Project Polo TURBO!

[str8ballin]

Hello all!
I been off the forums for a while as i've been soo busy but finally been working on the car the last few weeks and its nearly finished.

Thought I'd add a thread see what you guys think and any tips or advise you may have...

Im just waiting for my ECU and external fuel pump to come in then I need to get my car towed to birmingham for the exhaust system.

Should be done by next week... im hoping to go santa pod on 12th August.

Here are a few photos...




Out with the old FSI....





And in with the new 1.8T.....







The sexy Forge Front mount intercooler finally on...



The intercooler took awhile as I used the original bumper so there is literally no space if you keep the A/C which I need!
And for the intercooler pipes i got some universal 2.5" pipes from ebay for £85! And it all fitted perfectly!









I have two gauges, one is a Blitz boost gauge, its 80mm which are very rare now so I had to buy it second hand from ebay and the other is a GReddy EGT gauge. I want to keep a standard look but they are essential.



Heres a list of my spec:

AYP 1.8T engine & gearbox (ibiza cupra)

K04-23 turbo & manifold from Audi S3

Forge Front mount intercooler

386cc injectors, S3 fuel pump & Walbro 255 external pump

Forge Split-r Dump Valve

Brembo 4pots from Leon cupra R

3" Turbo back Exhaust system

MRC tuning custom re-map to just under 300hp & s**t loadz of Torque!

Thanks for looking! !

And many many thanks to Chris (ceedubya), Andy and everyone else who helped me out... I may still need your help by the way!

[david burton]

looks good! bet you can't wait to get it finished

[str8ballin]

looks good! bet you can't wait to get it finished

Thanks mate!

Yea I just cant wait!
there are a few of the new polo gti's in leicester and they all love taking the p*** driving past me but they'll be in for a suprise!

[dino]

nice - looking forward o some more updates

[Jeff GTi]

great project but im not in to the on show front mount or butchering the bumper or impact bar as those are all breaching yours and others safety

i would of opted for the apr intercooler for the 9n3 gti as its smaller but thicker and just as effective, without affecting flow rates to the radiater or ac or oil cooler and it fits behind the bumper

[DAZZA_TDI]

Fook me bet that`s a weapon when it`s finished nice work m8
Dazza

[str8ballin]

great project but im not in to the on show front mount or butchering the bumper or impact bar as those are all breaching yours and others safety

i would of opted for the apr intercooler for the 9n3 gti as its smaller but thicker and just as effective, without affecting flow rates to the radiater or ac or oil cooler and it fits behind the bumper

Hi thanks every1!
I need the forge fmic when im running 20psi!! The apr intercooler i not as effective as this one.
The polo gti have k03 turbos so for your car it would be ok.

I know it looks a little boy-racer at the moment but once the number plate etc is on it should be more subtle!

[david burton]

I quite like the intercooler on show, although perhaps the words "forge" could be removed..... each to their own!

also, I know this is a quest for power but is 300bhp going to make it a bit stressed and hard on the components? the longevity of setting it to 250 might be a bit easier to live with, but this is your car of course

would love to have a project like this, you need to give us more info on costs and what's involved. I'm not going to do it but would be very interested.

[mc_iver_9n]

Good work so far mate. more updates.

[str8ballin]

I quite like the intercooler on show, although perhaps the words "forge" could be removed..... each to their own!

also, I know this is a quest for power but is 300bhp going to make it a bit stressed and hard on the components? the longevity of setting it to 250 might be a bit easier to live with, but this is your car of course

would love to have a project like this, you need to give us more info on costs and what's involved. I'm not going to do it but would be very interested.

I love the forge logo!
Give them sccoby drivers something to think about!

Heres a basic list of parts I needed and the cost involved...

£410 1.8 Turbo AYP from Seat Ibiza Cupra
£150 02J Gearbox 5Speed Seat Ibiza Cupra
£115 Drive shafts
£285 K04-23 Turbo, Manifold & turbo pipe - off S3 225
£190 Engine/Gearbox Mounts from maindealers - various vw seat and skoda
£50 384cc Injectors off audi TT 225
£10 3" MAF off TT 225
£45 4bar fpr
£30 S.A.I block off plate and MAP sensor flange from U.S
£30 Fuel pump 1.8t off S3
£75 Walbro in-line 255lph Fuel pump (NOT NEEDED BUT TO BE ON SAFE SIDE)
£30 Starter Motor
£11 gearbox mounting bolts
£50 Engine Support Bracket OEM from VW
£33 K04 Gasket, TUrbo bolts from AUDI
£10 Turbo Oil return extension
£107 Forge Front Mount Intercooler ( usually £300 but I got very cheap)
£85 Universal 2.5" Intercooler pipes
£125 Forge Split-R Dump Valve
£72.5 Forge S3 Turbo inlet pipe
£500 3" Custom turbo back DownPipe & exhaust to backbox by MIJ
£60 Towing car to Birmingham for exhaust
£60 1.8t ecu
£15 Anti Roll bar bushes & suspension bushes
£450 Fitting and using my mechanics' garage and time
£320 Immobiliser defeat & custom wiring to make original dash work with 1.8T
£100 Misc. Clips, hoses, nuts & Bolts
£45 Blitz 80mm Boost gauge
£70 GReddy EGT Gauge
£500 MRC custom re-map

£4036 TOTAL COST.

And the items I sold...

£65 K03 turbo & Manifold
£20 Cupra Fuel Rail
£60 Polo FSI A/C Compressor
£300 FSI Engine
£200 FSI Gearbox
£55 Secondary air pump
£40 S3 Turbo Pipe
£15 Cupra Injectors

I still have about £100 worth of parts to sell.

So...
4036 - 755 - 100 = £3181 TOTAL COST.

I must say alot of the parts I got are bargains, I have spent soo many hours on ebay but it paid off!

I rang JBS and TSR, they both quoted me £6500-7500 drive in drive out & they need the car a couple of months.

With that they do source the engine but it would be the 150hp or 180hp engines, and they remap them to 230 max.

With my setup I got the bigger turbo, intercooler, re-map to near the 300 mark etc and saved over 4K and it looks just VW made it... just with flashy parts!

This is defo harder than I first thought!!
The way the germans put things together is mind boggling!
I just got the engine and thought it would be a straight swap but it isnt!

The main problem is the wiring not the engine or gearbox.
THe new polo dash reads the signals in a different way to older cars.... THe Fuel gauge, temp gauge, revs and speed signals go into a control box and then they send the reading to the clocks, even the audi S3 TT etc dont use this system; so if I wanted to keep my original dash instruments I needed a genius to make the wiring for me so the dash works.... luckily I found one and he done a great job for me.

I have heard people telling me all the time if you want a fast car buy one or why drive a chaved up car!?!

But its all down to personal taste., I love my polo, i've had it 4years now and have never thought about changing it... the looks of the car, the drive
everything is so nice, but all i needed was the power and i've got it now!
And the look is standard all over... well except the front!

The exhaust and remap will be done by this weekend and im ready for the road!

I will keep the thread updated, maybe add a few clips on youtube.

Thanks everyone for your comments & reading my essay!

[david burton]

great read, and yes, a lot of those parts are bargains - £50 injectors

[grant hunter]

thats brilliant well done mate hope to see some clips soon

[poloecosse]

looks amazing! been wanting to do this for a while, posted up a while back to ask for info but no replies. any chance of the part numbers etc... for the mounts and driveshafts.

do you have the phone number of the place that done the wiring?

give me a pm or post up here, any info much appreciated

[DanDiesel]

hmmmm looking forward to some more updates!

[bizcuitBox]

what mounts and drive shafts did you use mate?