GCTech Motorsports 6765 2.5L Build Thread

[Serrari]

Hi guys, I had a 2.0T FSI engine in my car and made 653whp, here is the link to th build thread: http://forums.vwvortex.com/showthrea...PTE-6262-build. Just blew a valve and I decided it was time for a change. I am building a 2.5L engine and will be trying to get 850whp. Here is the parts that will be used in my setup:

Engine

• VW 2.5 CBT Engine
• Pistons JE 83mm 8.5:1CR
• Rods IE 4340 Chrome Moly steel +900hp
• Ferrea Valvetrain kit +1mm oversize +9000rpms
• Port and polish head by GCTech
• Custom aluminum intake manifold by GCTech
• 90mm Throttle body
• BSH engine mounts
• ARP head studs
• ARP main studs
• Calico rod bearings
• Radiator Koyorad

Drivetrain

• Transmission 02Q
• Spec Mini Twin Disc Clutch
• Billet flywheel
• Wavetrac LSD
• Custom traction bars by GCTech

Turbo setup

• Comp Turbo triple Ballbearing 6765 T3 .82ar CT4 +900whp
• Tial wastegate 44mm
• Tial BOV 55mm
• Garrett FMIC 24x12x4.5 950hp
• Hotpipe aluminum 3" by GCTech
• Chargepipe aluminum 3.5" by GCTech
• Turboheader stainless steel by GCTech
• Dumptube stainless steel GCTech
• Downpipe stainless steel 4" GCTech

Fuel system

• 5 Injectors 1200cc
• 2 Bosch 040 fuel pumps
• Fuel pressure regulator
• Return line kit by GCTech
• Direct port Coolingmist meth kit

Electronics

• Standalone (havent decided which)
• AEM wideband UEGO
• Turbo Smart Eboost2 Boost controller
• Autometer tachometer 10,000rpms
• Autometer oil pressure gauge

Suspension

• Bilstein shocks
• Eibach Pro-kit
• Tires Nitto NT05
• TSW Nurburgring wheels
• AWD conversion (after the engine is done)

SPONSORS ARE WELCOME!!!

The car is a Leon Cupra 2008, this is a pic of my last setup:



I just got the engine, but will be ordering a lot of parts and to update the thread with pics:

[pennsydubbin]

Wow this is going to be awesome how long do you expect it to take till its completed?

[Serrari]

Wow this is going to be awesome how long do you expect it to take till its completed?

Fully tuned around 4-6 months, many custom parts are going to be designed.

[TylerO28]

I'm in!

This is going to be GREAT!
good luck man!

[CoNGLoMeRaTeGTi]

looking good!

[gabe@bwperformance]

Looking good!

[kevin FaKiN spLits]

[sagerabbit]

SUBSCRIBED.

ALL CAPS.

[GTACanuck]

I just got a boner

Sub'd

[ReinertAngle]

This will be a sweet build. Interesting how he will sort out the fuel management and still be able to "drive" the car. Hope it doesnt end up a trailer queen.

[pete@integrated]

Hey, shoot me an email before you order those +1mm valves. We have made valve seats for much bigger valves, plus even the 1mm hang off the edge of the stock seat.

This should be an interesting 6 months for the 2.5L

[GTACanuck]

This should be an interesting 6 months for the 2.5L

Indeed

[pete@integrated]

This will be a sweet build. Interesting how he will sort out the fuel management and still be able to "drive" the car. Hope it doesnt end up a trailer queen.

There are tons of good standalones that will drive the intake cam VVT, the drive by wire, and hell- even haldex.

Vipec v88 is one- that's what we use and sell. I'll have basemaps for the 2.5L here pretty shortly.

[Serrari]

There are tons of good standalones that will drive the intake cam VVT, the drive by wire, and hell- even haldex.

Vipec v88 is one- that's what we use and sell. I'll have basemaps for the 2.5L here pretty shortly.

Im interested, just sent you a PM and email you.

[eatrach]

HOT TAMALES> that is going to be a nasty tune

[thygreyt]

you should talk to INA, they are the forum sponsor, and they have a lot of answers!

[spdfrek]

This looks like its going to be a good build. I have a question about the trans though. I don't see those stock gears holding that kind of power. Do you have plans for a different gearset?

[MKVJET08]

[pete@integrated]

This looks like its going to be a good build. I have a question about the trans though. I don't see those stock gears holding that kind of power. Do you have plans for a different gearset?

Powerglide! I'll make the adapter plates.

[INA]

Love it Serg!

[INA]

Hey, shoot me an email before you order those +1mm valves. We have made valve seats for much bigger valves, plus even the 1mm hang off the edge of the stock seat.

This should be an interesting 6 months for the 2.5L

You shouldnt be installing +1mm valve on stock seats anyway.

[08Drabbit]

high horsepower number out of 2.5 In for build and results. its probably hard to tell at this point but how reliable do you expect this thing to be? obviusly not DD, but do you plan on it being reliable enough to drive it to the track, beat on it, then drive it home?

