Petes Polo goes big

**Bullet Fast** · 12-07-2013, 10:13 AM

It's pretty ugly. I couldn't get pressure readings this morning, neither gauge I used actually registered before the gates lifted. Having said that the short stroke issue is well and truly built into my turbo. Measured at the widest opening; once both actuators are bottomed out the OEM gate is 4 mm further open than the FT.

**Bullet Fast** · 12-07-2013, 03:13 PM

https://www.dropbox.com/s/t093uc6e98...712_072033.jpg
K03 at full lift. About 19mm at the highest point

https://www.dropbox.com/s/v2c0bswa9t...712_071951.jpg

FT at full lift. Only 15mm of opening. There is a waste gate port there, but its 2mm less across the diameter than the standard housing?! Absolutely not ported at all.

On a positive, once I'd swapped the actuator over I ended up with 24mm of lift and the same amount of preload, assuming this was correct to begin with.

Doesn't look like Dropbox public images will show using IMG function?

**VWindahouse** · 14-07-2013, 04:09 PM

Holy crap, I didn't suspect the FT to be that bad. Nice work!

**noone** · 14-07-2013, 05:08 PM

Photobucket is the way forward for your pic hosting. Franken seem to know their internals but the rest seems pretty rubbish.

**Bullet Fast** · 30-07-2013, 08:32 PM

Check this out, so I didn't realise the airbox, 3in MAF and TIP wouldn't play nicely together. So I designed a new one.

The green colour comes the plastic, it's a digital ABS like material from objet. It's designed to fit the bottom half of the airbox and my ebay tip. It'll fit the Seat CAI of course. This is the MAF join, cut out is for the welded boss. The port is also angled off by 10degs to meet the tip at a better angle. It's a bit hard to see in the image. It fits the bottom half of the airbox beautifully.

And here's the underside. The inlet porting continues to twist in two planes to meet the existing air filter as best as possible, whilst maintaining one throat (2.75in) width standoff-ish. Wall thickness is about 5-7mm depending on the spot.

Material is temp stabilised (HDT) to about 90-100 degrees, and very strong. It's a bit heavier than I'd hoped, around 2.5kg. Better than too light of course. That's about it. Ill post up another picture once its sanded painted and installed. Google Objet Connex printer for more info on the machine.

**vwthunder** · 30-07-2013, 09:06 PM

Wow that is awesome, thinking of all the things that could be made, hmmmmmmmm

**noone** · 30-07-2013, 09:06 PM

Wow. Very impressive

**AntiFun** · 31-07-2013, 09:47 AM

Originally Posted by Bullet Fast

Objet Connex printer for more info on the machine.

I knew this looked like a 3d printer job, that's so awesome! I never even considered 3d printing in automotive applications..... This might be a good work around here in vic for those who need a stock filter box for RWC.... How much did the plastic cost you all up if you don't mind me asking...