Scirocco Quattro Turbo Project

**twin eng, twin turbs** · 01-05-2010, 03:28 PM

I purchased my MK2 GTI 1983 rocco many years ago with the intention of building a show / race car that could still be streetable and legal. This project has no real budget... and will be completed some day..

Although i have yet to complete half of the body work i have made many alterations to it allready with the aim to improve aerodynamics as much as possible whilst keeping it tasteful. I have grafted in the original bodykit pumping the guards out a little and manufactured fibre glass bumpers, mirrors and rear wing.

The 2+ litre 16v turbo engine features so far...
* JE forged pistons 83.00mm diameter 8.5:1 compression ratio.
* Pauter " X beam" connecting rods with arp bolts.
* Forged Knife Edged Crankshaft with 92.8mm stroke, enlarged oil gallerys and linished.
* Billet 4340 forged ligthened flywheel with 6 puck ceramic sprung centre single plate clutch rated 580hp
* Extensively ported and polished head, flow bench tested with new guides.
* Supertech 1mm oversize valves inconel coated on the exhaust ones.
* Supertech valve springs with titanium retainers.
* Light weight INA hydraulic lifters.
* Cat Cams turbo grind.
* Techtonics Tuning adjustable cam gear.
* Autotech light weight intermediate shaft gear.
* Aluminium light weight pulley kit for serpentine belt setup.
* ARP headstuds, main studs and flywheel bolts.
* Schrick cast alloy sump.
* vw motorsport sump windage tray.
* Custom alluminium inlet manifold with 4" plenum chamber and 2 1/4" tapered bellmouthed runners.
* Custom billet 80mm throttle body matching inlet manifold.
* Water to Air intercooler 3" inlet and outlet 1200hp flow capacity 260 by 260 by 110mm core.
* 600cc turbo logic fuel injectors.
* Custom stainless steel fuel rail.
* Bosch 910 fuel pump to 1.5 litre surge tank bosch 044 pump to fuel rail.
* Malpassi 1.5:1 adjustable rising rate fuel pressure regulator, with autometer gauge.
* 30 row oil cooler with braided hose and thermostatic flow control.
* Custom steam pipe 4 into 1 equal length exhaust manifold.
* Garrett GT30r turbo with 4" inlet 0.7 air ratio compressor housing, customised 4" outlet 0.86 air ratio exhaust housing with 38mm Tial wastegate off the side.

To buy and manufacture list...

* Aftermarket engine management purchased last as technology is allways improving.
* Manufacture hollow stainless steel intermediate shaft for weight savings.
* Full gasket kit with cometic head gasket.
* Toga high volume oil pump and racing engine bearings.
* Alluminium radiator and heat exchanger for water to air intercooler.

The drive train i am using is the 02M 6 speed quattro with haldex from the audi S3, should prove interesting to fit.... I will be cutting and raising the floor tunnel between the firewall and back seat for clearance as i also plan to fit a 4" stainless polished exhaust system.

Lots of pics coming...

**GoLfMan** · 01-05-2010, 03:58 PM

WAHHH!!!!

another crazy build! Really looking forward to pics!

**jasonO** · 02-05-2010, 03:23 AM

drooled on my pork whistle.

**Jarred** · 02-05-2010, 03:06 PM

Can't wait to see this!

**Oneofthegreats** · 02-05-2010, 03:56 PM

Now this sounds like one hell of a project & even more one hell of a parts list.

Very interested to see how it goes.

I also have a GT3076R but with a .82A/R exhaust. I didn't think they made a .86?

I'm thinking of down grading to a .63A/R to promote faster spool due to my capacity staying 1800cc & hopefully running an auto with a high stall convertor

But depending financially & how power hungry I may get, will end up upgrading to something like a GT3582R with a .63 or a Borgwarner, Precision equivalent due to Garrett products going down hill & also a 44mm Tial Wastegate

My advice is maybe look at upgrading your injectors, cause you'll be able to max them out quite easily I reckon, cause with a turbo like that 450hp is easily within grasp.

You should try & avoid ever going past 80% duty cycle on your injectors as a matter of safe guard.
I'd personally be looking at something like a 680+cc.

A good base to start with...

5cc for every HP you plan on making.

eg. 400hp = 100hp per cylinder = 500cc + safe guard = 550cc injectors

One other thing is to maybe consider upgrading your rising rate fuel reg.
I've tried & had several friends use a Malpassi rising rate & they are junk. They have never been able to keep the fuel pressure stable under boost.

My personal choice & alot of sport compact racers is one of these for these kind of power levels is....

Aeromotive

**twin eng, twin turbs** · 02-05-2010, 10:01 PM

Cheers Golfworx,
I am aiming for 500hp.. that would be violently fast in a hopefully sub 1000kg car!
You are right they didn't make the 0.86 for that turbo i have used one off another garrett GT and machined it out extensively porting and polishing it in the process, making a 4" outlet for it to match the full 4" system i plan on manufacturing. Why 4" some may ask? Because i have the materials and i am chasing every hp i can get.
You are right about the injectors, i will see how it goes when i get to that stage and upgrade them if i need to, its one thing to buy all the best parts and build the best engine i can but its another to really make the power in the end... Im not going to say i will make 500hp from it, though i aim too, what it actually makes is another thing...
Might sell the malpassi and upgrade if they have such a bad reputation!