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    Thread: VR5-TURBO STAGE 4

    1. 11-10-2005 07:31 AM #1

      Time for a new project tread for the new engine .
      This is the 4th stage of the Bora/Jetta Mk4 turbo evolution. Updates this upgrade will get me in to high 10s low 11s with 1.7 60ft.
      Turbo size have already proven to be a great upgrade after Team AVR 1,8T Golf Mk4 went 11,2/129mph with similar turbo .

      So ... A list of modifications before i post the new pics under the headline This is just a feeler and soon i will post pics almost every week.

      1:Race proven for 2 season tubular manifold will get 2 modifications . T25 bolt pattern with new pinbolts and coating instead of the old polished finish . Portes vs turbo inlet. EGT bung. With help from Josef Pilot custom pro welding
      2:USRT 580cc injectors aka "600" @3bar
      Will run em at 4 bar and use 50/50% alcohol for track days .
      Street will still be on pump fuel

      3:Spec stage 3/4 clutch
      4:New final gear for the 02J because i was tired of putting 5th in @ 118mph and losing mph/sec
      New high final drive for 130mph+ in 4th gear .

      5:USRT Walbro 255lph inline fuel pump
      6:Simens VDO catch tank to prevent car from going lean at hard acceleration and cornering
      7:APR stage III intank fuel pump
      8:USRT/Autotech light weight steel flywheel and ring gear
      9:Modified turbo intake with integraded 3.5inch/90mm/86mm inner diam MAF
      By Mattias Olsson custom pro welding .

      10:Modified Plenum with new shape for even better flow for the last 3 cylinders. New unions Not polished ...i will do that later With help from Mattias Olsson custom pro welding .

      11:Same Race proven semi cross flow 800hp intercooler with air scoop for more and better airflow through the core

      12:USRT Lm-1 wide band lambda kit
      13:New Garret GT BB style downpipe with "home made" flange
      With help from Josef Pilot custom pro welding
      3,5 inch cone to 4inch to fit the RS oulet from the exhaust flange without covering anything LIKE the ATP aftermarket 3 inch does. Free flow ! Exhaust wraped .

      14:New Airfilter box with even smother inside and without plastic velocity stack from last years setup. OEM Paper filter . MAF mounted in semi-velocitystack maf housing . Smothed airbox for good flow .(box will support over 400hp with smothed innera and 4inch snorkel) Air box with 4.5 inch snorkel+stack

      15:K&N filter
      Huge K&N filter for track use .
      Double filter area vs OEM .
      But i will use OEM box and filter for street use .
      Paper filter will support peak hp but will give me less reponse . But with much much cleaner air for street use .
      RF-1004 Product Specifications
      Product Style: Round Tapered Universal Air Filter
      Base Outside Diameter: 5.75 in (146 mm)
      Flange Angle: 10 degrees
      Flange Inside Diameter: 3.5 in (89 mm)
      Flange Length: 1.75 in (44 mm)
      Flange Type: Angled
      Height: 12.125 in (308 mm)
      16:USRT/Tyrolsport adjustable FPR

      17:New oil return assy/bracket
      Oil return and turbo bracket

      18:New home made gaskets
      With help from Mattias and Josef
      Home made gaskets

      19orted and grinded K24 inlet T25 style flange Garret GtBB Turbine
      -Wheel: 56.5mm w/ 84 trim
      -Housing: 0.64 a/r
      -Internally Wastegated

      20:USRT Waste gate accutator 15psi
      Custom adjustable WG
      Notice the "perfect" bend for free flow .
      Crappy silicone bend´s are a big no no for good flow .
      21:ATP/Garret GT3071R-WG Dual BB, 64AR, 84 Trim Turbine
      Fast spool is the key to fast quartermile times
      450 spec HP BUT similar size AND with 22psi (waste gate semi open = good flow) Can make 450whp . Proven from last year making ~370whp from the small K24 0.41 A/R exhaust housing@1.2bar Turbo With KKK24 flange
      Notice the difference aginst T25 .
      Custom ported gate that will open 90% for full flow at high rpm´s

      22:Support by BILTEMA
      Tools ,Airfilters,oil and new 17" wheels for 2006 .
      ( ©Photographer Håkan Ahldén)

      23:Same home made catch can from last year.

