332cfc01538d7) (http://imageshack.us/photo/my-images/9/011020117201.jpg/)
Pics of my Garrett GT2860RS Turbo + Manifold
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg713.imageshack.us%2Fimg713%2F990%2Fgarrettturbo.th.jpg&hash=d887de4cb797e20d0c9c1bdf0d7886c4229c1fb7) (http://imageshack.us/photo/my-images/713/garrettturbo.jpg/)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg542.imageshack.us%2Fimg542%2F4605%2Fmanifold.th.jpg&hash=771085c329908ce84f5c0464878fca88f1457b6a) (http://imageshack.us/photo/my-images/542/manifold.jpg/)
Engine Removed
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg703.imageshack.us%2Fimg703%2F6770%2Fstippedmotor.th.jpg&hash=0dbccdc2d1fc379ec016e9bc5c630a70570828e2) (http://imageshack.us/photo/my-images/703/stippedmotor.jpg/)
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Some pics I took of the stripped motor.
Cracked Piston on the left
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg31.imageshack.us%2Fimg31%2F1919%2Fcrackedpiston.th.jpg&hash=518b92fd0f24fb76d843173038952ca93ce2d51e) (http://imageshack.us/photo/my-images/31/crackedpiston.jpg/)
Head removed
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg443.imageshack.us%2Fimg443%2F118%2Fheadsm.th.jpg&hash=96f099e21c8e819b31cefcf475f6814696a757a3) (http://imageshack.us/photo/my-images/443/headsm.jpg/)
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Block with the new sleeves installedand IE Conrods. I also ordered Eibach lowering springs as I plan on fitting 19" wheels. Some pics I took.
Block
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg827.imageshack.us%2Fimg827%2F5839%2Fblockc.th.jpg&hash=0c2e280bada02e1ad20d7694ccb7cb9d43313f2a) (http://imageshack.us/photo/my-images/827/blockc.jpg/)
Integrated Engineering Conrods
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg543.imageshack.us%2Fimg543%2F3910%2Fieconrods.th.jpg&hash=f6959a9c6fa9f63090c1af61156b5872aa38469f) (http://imageshack.us/photo/my-images/543/ieconrods.jpg/)
Pistons
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg689.imageshack.us%2Fimg689%2F2608%2Fpistonsg.th.jpg&hash=807965a8d771df5502b479e674b92e9ef7cc6669) (http://imageshack.us/photo/my-images/689/pistonsg.jpg/)
Eibach Lowering Springs
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg842.imageshack.us%2Fimg842%2F1415%2Feibachsprings.th.jpg&hash=02694b8974a24ebf04ae5b8a182c7011c1478dba) (http://imageshack.us/photo/my-images/842/eibachsprings.jpg/)
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Some pics I took of the motor being assembled.
Seeing as I use the car daily I thought it would be nice to have 3 different maps, cos during the week I spend alot of time in traffic and the lady is already heavy on juice, below is the GIAC handheld controller, I must still order it but it has 3 modes, stock, pump and race mode.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg836.imageshack.us%2Fimg836%2F1499%2Fassemble1.th.jpg&hash=5d1d8022c80f6a73ddec998876509dc0de4cb85b) (http://imageshack.us/photo/my-images/836/assemble1.jpg/)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg137.imageshack.us%2Fimg137%2F6942%2Fassemble2.th.jpg&hash=4fb63a2ea02bd4379a5b92d5434408e6ae67e14e) (http://imageshack.us/photo/my-images/137/assemble2.jpg/)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg850.imageshack.us%2Fimg850%2F9424%2Fgiachandheld.th.jpg&hash=05fa232e5cb7e6b38714a9a77f284bb2f87c2b57) (http://imageshack.us/photo/my-images/850/giachandheld.jpg/)
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Pics of motor finally back in the car. I decided to order a custom made 76mm Cold Air Intake as my current one is 63mm and also bought a boost guage.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg838.imageshack.us%2Fimg838%2F7346%2Fenginedropped.th.jpg&hash=e88456de9cad40e275f105536d521c7a9b3642a7) (http://imageshack.us/photo/my-images/838/enginedropped.jpg/)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg59.imageshack.us%2Fimg59%2F3497%2Fenginedropped2.th.jpg&hash=ed6f3b8af82bd42cd15ab079980d4b3b26f4701e) (http://imageshack.us/photo/my-images/59/enginedropped2.jpg/)
Boost guage looks similar to this one below
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg135.imageshack.us%2Fimg135%2F4587%2Fboostguage.th.jpg&hash=eeb2b46060afcf064e0de5899642bc26b3dcc973) (http://imageshack.us/photo/my-images/135/boostguage.jpg/)
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Very nice man. Where did you get the manifold for the Garrett Turbo from? I work for Honeywell at the moment, and as Garrett is a Honeywell company, was wondering if I could get one of them turbo's and put it in my car rather than a K04.
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Very nice man. Where did you get the manifold for the Garrett Turbo from? I work for Honeywell at the moment, and as Garrett is a Honeywell company, was wondering if I could get one of them turbo's and put it in my car rather than a K04.
