Little Red Devil

[VWindahouse]

Ok sorry for the delay again

Well just picked up the Devil from Jimmy's and once again he has delivered as best he could with the challenge I unknowingly gave him.

As it turns out the hybrid turbo was the root of all evil. I will let Jimmy give his blow by blow on the situation but bottom line is if youre going to go down the hybrid line get it from a tried and tested supplier like JBS or so on.

Then there is the ATP manifold it seems the cast is a little big for the polo and fouled on a few things so Jimmy had to grind some key areas off it to get it to fit. Once again I will get Jimmy to explain.

So to the good no, friggin great news! Even with only the Ko3S turbo matched with the HPC coated ATP manifold the car is better than I expected! I think this is one of those senarios where a few keys mods work together in perfect harmony. One of those mods would be the new ECS clutch and more impressive 14 lbs lightweight flywheel! Absolute OEM feel and friction point...... to be honest I was not expecting that.

Now for the good stuff, it is now boosting of its tits And others who drove the Devil will attest it was ballistic before. But now the spool up is soooooo damn fast and throttle response is nothing short of amazing. I think the combo of the lightweight FW and the massively increased air flow from the HPC coated manifold has not only given me a true HP increase, but it seems to have given me an even more linear and stronger torque curve starting really down low before boost kicks in. And the best way do describe the sound I will have to borrow from Jimmy's text... "heaps more throaty man!" The sound is alot deeper, meaner and the burble when you let off the gas is fantastic. Reminds me of a chipped MK V golf GTI with exhaust!

So where to from here. I am wrapped with the car, it finally seems completely balanced in all aspects. So that being said I think phase 3 I will have leave to some other passionate dubber (please let me know if anyone wants to buy my unused uprated 315cc injectors, FPR, 3" MAF & APR fuel pump?). So the only thing left now is some 8" wide light weight rims for more of a contact patch with the 215/40R17 rubbers and more of a stance for looks and cornering. And a Miltek catback exhaust.

I have asked Jimmy to hook up some Dyno runs with a mob he has been
up-skilling his Diagnostic Dyno skills with (to complex for my simple mind to understand) so I can see the fruits.

Anyone else interested in a Dyno day?

[pogo_55]

Congrats on the power increase. I will be up for a dyno day once jmac fits the lwfw to mine. As I said after the last one I reckon this is a mod that isn't really being recognised. Shaneth's car and yours are very similar engine wise, except that his has a lwfw and on that day had 20 bhp more. I don't think the manifold would give a lot of extra power as I think the stock turbo itself is probably more restrictive than the manifold. Could be wrong here and willingly to be corrected.

[vwthunder]

I will be up for a dyno day once jmac fits the lwfw to mine. .

What is a LWFW ?

Trying to work it out lol

[Jmac]

Hey buddy Low weight Flywheel. Hey Kenny i agree mate.I said to Ant today im keen to watch all you guys again in the rollers with all sorts of mods flywheels etc. Seriously Ants car is mad. No joke butt dyno it feels crazy and thats a clutch that hasnt be bed in yet. Surely the ATP high flow with heat coat inside and out would affect it. I hope you can come to the dyno day im organising.
Im organising this as we speak so Kenny be quick with the clutch hehehehe
I have to add the technical to this thread as it is most called for.
Cheers
Jmac

[VWindahouse]

Congrats on the power increase. I will be up for a dyno day once jmac fits the lwfw to mine. As I said after the last one I reckon this is a mod that isn't really being recognised. Shaneth's car and yours are very similar engine wise, except that his has a lwfw and on that day had 20 bhp more. I don't think the manifold would give a lot of extra power as I think the stock turbo itself is probably more restrictive than the manifold. Could be wrong here and willingly to be corrected.

Yes I would have thought the same about just adding a manifold but after seeing the OEM one out in my hand I couldn't believe just how boody tiny it was. Where as the ATP is almost twice as thick, to the point Jimmy had to grind some of the support veins off to get it to fit in. And as Jimmy says it was coated both inside and out I really do believe it is responsible for more HP and that completely changed exhaust note.

