Front mount options?

[vwthunder]

First of all thanks Instigator for all the information. Absolute champion. I'll reread your post again when im home but im almost certain you have answered all the questions i had. I am also keen very keen on getting one of these intercoolers. I am looking for around 180-220kw at the wheels so im sure this will be suitable for my purposes.

Wow how are you going to get that ?

[blitDz]

Wow how are you going to get that ?

To be honest i have got a lot of research and learning to do before i get exact details. I will keep everyone informed as the build goes on. There is a wealth of information in this forum alone. Its just a matter of wading through it all. However i have been reading about these intercoolers for a long time and i really do believe this is the one i want to go with.

Instigator what kind of power are you pulling these days. I know your a king at drag racing from the videos i have watched.

[instigator]

@blitDz: i'm running about 208Whp/240Fly, measured with Vbox.
torque must be around 400nM, wich is about MAX the K03s can provide.
soon i will be on the dyno and i know exact figures.

i ordered the Seat sport intercooler at a local seat dealer.
said i needed that IC and they ordered it, 2-3 days later i had it.
all together, Seat IC, Forge piping and installing it cost me about 750€.
if i wanted the APR one it would cost me +-1100€ to get it here.
APR is hard to get in Belgium, if you find it, sending it over costs alot
and as for the forge that was about 850-900€ but i allready knew i diddn't want that one.
so for me the Seat one was also cheapest, and turns out to be on of the better choises also.

as for getting the SSIC in australia, aren't there local Seat dealers??
just get the IC from seat itself.
think if you order it via VW, they might be asking more for the IC..? not sure but it's possible.
or keep an eye on Ebay, might be lucky to find one.

i know Forge has made a replica of the seat sport IC.
but don't know if it is as good as the original one, never seen results from it.

[noone]

I've been interested in replacing the Forge cooler with something better, but I'm not up for another grand or more. Get quotes in shipping, it's a major component of the cost. Shipping in batches will bring it down but prob best to keep the hardware in <$1000 lots.

Those numbers look high for a stock turbo, but if it's just peak power you could hold the boost back until higher in the RPM to get around the K03s' limited flow. I read a while back that the turbo's for the GTI and Seat Cupra changed a little over the production life, suble little changes which may mean you have better chances if your Polo is newer.

[vwthunder]

To be honest i have got a lot of research and learning to do before i get exact details. I will keep everyone informed as the build goes on. There is a wealth of information in this forum alone. Its just a matter of wading through it all. However i have been reading about these intercoolers for a long time and i really do believe this is the one i want to go with.

I didnt think there was that much information on here, as no one have really gone crazy on a 1.8T, if they have only a few.
Vortex is great, seeing as they have their own 1.8T section.
For that kind of power you would need a GT28?

[instigator]

on here there are indeed no major horspowerfreaks, a couple maybe.
but i'm also active on a dutch forum from holland, Seat Cupra online.
those people are crazy when it comes to tuning, they are also allowed to do more to an engine as in Belgium.
so i also seek "high power info" elswhere.
if yoy understand dutch, take a look at the forum, verry intresting topics on there.
a 1.8T with 400Hp is no exeption
i have driven once in a friends Ibiza (older model) with 1.8T engine, that day it was on low boost making 380Hp.
ride was pretty extreme, once you get about 3500 - 4000rpm it realy becomes a bullet.
when it's on high boost it becomes just sick and pretty undriveable, 430Hp and limited to 420nM.

but as for power from about 300 - 350Hp i would recommend also a Garret GT28RS.
this is er verry safe turbo wich spools at about 3000-3200Rpm on 1.8T.
but when it spools, it goes strong!

or the IHI VF34 turbo.
wich is about the same as a GT28RS, also making about 350Hp.
but it spools quicker as the Garret, somewhere around 2800-3000rpm it's off.
both turbines will be laggy under 3000RPM but will provide more than enough power al the way to the red line.

personal choise off course.
but i won't go higher in power or getting even bigger in turbo.
the bigger the turbo, the more turbolag you create.
and my experiance has showed me that you are better off with a quick spooling turbo for daily use and rolling start races.
a stage 2 polo will eat a GT28RS polo in a rolling start, for the first hundred meters.
after that, the bigger turbo will fly over it as if it wa standing still.
but, if you want to do dragraces and circuit work youre better of with high end power, such you get from Garret or IHI.
but know that when you have +300Hp, youre 1ste gear will be as good as useless.
so for every day use it might not be the perfect set up...
think before you buy.