Thanks, the workshop thats doing the conversion for me ordered it with the turbo from Turbo Direct, just remember im from South Africa :smiley:
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Yep, me too originally, lol. :happy2: Recognised the Western Province plates. Keep us posted on how it goes ok?
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Yep, me too originally, lol. :happy2: Recognised the Western Province plates. Keep us posted on how it goes ok?
Oh okay :smiley: yes if all goes well we will start her up saturday, then next week start running the engine in for 1000 km's and after that she will be tuned again.
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With WMI you should get quite a bit more than 360 :happy2:
suprised you went for a GT2860RS as as far as i know they are very similar size to the k04 twinscroll
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With WMI you should get quite a bit more than 360 :happy2:
suprised you went for a GT2860RS as as far as i know they are very similar size to the k04 twinscroll
Yes true, as 360 BHP was achieved with a car that didnt run WMI, I chose the GT2860RS as they made more power than the K04 and I wanted something different to the normal K04 route.
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Update: Turbo fitted on Thursday, 76mm exhaust going on today (see pic).
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg545.imageshack.us%2Fimg545%2F3770%2F76mmexhaust.jpg&hash=3cc3acf5c23b5b7df3ac4cc196ce515e3e04b9f1)
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Nice mods :happy2:
Good to see another build car but going a different route.
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Ordered these carbon fibre look DSG paddle shifters today.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg407.imageshack.us%2Fimg407%2F9530%2F25558573.th.jpg&hash=b3ed0cb18126c029955c141f363592f3e9c5e17b) (http://imageshack.us/photo/my-images/407/25558573.jpg/)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg20.imageshack.us%2Fimg20%2F9867%2F23518436.th.jpg&hash=6e0408d864d38463c83df7960d692d4db2bbe3a6) (http://imageshack.us/photo/my-images/20/23518436.jpg/)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg703.imageshack.us%2Fimg703%2F6274%2F95165077.th.jpg&hash=2b780951b5d1902cd3875a4a6226f31b5f71a49e) (http://imageshack.us/photo/my-images/703/95165077.jpg/)
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looking good mate :laugh:
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Update: yesterday after work I finally started her up and she sounds just like a Ferrari :happy2:
When I left the workshop they only had to fit the bumper but I guess they will do it today and on monday the software file will be loaded, they just made my weekend but the wait was worth it :happy2:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg138.imageshack.us%2Fimg138%2F6427%2Fbumper2h.th.jpg&hash=0cb8072686f7f6183522fad221770d46a934883a) (http://imageshack.us/photo/my-images/138/bumper2h.jpg/)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg651.imageshack.us%2Fimg651%2F9541%2Fbumper1.th.jpg&hash=55685335b003e053726d5b04fae9a18df289f565) (http://imageshack.us/photo/my-images/651/bumper1.jpg/)
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What does WMI stand for? :confused:
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Water methanol injection
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DOH!!!! :laugh:
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Update: Tuning started today.
On the dyno :smiley:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg834.imageshack.us%2Fimg834%2F8871%2Fdynotuning.th.jpg&hash=8686cb3be623429b7bad72a4ea42f8a03fa367a0) (http://imageshack.us/photo/my-images/834/dynotuning.jpg/)
Until the GIAC controller arrives to save the 3 maps the car will have the 1.5 bar boost file on that will be good for 280 kW, when the controller arrives the race map will be loaded onto it which boosts 1.8 bar :evilgrin: which I will only load for special occasions such as dyno days as this was the main reason for the build so who knows I might even hit the 300 kW mark.
Pic of engine bay with new Racetech 76mm CAI :)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg20.imageshack.us%2Fimg20%2F8400%2Fnewintakeu.th.jpg&hash=0d71a2f61e77f1730dbfb5a3291d9d7b31eeb3e2) (http://imageshack.us/photo/my-images/20/newintakeu.jpg/)
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Nice one, I bet that's a beast to drive. 300kw, the magic number, lol.
What fuel are you running there?
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Nice one, I bet that's a beast to drive. 300kw, the magic number, lol.
What fuel are you running there?
Thanks, 95 octane but for the race file will be running octane booster
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Some updates: Decided to buy the V-maxx coilovers, they are only height adjustable, also bought a BSH catch can, all of this will be fitted this morning, decided to take the 19" BBS wheels but that will only be on the car in a week or two, below some pics.
My coilovers look similar to these
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg26.imageshack.us%2Fimg26%2F5853%2Fvmaxxcoilovers.th.jpg&hash=f34964b640dd86c49672cc04ce36186bf216ad8f) (http://imageshack.us/photo/my-images/26/vmaxxcoilovers.jpg/)
BBS Wheels
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fimg833.imageshack.us%2Fimg833%2F34%2F1105201218331.th.jpg&hash=aab3bd233de11423c5de5a1f08d297f143ea6883) (http://imageshack.us/photo/my-images/833/1105201218331.jpg/)
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Below are some pics of before and after fitting the coilovers.