Not taking anything away from the LW FW though, clearly a great mod and as I mentioned before the reason it's spooling up so hard and fast but from what I have read won't give an actual increase in HP where as greater air flow and less heat transfer (new manifold) can definately help acheive that.

Anyway just my thoughts and can't weight to put my butt dyno money where my mouth is at Jimmy's dyno day!

[pogo_55]

.... but from what I have read won't give an actual increase in HP ...

Eh, actually I disagree and by the fact that you say "it's spooling up so hard and fast", I think that proves it is making more power.

A little example here might help. A stage 1 polo puts out around 123kw at the wheels yet most of the tuning companies rate it around 150 kw at the crankshaft. Now obviously fitting a lwfw does not effect the power at the crankshaft, but as it will lower the transmission loss due to taking less power to spin the flywheel, the same 150kw at the crank with the light weight flywheel would probably equal over 130kw at the wheels. So although technically you haven't increased the power the engine is making, you have increased the power at the wheels.

Just my take on it, could be wrong.

Anyone that actually knows anything about this like to comment??

[h100vw]

Probably only a limited gain in top end power but the area under the curve will have filled out a fair bit.

More usable/easily accessible power.

A shame about the K04 though, I was looking forward to that!!

Gavin

[Jmac]

Eh, actually I disagree and by the fact that you say "it's spooling up so hard and fast", I think that proves it is making more power.

A little example here might help. A stage 1 polo puts out around 123kw at the wheels yet most of the tuning companies rate it around 150 kw at the crankshaft. Now obviously fitting a lwfw does not effect the power at the crankshaft, but as it will lower the transmission loss due to taking less power to spin the flywheel, the same 150kw at the crank with the light weight flywheel would probably equal over 130kw at the wheels. So although technically you haven't increased the power the engine is making, you have increased the power at the wheels.

Just my take on it, could be wrong.

Anyone that actually knows anything about this like to comment??

You wont actually increase engine horsepower but with the rotational mass being a lot less the engine revs quicker, which was evident at the last dyno. Having said that it gives the feel its quicker butt dyno style. The manifold would definately give an increase being more flow efficient and being heatcoated at the same time. The heatcoating will help reduce engine bay temps and should help with exhaust scavenging , and being on a larger manifold. One interesting point too, not too sure by how much the temps will reduce but might and its a big might, the turbo bolts may have a better chance of staying tight. They are wirelocked anyway but will be monitiring this one
Jmac

[noone]

Great work...

JMac, how much work was involved in fitting the manifold? These are fairly cheap from the US uncoated, considering as an option before the final tune...

[Jmac]

Great work...

JMac, how much work was involved in fitting the manifold? These are fairly cheap from the US uncoated, considering as an option before the final tune...

As this one was a first for me with the Pogs it was a total whatdoyamaycallit!!!!! Simple terms awful. Anyway if i knew then what i know now its the same old story R and D. The manifold needs to have the ribs dropped if you get the same one as Anthonys one. The reason for this is that the ribs ride on the coolant pipe that runs across the cyl head and it fouls really badly on the oil pressure feed line on top of the turbine. ATP manifolds of old never had ribs, verified by checking with Gav H100VW. He has a JBS set up he is selling with the same manifold. The job was made that much bigger because the Hybrid turbo was on and off so many times. turned out it was clocked wrong, which is ok but was all sealed with silicone so would need new seals, and there was various things wrong with the compressor housing, mount point for oil pipe missing, mount point for wastegate actuator cut off, not sure what the compressor housing was off to be frank. Anyway i reckon it was a wise move on Anthonys part to have the k03 back on and have the ATP fitted along with the ECS clutch. I would have been happy to try the K04 but it had disaster written all over it. If you go the ATP manifold dont hesiatate to give me a buzz, doing the manifild itself will be heaps easier than all the turbo stuff around i had. There is of course a few tricks and i also wirelocked anthonys turbo bolts as my invention has some more hurdles to jump. Now i mentioned the heat coating. Anthonys was treated inside and out with the same method and pretty much the place that does coating for V8 supercars. If you need it done drop me a pm, i can get pistons, rods and gear clusters done no worries and also if you go crazy i can get anything shotpeened.Anyway I think the coating may also give the turbo bolts a chance to stay tight, we can only hope.
Cheers
Jmac