      24:Still same Pimpe´d Gauges from last year.
      Oil pressure,boost pressure,Oil temp,EGT,And wide band lambda

      25:ASSY pics

      26:I got a "top sectret project for the cyl head
      8000RPM Cylinder head .
      1:New natrium valves
      2:New lifters from INA (latest version)
      3:new seals
      4:Autotech Sport tuned valve spring kit
      OEM 230degr with 10.1mm lift 114!?!?lobe ctr
      Let the rebuild of the new Super-vrthead begin.
      These stiffer valve springs alone will extend the revving capabilities of your valvetrain to the 8000 rpm mark.

      OR if i get some sort of sponsorship on this specific matter i would go for DSR 256degr 10,9lift 118 lobe ctr . DSR regrind is my only hope cause budget is low and a company here i Sweden has already made a set of FI 260s that didnt give me a single hp in 2004 .
      I have e-mailed DSR about supporting me and im waiting on their answer

      I will do the fine tuning of the valves/valve seat my self.
      27:NEW bushings and modified stage III motor mounts.
      1:Rock har bushings VS "soft" stage 3 uretane bushing . 2:ENGINE LOWERED 10mm to prevent turbo from hitting upper firewall

      28: 70C Fan temp switch and 70c thermostat instad of the old 100c ones

      Modified by foffa2002 at 10:39 AM 1-20-2006

      Modified by foffa2002 at 6:15 AM 2-28-2006

      Modified by foffa2002 at 1:10 PM 5-29-2006

    2. Member veedub11's Avatar
      Join Date
      Mar 9th, 2002
      Shaw District DC
      MK6 GTI Autobahn & 2013 Tiguan SEL 4-motion (Past: MK4 Golf TDI, MK3 Surf Green GTI 2.0T, Corrado VR
      11-10-2005 09:46 AM #2
      Pic editting is > turbo tuning.

    3. Banned V84LNCH's Avatar
      Join Date
      Aug 29th, 2003
      11-10-2005 01:06 PM #3
      you might want to consider bigger injectors than the 440's.
      and why the small turbine housing? why not go with a t3 turbine? at least go with the .86 is you're staying with the t25...

    4. 11-11-2005 01:29 AM #4
      440cc running at 4 bar is enought. [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Depending if you run 12.6-12.9:1 or ultra rich 11:1 etc
      And the "small" housing is just for spool respons .
      last year i ran size 6 and now size 9 housing by KKK/Mitsu standards and thats a huge diffrent in my eyes .

      BUT atleast i can get a bigger one for this if i have to i couldent do that with the KKK.
      But my trick is to get the engine to give great power at low boost so that i can run the waste gate open at higher rpms .
      Thats were i get the power .
      VR5 2,3L VS VR6 C2 2,9L
      Foffa @22psi VR5 2.3L =178WHP/Litre @ pump gas (still untuned)
      C2 @22psi VR6 2.9L = 148WHP/Litre

    5. Banned
      Join Date
      Jun 24th, 2004
      11-11-2005 02:57 AM #5
      too bad the t3 housing turbo spools the same if not better then the t25 one.

    6. 11-11-2005 03:01 AM #6
      Its a K24 inlet on my turbo and not t25 .
      Flange = T25

      Angle of the collector is also port matched to the angle of the turbo inlet for better flow .

      Modified by foffa2002 at 8:03 AM 11-11-2005

    7. Banner Advertiser Scott@USRT's Avatar
      Join Date
      Jan 13th, 2005
      Haddon Heights, NJ
      MK4 Jetta 2.0T, Mk1 Scirocco 16v, 323 GTX
      11-11-2005 09:36 AM #7
      I want to hug whoever made your intercooler. That's some sexy work! I love it! [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Scott F. Williams, Team Director
      US Rally Team

    8. 11-28-2005 01:47 AM #8
      New update with Turbo inlet and Plenum chamber.
      Modified intake .
      90mm MAF with Small velocity stack .
      Har to se in the pictures but its actually 90mm>95mm with 86mm inner diam were the sensor is mounted .
      Modified Plenum chamber .
      New shape of the rear part for even better flow and air distrubution.
      New In/Outlet bungs .

