track slag mk3 cupra build - Forged engine, k04 turbo & water meth injection :)

[ThrushMotorsport]

Couldn't help myself again and bought another turbo tonka toy... Well this is my little project, I had one about 2 years ago with the same problems, engine dosent run.. however this one wasn't timing belt, it was low compression, all for the sum of £500

The previous owner(S) had not taken care of this car, but honestly, Im not fussed, I enjoy wasting my money reviving or buying shit cars just to play with them, sometimes with a profit, or a loss - however, they left me a AUM engine with a ko3s and a revo stage 1 map on it (supposedly), and a few goodies, but ive bought allot of goodies on the way.

Ive built the car up and tested it last night until I broke it, and my god, it is quick, im still unsure on the turbo, its casing is marked as a ko3s, however the turbine is not from a KO3S so im unsure if it is modified, it boosts to 22psi and holds 18/19 comfortably straight to redline, but for me.. fun as its rapid to say the least.

Ive just fixed it again, so plenty more boosting to come in the future
Well, here we go.



I got the car delivered on my house on the Thursday, and by the end of that night, it was looking like following.



the plan was to remove everything I did on the last cupra, N118 N249, SAI, AIRCON etc etc


but I picked my new engine up from james on the Friday and started swapping everything over to it, brand new gaskets everywhere to avoid any troubles



Then mated up my gearbox to the new engine, the clutch on the old engine was brand new, so well chuffed, the clutch on james old engine was... well, ****ed. Tons of signs of slipping from the colour discouloration



Then I took out the old engine, had a few helpers round to help me wriggle the engine out of the bay - always nice to have company, and buss boys to go for the food! haha





so next morning, this happened, unfortunetly I had no helpers as everyone was busy or working, so I decided to do it solo like a real man, :funk:







Then everything was bolted together

Then went on the forge front mount intercooler I had bought which is a quality bit of kit, the reasons for this is I have always had problems with boost pipes popping off under high boost.. which I had to sit fixing late night or early morning to get home - This wont be happening anymore



Unfortunetly, whilst putting the O.S driveshaft back in, it shit its bearings all over the floor, so a new drive shaft was ordered, and installed, and ive test drove the car, I also had problems with getting gears.. which took me a while to suss out - eventually finding out it was a tiny little clip..
I have fixed everything, and the ONLY problem is a leaking Slave cylinder on the gearbox - this is on backorder from VW so until that comes.. there will be no action.



Specifications;
AYP Engine
SAI Removed
Air Con Removed
N118 Removed
N249 Removed
Carbon Cannister Removed
Ko3S??? turbocharger
Silicon Intake pipe
Dump Valve
Air filter
Forge Front Mount intercooler
Revo Stage 1 Remap
AUM Injectors
Forge SIA Blank
Catch Tank hidden behind Air filter
3" Downpipe
Full exhaust system
I will be updating this thread as I go, althought im pretty lazy at that

[Manwhore]

Looking forward to the updates

[ThrushMotorsport]

Have had progress over the weeks, had to replace this line for the clutch fluid to go from master cylinder to slave cylinder as it was leaking at the seals.



Have used the car for a bit to test and she is fast except I broke it, but.. I still have heaps to do, but mechanically its all done except mapping, im waiting on one of these to arrive, a AEM Uego;



Then the next step is water methanol injection, but im needing to buy a trailer for the car so Im thinking that I will stop buying things for a month or two - but we will see.

Also ordered this;






Will be putting my Water meth press. gauge in there and also the AFR gauge.

[martin1985]

looks an interesting project

[ThrushMotorsport]

Thanks dude, still got allot to do before she will see her first outing at knockhill, ill hopefully have all the parts and finished by start or end of june

Anyways, got some progress today, a quick 20 min job

Crimpling skillz to pay for bills, naat.



This is it with ignition off.



Ignition on, still need to weld the bung for the wideband sensor in the downpipe, will get that done shortly, will be needing done before mapping anyways.



This gauge and wideband has the options to use a serial port auxiliary, so I can log everything by laptop seeing the AFR in real-term values, the gauge itself is accurate to 0.1 - would have hoped so for the price.. just need my water meth gauge, and im going to be wiring in a low fluid level LED for the water meth gauge too so I can see how much is flowing and when I need to top it up.

[ThrushMotorsport]

Today I just spent over £550 on methanol injection *sigh*, expensive day, managed to get a deal on some money being shaved off but was still an real expensive day.

Devils own 2.5 bar 1.8T progressive methanol kit
Utilising a DO2 Injector

I ordered a big bottle of methanol (virgin grade) to mix, and a float switch, and I bought an LED light that flashes in sequence, I will be drilling a hole next to the water meth gauge so I can mount the LED aside it neatly - the purpous of this is to let me know when methanol is low.

also ordered a weld on adaptor for the nozzle, will stick this before my map sensor so it can read the changes, and a 2 litre methanol tank - also ordered a few other things, cant remember it all though.

I bought an AEM water meth flow gauge too, just so I can keep eyes on the flow of the pump to the nozzle.

[martin1985]

how much more power does methanol injection add?

