Last summer I was having problems with the G-lader on my Squareback G40 conversion, and ended up with a cracked scroll on the 'charger:
Steve from PSD sorted me a lash-up lader, equal measures of lader bits from his workshop bin and JB weld... Still, we got the car mapped and it made 167bhp and 162lb/ft on the dyno - not bad considering it was lacking in boost. But it was time for some soul searching, and I decided it was time to go turbo - I reckoned if I didn't get too greedy in my quest for power, I'd end up with something that wasn't too laggy.
Did a lot of reading, and too much maths, and decided that a K03 would be a good starting point - the aim is 200PS.
K03 turbo,and a manifold and downpipe from eBeg.de:
Early stages - only turbo and manifold on, G40 engine mount/alternator bracket to change:
Trial fitting of front-mount i/c:
Radiator out, because it fouled on the turbo:
Can I clock the turbo to a more useful position? No:
Bit of luck - some scrappy boost hoses that cost all of a fiver, and fit nicely:
Re-mounted i/c - proper brackets at the bottom, cable ties at the top... I have a new bumper iron to do things properly on once I'm happy with the location:
Exhaust pipe adaptor (a small detail, but really pleased me - it was a custom part I had made, and fitted straight on):
Oil drain into the sump, proper bits to follow from PSD:
Upskirt turbo shot - oil drain pipe connection to turbo is not ideal:
Improvised re-circ dump valve - I need to paint the bit of tufnell a guy at work turned down for me:
Compressor inlet (filter in wing) with re-circ pipe:
Silicone hose from compressor outlet to i/c:
In need of a tidy-up cosmetically to say the least:
Spot the pikey bleed valve on the turbo:
Water cooling lines for turbo fitted:
Radiator hose t-piece:
Coolant expansion tank hose t-piece:
Clutch was dying, so got a spare Helix paddle I had re-lined:
Bit of paint on the intercooler, and she'll be pretty stealthy:
Testing at Santa Pod:
It's booked in for a remap in a couple of weeks, then I'll have an idea of whether it's all been worth it! It's not much to look at, but hopefully that won't matter too much...
My blog has more details.
Am back up in the real world now. In the Saab though! Keeping the miles on the Polo down 'til it's remapped. Just one more week to wait now...