    9. 11-28-2005 12:27 PM #9
      I'll bet that sounds damn good! [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    10. 11-29-2005 01:23 AM #10
      The sound is pure porn .
      Got some movies if anyone want to se the car in action

    11. 11-29-2005 02:19 AM #11
      Pics of the new wheels added.
      "22:Support by BILTEMA
      Tools ,Airfilters,oil and new 17" wheels for 2006 .
      ( ©Photographer Håkan Ahldén)"

    12. Member
      Join Date
      Sep 15th, 2005
      Silver Spring, MD
      '02JETTA (SOLD) '00TTQ (SOLD) '90 C2 964
      11-29-2005 11:56 AM #12
      vids plz

    13. Banned V84LNCH's Avatar
      Join Date
      Aug 29th, 2003
      11-29-2005 01:24 PM #13
      Quote, originally posted by 18T_BT »
      vids plz

    14. 11-29-2005 02:44 PM #14
      Give me an e-mail adress and i will send them .
      please post em online!

    15. 11-29-2005 02:53 PM #15
      Air box/mounted maf,injectors,clutch,etc etc pics posted .

      Modified by foffa2002 at 8:05 PM 11-29-2005

    16. Member
      Join Date
      Sep 15th, 2005
      Silver Spring, MD
      '02JETTA (SOLD) '00TTQ (SOLD) '90 C2 964
      11-29-2005 03:53 PM #16
      Quote, originally posted by foffa2002 »
      Give me an e-mail adress and i will send them .
      please post em online!


    17. 11-30-2005 10:47 AM #17
      Wow, that's one of the best looking Mkiv Jetta's I've ever seen. And that's some nice looking work with the turbo/ic
      We race for long periods of time.
      Mediocre Motoring

      #48, 89 Golf ChumpCar with ABA

    18. 11-30-2005 02:03 PM #18
      Quote, originally posted by Tikigod_III »
      Wow, that's one of the best looking Mkiv Jetta's I've ever seen. And that's some nice looking work with the turbo/ic


    19. 12-01-2005 08:37 AM #19
      **Catch can picture added**

    20. 12-07-2005 01:32 AM #20
      Latest update .
      My 3inch/76mm downpipe ive just spent weeks of making is now in the trash can .
      Im going for 3.5inch /90mm downpipe for maxing out those last ponies at high rpm and its already on the welding fixture .
      Backpressure on a turbo car sucks
      **Flywheel pic added**

      Modified by foffa2002 at 9:27 AM 12-7-2005

    21. Member Jefnes3's Avatar
      Join Date
      Aug 17th, 2001
      12-07-2005 09:12 AM #21
      Quote, originally posted by foffa2002 »
      Backpressure on a turbo car sucks

      Run a larger turbine housing...

      Modified by Jefnes3 at 9:46 AM 12-7-2005

    22. 12-08-2005 12:54 AM #22
      the back pressure in the turbo housing/ exhaust manifold is seriously higher than in your downpipe (especially a 3") your restriction is the housing, not the pipe (seen guys run 500 whp off a 3"DP)
      if my memory serves me correct (and someone can verify this... Plaese) that your pressure in the exhaust manifold should not exceed a ratio of more than 2:1 (i.e. if you are running 1 bar boost in the intake manifold you should not have more than 2 bar in the exhaust mani) and if you want maximum power then a ratio closer to 1:1 should be aimed for.

    23. 12-08-2005 02:18 AM #23
      Nope ...no larger exhaust housing for me .
      Still going my own way on this stuff
      My theory is stolen from F1-T
      Run a turbo that will get your boost goal @ 4000rpm and run maximun rpm with WG fully open and still have your requested boost .
      So that you will get full response from turbo and get the high rpm flow through the WG and not try to squeest it all down the snail .
      Then you can run small exhaust housing without lag and high rpm chocke [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      have worked 2 years in a row
      BUT i still can upgrade the housing if i want .... thats the nice thing about garret .
      KKK got no upgrade´s

    24. Banned GraffixWB's Avatar
      Join Date
      Aug 20th, 2004
      12-08-2005 08:55 AM #24
      have you done anything to the bottom end?

    25. Geriatric Member CapeGLS's Avatar
      Join Date
      Aug 2nd, 2002
      01 Golf GLS 1.8T, 11 Jetta SE, 11JSW 2.5SE (Wifes)
      12-08-2005 09:02 AM #25
      Thanks for this great post. I am going to be purchasing a couple of the fuel products you listed.
      ET Feature Car 1/08|Forgeline Wheels|WRDusa.com|

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