a quick story,
a good friend of mine, also with older model Ibiza sport 1.8T, started out with stock K03 turbo.
chipped it to 210Hp.
ride was good and he was quicker as most cars on the road that came along.
after a couple of months he upgraded to a K04s (K04-023 from TT225, Cupra R etc) with exhaust, injectors and other stuff.
made 270Hp, spooled about as quickly as the K03 but with alot more Hp and torque.
did a 13.6sec on the quarter mile (best time)
after that he upgraded to GT28RS, beast of a turbo back in the days (2004-2005, and it still is)
made about 340Hp but it spooled not as quickly as the borg warner turbo's K03/K04 etc.
best 1/4mile was 12.8sec with stripped out interiour and street tyres.
it was extremly fast in higher RPM range.
after that he wanted more, and got a Garret GT30 i think it was.
no nonsens and full boost on the sucker.
it made 455Hp and just over 500nM torques.
on hot dry tarmac with good street tyres: 1ste gear became totally useless, same as 2nd gear.
3th gear he started to get a bit of grip, 4th gear it was off, 5th gear pull was insane.
under 5000rpm there was nothing, absolutly nothing!
did a rolling start against his friend with the same ibiza but with a K04s set up,
they have to do the rolling start against some speed because otherwise it had no grip.
so they started at about 100Km/u in 3the gear.
from 100 to +200Km/u the K04s was faster becaus it spooled much quicker and getting his power down.
did a 5th gear run against a Yamaha R1, it was neck on neck at first, but after a while at about +250km/u the car was getting faster.
he also once tried a top speed run.
maxed out the tacho, and on GPS he just went just over 290Km/u and he had to let off.
car wanted to go faster still but it was to dangerous, car was dancing all over the place.
1/4mile times was low 13's at it's best.
as he could not get his power down from 1st to 3th, so with the GT28RS set up he was faster.
problem with the car was that it eat gearboxes with that much torque.
every week there was something wrong with it, in total he destroyed 4 stock gearboxes and 2 upgraded stronger ones...
in my eyes, this is someone with experiance and knowledge about 1.8T tuning.
and he said, "if i knew in the beginning what i know now at this point, i would probably stick to a K04s set up"
it might not be as spectacular as a GT28RS or even a GT30 (or whatever it was)
but it's more usefull, gives power at the time you need it most, and thats whats makes a car quick.

sorry for the off topic
but when i'm going, i'm going good

[firdausasri]

Hi Guys,

Another option is to go for custom FMIC which is what I did few months back. Basically, the intercooler is coming from Evo 3 (500x300x65) and all new custom piping from from turbo towards IC and IC towards manifold. As for the drives, well, what I can tell though there’s a slight (very slight) lag of 300-500rpm for the turbo to spools but once the revs past 3k all the way to 5.5k, the car pulls with fatter torque figures and more rush feeling at high revs. It registered 216whp & 326wnm on dyno, I'm fitting in 4 bar FPR to fix lean issues at high revs, aside that this mod works like a charm!


Some adjustment on the inlet/outlet needed, if Evo 7/8 intercooler of the same size, it would be ideal


The old Evo 3 intercooler seems to be working well which defies its age


The guy managed to make a hole when I didn't think it can be done


Got to love the welds done by the Myanmar national staff, reminding me of seeing these things in the US




Pretty stealthy too

[instigator]

verry good set up there!
nice work done!!

must be the nicest self made IC set up i've seen on a polo

[vwthunder]

The thing with a custom intercooler is that I would be worried about getting a good core, so much stuff out there, hard to know what works and flows well and what dosent, unless it has been tried and tested.

I would think about doing the Seat Intercooler as I am chasing 300hp (at flywheel). Remembering that at around 300 or over 300hp, you need to do rods to be safe.
That will involve a Hybrid K03/04, Jbs manifold, good intercooler, custom tune and maybe even water meth, I think it would be a realistic goal

[instigator]

i'm currious if there is any hybrid K series that will give you 300Hp...
if you do get another turbo, just put a GT28RS or IHI like i said above.
let it get custom tuned and set it safe at about 300Hp.
turbo won't run at his maximum and you have youre HP goal.
if you want a K series make 300Hp (i wanna see that happen ) it will probably be at his ultimate limit.
wich can be dangarous at track days...

they say 300Hp is safe with the 1.8T engine without changing internals.
they can easy handle that power.
my mate with the 455Hp ibiza i was telling about has drivin the GT28RS with 340Hp on stock internals without any problems.
but, it's absolutly safer to change internals @ +300Hp.
but it's not the Hp, but the Torque that destroys everything.
specialy high torque at low RPM, so i guess you will run more danger with a K04 as with a GT28RS.