BEFORE
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FDSC00668.jpg&hash=bd9327ea800e4a0ee0ecada5e4193d52d1925208)
AFTER
You guys will notice the front is a few mm higher than the rear, thats for when I get in the car my weight lowers it even all round
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FAfterCoiloverSuspension.jpg&hash=124337d38ee2b14e4aa062d285367f3e7f2ba405)
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looking good mate :happy2: i am sure there is more power to be had out of that :drinking:
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Im now just trying to sort out the exterior, decided on a Vortex front spoiler, colour code the side skirts, and two tone rear bumper, im still checking who is the best is to do the spray job.
Ordered the following LED’s, CREE Number plate lamps, LED interior and LED park lights.
Vortex Front Spoiler
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2Fvortexspoiler.jpg&hash=349038fa71860a90f5c623e579a5553ea4264c25)
CREE Number Plate Lamps
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FCREElednumberplatelamps.jpg&hash=67ebb12c18d8d7a2e9741b3881e63b0360757a0a)
LED Interior lamps
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2Finteriorleds.jpg&hash=96abe79835b447871271feb0a5806b66fd1ee19c)
LED Park Lamps
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2Fledparklights.jpg&hash=594122180b467e8f25caa3830f179100a56613ef)
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Update: Running engine in now, boost were left at 1.2 Bar Boost, power figures:
95 Pump Fuel = 240 kW / 321 BHP
95 Pump Fuel + WMI = 255 kW / 343 BHP
Fitted 19" BBS wheel yesterday
Before:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FWheelsBefore.jpg&hash=86094fca21addfc9f3ae8a1de2f31d1261530704)
After:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FWheelsAfter.jpg&hash=f2f52f8a3bcffd0ac2743a7ac115b4963b9511d7)
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Really like that, the BBS make a huge difference :happy2:
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Update: Completed the 1000 km's yesterday and everything still running smoothly, I still want to get used to the car so I decided to take it in for the service next Tuesday and for the final tuning.
After work I dropped off the Vortex front spoiler to have it sprayed, removed side skirts and rear bumper for colour coding. Still waiting on my LED light package to arrive.
Also ordered carbon black vinyl to cover the front VW badge, red mag wheel pinstriping kit and while at it also just got some new valve caps.
Rear bumper removed
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FRearbumperremoved.jpg&hash=034c0230a57244e638f2e935d45c806cb9a3e51e)
Side skirts removed
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FSideskirtsremoved.jpg&hash=7a5883e641edf444046edc6b0dd9b17cb2f3fc0b)
Black carbon vinyl
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FBlackCarbonVinyl.jpg&hash=407376c6fe078d9ee91255c4725c9e0934b739ec)
Wheel pinstriping kit
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FWheelPinstripingkit.jpg&hash=2915b0d42eb0e9dae935e5b3697c4aaf55f011cd)
Valva caps
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FValvecaps-1.jpg&hash=76dd8bc785565a93e5bc01b6d3027eae3cdd54db)
:happy2:
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Hi Guys, almost nearing the end of my project, tomorrow she will go for a service and will be tuned properly :wink: even though a BMW Z4 ///M was murdered yesterday eve :evilgrin: .
Exterior now sorted out, took some pics.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121875.jpg&hash=97c9b5233174cbc872ee9100c97757d38e199def)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121874.jpg&hash=a87ee3f3c745b75fd86b2d470dabc9e23cd9d892)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121873.jpg&hash=98b4eb0cdfbd690d2395cd1cdde91b02b9c3a057)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121872.jpg&hash=e6c3de375429cb77c9f96b2b450e0f41672eba7d)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121871.jpg&hash=e03e59163f2df9c7c430282717a854d508bd6253)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121870.jpg&hash=8487caf80cf4cca9685ef72dc8b493c553562b0a)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121869.jpg&hash=09d56528b279d6be7d01ae2281ce2655bc5664b5)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121868.jpg&hash=f707ad9ace045b9ce48d906a180f4f5348d65898)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121867.jpg&hash=1db104ff6b0ec33866e8ef0e0477efaec17ed375)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2F270520121866.jpg&hash=636e8068ac6a1bdbb59d45f35da8987478af1cbc)
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Update: The car finally went in for the service and tuning today, Oil catch can was fitted today aswell and my LED package finally arrived but im going to fit them over the weekend.
Phase 1 is complete now and max power was 255 kW / 342 BHP as you all know, and this evening
we started with Phase 2 and she pushes out .............. 270 kW / 362 BHP
Now just 2000 km's to go then Phase 3 will start :wave:
Pics of Oil Catch Can fitted
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FCatchCan2.jpg&hash=571f3922006ddaa5619b0f93b2a4be2863f22d6a)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fgg602%2FEldridJ%2FCatchCan.jpg&hash=b5d4c76b5dc1a764bc95c1a07e05534ae2eecd1d)
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:notworthy: nice build guide - hope it goes well and look forward to seeing some videos of how she sounds :happy2: