Discalaimer! Don’t go looking for daily updates on this one! It’s fair to say I’ve been dragging my heels a little, so I’ll post stuff up as it happens, but it’ll be slow, especially since I’ve just bought a house! [8D]
So lets set the scene (screen goes wibbley in a flashback style)
I started putting this car together in 2004 and it’s spec was as follows:
2003 AUM 1.8t engine, stock internals, Garrett GT28RS turbo,
02J with a peloquin LSD
and that’s about as far as I got really, but then I started thinking about it, and 300+hp in a lightweight car that’s fwd seems like the perfect recipe for traction issues. So for the last few years while other projects and work have kept me from doing alot to the car, I’ve been slowly gathering bits and pieces to make it 4wd…………. and faster!
Here’s the current set up:
So now you’ve seen that, forget it it’s all change from here on……
So first things first, I got hold of a Garrett TR30-R Turbo from a WRC ford focus. These things are serious pieces of kit, making 300+hp through a 34mm inlet restrictor, and well over 400lb/ft of torque.
This is the compressor housing, it’s made of Magnesium, hence the weird gray color, and has a removable internal surface, so alternative compressor wheels can be fitted. The backing plate is CNC machined alloy.
The turbine housing is V-band fitment, and made of inconel:
The turbine wheel is a work of art, I forget what it’s made of, but it’s shiney, like ceramic, and capable of handling indecent quantities of anti-lag:
But this is the money shot, the compressor wheel is machined from a solid forged alloy billet! it’s absolutely gorgeous:
Now that’s no more power, but alot more torque than the 20v settup I have now is capable of. BUT, I found a back to back test of this very turbo on an EVO, with and without the turbo’s restrictor.
So WITH it’s pulling 316hp and 430 lb/ft of torque, not too shabby, but get a load of the unrestricted graph!
That’s 466hp and 542lb/ft of torque!!!! So that’s decided, the restrictor goes!!!!
So with that turbo purchase (for £300 incidentally, when they’re £8000 new from Garrett) I knew I needed to upgrade the engine internals, as this would melt, blow, and generally mince them. I came accross a 2008 TT 2.0 FSI bottom end with 150 miles on it, that had been swapped under warranty as it had a supposed knock. I figured at £150 for a block, it was a good purchase, and so far as I can tell there’s nothing much wrong with it. I’ll fit forged pistons and rods, and swap the all the bearings, so it’ll be all good.
To begin with, I was going to use a 20v head, but another chance purchase of an alloy blocked 2.0 FSI none turbo lump for £50 (I frickin love ebay!) meant I’ll use the head from that, as it has lovely roller rockers for the cams, and looking at the port sizes and valve lift, I imagine it’ll flow a bit more too.
I’ll machine up blanks to replace the direct injectors, and Build inlet and exhaust manifolds to suit.
So that’s some of th engine, I’ll update what tastey internals I get for it, but all this is useless without a transmission right?
I’d like 6 gears, and haldex, but the 02M is a heavy old hector, so I hatched a cunning plan….
I got hold of a Rallye Transmission, a Skoda octavia transfer box, and an 02S 6 speed box (that’s effectively a 6 speed version of the 02J) so out of these I shall create a 6 speed transmission, and the Octavia transfer box will allow me to use Haldex for the rear differential.
An 02S gearbox, Mine is now burried under stuff so not a pic of mine 
Octavia transfer box:
Now, getting a haldex rear end is no problem, but for the time being, I can’t be bothered (and can’t afford) a haldex controller, so when I found this for £155 buy it now on ebay, it was hard to resist! It’s a BRAND NEW transporter syncro rear diff, and has the same ratio as a haldex, and the casing is the same, but has a viscous coupling, so no controller required, and I can make a subframe for it, and it’ll swap with a haldex when I can afford it.
So yeah, there’s some more pics I’ll post up later on, but these are just some ingredients for you to digest for the time being! [
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