[ThrushMotorsport]

Mmm, it dosent really add power, well it does.. But in a way, you could run vpower wich is equivelent of 98RON fuel, adding methanol makes the fuel more potent, so the fuel could be equivelent to 104 octane whilst injecting methanol so that alone will add slight power

This means that there is very low temprature coming into the cylinder, there can be next to no chance of detonation, and reduces knock, which means you can get allot more power safely by addding more boost and adjusting timing

Also makes exhaust temps lower, and it steam cleans your engine is another bonus when you use it im hoping to break the 250bhp barrier which is very possible injecting methanol

Wont know til i get it on the dyno though :3

[martin1985]

ahhhh right got ya now!, nice bonus that it steam clean's the engine in the process

[ThrushMotorsport]

Yeah its handy, only does things like piston and valves, sparkplug tips etc

[ThrushMotorsport]

Some more progress, this meth gauge had so many wires to connect *sigh*

So got it in, and mounted after I wired everything up right



This is the LED im going to be running to my low fluid level indicator




Drilled a 8mm hole and mounted it in there, think it looks pretty good to be fair where ive placed it.

[ThrushMotorsport]

Got some of my goodies through today






Been making up brackets for everything to fit nicely in the engine bay, im not perfect at fabricating shit, but I try my best.

its booked into Wallace performance on the 2nd of june.. a while away, but atleast it gives me time so sort everything out I guess..

[ThrushMotorsport]

Pics do the talking, not perfect, but it does me.

Bassicly everythings in and wired, just need to weld my nozzle on to the intercooler pipe.

The interior has never been cleaned scince Its been in my possesion hence why centre consol looks filthy..

[ThrushMotorsport]

OK, little while scince I updated this, however im copy and pasting from a local forum, but ive decided to go an even bigger turbo, its off my mates car, this setup has been tested on 2 cars and has broken 300bhp numbers before

--------------

No I haven't, but it problably would be more expensive, I have another problem though whoever had my car before me, I noticed the exhaust had been welded by the previous owner(s) before.. however, I never knew the downpipe was welded onto it *SIGH*, so that's a new catback im going to need, at this rate, Ill most likely just get it running and worry about that shit later, who needs backpressure? luls

Few pics from the weekend, was out with richy getting his sump off so we could fix the leon, took a few snaps of his car whilst at the unit - its pure porn has always made me want a mk4





Was nearly finished away to go weld this up before this cunts leon broke








Nd the shit I managed to steal off richy




This is what it stood like by end of today, managed to get cracking on it today.. but turbo and mani are mounted, having problems getting the 3" tip over the billet though

[martin1985]

should be a fun car!

[ThrushMotorsport]

Should be, will break the 300bhp barrier no problems with water meth when this setup was in the blue ibiza - it flew like shit, it left my audi standing and my audi wasnt exactly slow

Cant wait to get it running again, hopefully have it fully built up and mapped somepoint in june, had to modify the sump return last night so spent my night doing that shit

Kinda at a stop with it, just waiting on parts now.

[ThrushMotorsport]

Not much updates, engine bay is looking more complete.

still got my downpipe to fit, injectors, a fuel pump before I can check for leaks and shit, still not too keen on the modified sump-return I did, im hoping its sealed properly (looks like it has, but wont know til fluid is in the engine.


Mathew at trackslag has kindly kept this to the side for me, hopefully fit it on Thursday, a 3" custom made downpipe for the new turbo, I am the first mk3 cupra in the u.k with his 3" design he said - so hopefully its promising and delivers some good gains




And only thing ive done to any car is this, some more of the blue cupra, was helping my mate paint the bay, had to remove everything to get it painted so I did all that shit for him, looks even better now - words can not describe how much I want this car.

[ThrushMotorsport]

Mathew at trackslag kindly put this aside for me im well happy with it, fits perfectly





The rest..







Marked my lambda's positions out, only need 2 put in


Fisting that shiz.



Also acquired a new laptop for the price of £0 lol.. I was looking for a shit one for vagcom etc, instead my sister dropped this off at the house whilst I was at work

[ThrushMotorsport]

So, I acquired a 4 bar fuel pump housing from a LCR, which now has a walbro 225 pump sitting at the bottom of it Well happy with it.

I didn't actually take a picture, I forgot, so I took a picture of the old grubby one



Also upgraded my injectors, to ones that are 380cc at 3 bar (I am running 4 bar)



Also modified the charge pipe and cut my own silicon pipe to mate to it and the turbo outlet.

[ThrushMotorsport]

Havent really updated much, however, car is now running with the k04 conversion, not long to go until I see the mapping, but the engine is getting fully forged now, so that will be done when my conrods come from America, still need a new catback system, and 630cc injectors

running forged conrods with calico coated bearings, the pistons are forged already - cant wait about not having to be worried about internals bending/snapping.

On first startup with the k04, it pissed out all its contents of oil, so changed a few gaskets etc and wipped all the manifolds etc off and found the problem, now it is completely leak free.

ive extended most of the wiring, modified my abs pump, and finally got my water methanol kit fully installed




heres how she stands now.