[ViRtUaLheretic]

high horsepower number out of 2.5 In for build and results. its probably hard to tell at this point but how reliable do you expect this thing to be? obviusly not DD, but do you plan on it being reliable enough to drive it to the track, beat on it, then drive it home?

The 653hp motor was apparantly a DD, I bet this will be as well.


subbed!

[Serrari]

Turbo is here, 6765 triple ballbearing:

[HIBB 304]

^^^^^^^

[ReinertAngle]

Very exciting build. Appears that this is a "cost is no object" build... So why not hook up with Ricardo for a H/D transmission solution? Or perhaps a sequential gearbox. The built 6 speed you are planning will be short of this world when this is all together...

[thygreyt]

i think so too..

you need a GOOD tranny to handle such power properly.

[donjuan1jr]

i think so too..

you need a GOOD tranny to handle such power properly.

The 02q is vws best manual trans to date. I don't think hell have a problem in that area, with that kind of power he should think about some custom axles.

[spdfrek]

The 02q is vws best manual trans to date. I don't think hell have a problem in that area, with that kind of power he should think about some custom axles.

The 02q might be god's balls but at the end of the day the gears were never ment to hold that kind of power and will break. The axles have a chance of holding but I wouldn't trust them if they car is going to be pushed hard.

[JC@DouglasVW]

Awesome build you are putting together, I would like to see a motec ecu on that motor. Talk to Andre (Audi4u on here) he has alot of inside info that will help you in tuning this motor that might save you some time.

i think so too..

you need a GOOD tranny to handle such power properly.

Let us know when you want a dog box.

[thygreyt]

What types of engagement are available? This is a common source of confusion when searching for information on transmissions. There are two types of engagement: Synchro and Dog.

Synchro engagement (also known as synchromesh) is what most passenger cars use.

Advantages:
a. Smooth operation on the road
b. No special driving style required

Disadvantages:
a. Synchros and shifting forks can break when abused and shifted aggressively
b. Slower to shift vs. dog engagement

Dog engagement is what most race prepared vehicles use.

Advantages:
a. Engage at any rpm
b. Allows for wider gear design
c. Will flat shift (Flat shifting is a practice where the clutch or gas do not need to be totally lifted in order to shift. Users will slightly lift one or the other to unload the dogs to allow a very fast shift)

Disadvantages:
a. Difficult to drive on the road
b. Recommended only for race use
c. Special care required under normal street use

What is a dog box? A dog box is the term for a transmission utilizing a dog engagement. A dog box can have either helical or spur gears or both.

What is a half dog box? A half dog box utilizes a combination of synchro and dog engagement. It depends on the manufacturer and customer preferences. Generally speaking, the first and second gears are dog engagement and the rest of the gears are synchro engagement. A half dog box can have either helical or spur gears or both.

What is synchronizer (synchro) engagement?
Synchros are synchronizers inside the transmission. These are the actual parts that move when you move your gear shift from side to side and back and forth. Their job is to connect the gears of the transmission to the shafts that they ride on and lock them together. This must be done at a gradual rate or the gears will grind. The synchronizer drives a cone shaped metal piece against the gear and starts the gear spinning. It accelerates it to the speed of the output shaft. When the gear reaches the speed of the output shaft, the synchro meshes completely with both of them and directs drive through its splines from the gear to the output shaft or vice versa.

What is dog engagement? Dogs are basically no more than cogs on a slider. The shifter pushes them into a receiver ring which engages the gear it is attached to. There is a separate dog and receiver for each gear in the transmission. On a racing transmission, there is a lot of "slop" (the gaps in the receiver are a lot larger than the teeth on the dog), which makes it easier to move into and out of the gears at higher RPMs without fully engaging the clutch.

Can a dog box be driven on the street? Though generally reserved for race applications, many users drive dog boxes on their daily driven vehicles. To do so, you need to learn proper shifting techniques and rev matching skills to decrease wear on the dog gears. The Shifting FAQ, this article, local personnel, or your transmission professional should be able to provide assistance with proper shifting techniques. This is one decision that should not be made lightly. If there is the slightest doubt in your mind as to your technique or attitude towards a daily driven dog box, you should opt for a synchro engagement transmission. Another thing to keep in mind is that a dog box is definitely not an option for a vehicle that sees occasional use by others such as your spouse, friends, visitors, valet, etc.

i diddnt know what a dog box is...

oh and btw a couple of the tdi race cars are using the GTI 6spd 02q.. i was told so first hand... but they arent making the power that this is hoping to!

[kamahao112]

very nice no more fsi bs..

comp turbo sound clip from the last 1.8t i finished

[BETOGLI]

Man... You're sick!

[kamahao112]

just a little tip comp turbos need oil restrictors.. well mine did my car makes 80-90 psi on cold start and 20-25 at full temp and 60psi while cruising.. just a little guideline

[BETOGLI]

It might be an ultra-dumb question but... Did you considered as well the 3.2 or 3.6 V6 engines for your new set up?

Also I haven't heard of anybody moding a Volkswagen's W8 engine!