Golf 2.5T Project

[OldPhart]

This thread is devoted to converting my Golf MK6 naturally Aspirated to Turbocharged. This is my 1st Vortex thread, and I figure it'll be somewhat of a diary (to start), but I'm also looking for conversations. I have a lot to learn and appreciate anyone with wisdom or well-intended opinions.
Please be civil.

...

Little background:

Fall 2011 - Bought used 2010 Golf MK6, and installed a Carbonio CAI, AWE Catback, and a few other small mods. Love the way the car sounds and pulls. No dyno. Had a tune from Speed Tuning in MD - waste of money.

Jan 2012 - Visited C2 in KY, drove the bunny, and spent a lot of time w/ Chris Collier. 1) The car was a monster! It was also beautiful. 2) Chris is the bomb. Very, very smart. Does amazing engineering work. He is very patient and an apt teacher. Would do business w/ him blind.

Feb 2012 - Moved East and found AP Tuning in PA. They sold / installed HEP SRI & UM Tune. Brought car and did the work. Took 4 days! (First MK6 & funky ECU...) But the craftsmanship at the APT crew is tops! They do serious work, are passionate, charge very fair rates. Dyno pull @ 180 / 165. Pulls strong and steady, and sounds like Frankenstein in a cave. Love that SRI.

June 2012 - Dropped my car off @ APT for a BW Turbo / UM Tune. Car's been there 3 weeks this Sat. Can't wait to see / drive it again.

...

Here's the setup on the install:

Bluewater Performance T3 Manifold: In-house / Made from Sch. 40 steel
V-Band equipped
Turbocharger: Precision T3 (was not given model #)
Turbo Intake Piping: 2 – 2.5” Stainless (medical grade)
Side Mount Intercooler (SMIC): BW SMIC / Treadstone Core.
Includes all necessary piping:
Tial 38mm Wastegate: Tial Sport F38 Wastegate (recirculated to DP)
Wastegate set to 10 psi
No Boost Controller *
Bosch 550cc High-Impedance Injectors
Forge 007 Diverter Valve

* I don't need a boost controller because, even if I could, I do not want to run more boost (yeah, you read that right). The 2.5 engine is supposedly OK to 300 wHP (according to: Blue Water, United Motorsports, AP Tuning, and Integrated Engineering). As you'll read later, power is only one part of the larger picture / objective.

In addition to the turbo installation and tuning, we added a Blue Water Oil Cooler kit and gauges (pods) for Boost, Oil Pressure, and Oil Temperature. We also added a Treadstone turbo blanket ** and heat wrap for DP to mitigate heat contagion to the engine bay and filtering into intake temps.

** Yes, I did a lot of research on the pros & cons of any turbo heat reducing equipment. The final logic was that reducing ambient charger heat was better for all other components (including the compressor) including oil. Speaking of oil, this blanket is designed to reduce central oil temps between the turbine and compressor. The only risk is coking (cooking) the oil in the turbine housing. But if the turbo is cooled down properly and not driven w/ insanity, it should be OK. (Hope the gauge reads oil temp relative to turbo area.) Worst case... I simply take the blanket off (when it's cool).

There are other mods we're doing such as upgrading the brakes to cross-drilled & slotted rotors, better pads, and SS lines. (I'm also having a large hole drilled out near the pedals in case I have to stop the car w/ my feet.)

Lastly, we're upgrading some bushings to try and firm the car up under heavy acceleration.

…

That's it for openers.

Peace.

-Chris

[vwluger22]

Cool

[thygreyt]

rule #1: pics for clicks!!

[itskohler]

rule #1: pics for clicks!!

This.

[OldPhart]

Seeing that my car will be on the operating table another 2 weeks, here are pics of the SRI work
done on it back in Feb 2012 @ APTuning.

Golf MK6 2.5 SRI Install & Dyno

BTW - Those wheels are not mine; they're off a track car. APT put them on to run the dyno since
I had snow tires on my rims.

Meanwhile, I expect Tom @ APT will be posting pics on their facebook site when the project
is complete.

[OldPhart]

What was a three (3) week effort is no more...

It's now been six (6) weeks, and we're definitely going to week seven (7). This is far, far
longer than planned. My patience is normally high, but this is wearing it thin.

We hit hardware issues where the down pipe didn't fit and had to be machined, which added
about 1 1/2 weeks. Since we were delayed I threw in some more bolt-ons.

For a full week now, the ECU doesn't want to cooperate. I'm waiting til next week until I
see this as a serious roadblock. Then we have to find a backup plan..., but ~

It's not like w/ the SRI where you just pull it off. We're talking about $4,000 + in turbo
hardware (alone), so how do you back that out?

Granted, if successful, this is likely the FIRST MK6 2.5T in the world. So you have to expect
some bumps. But I get nervous when software is the issue (I'm a software engineer, 20 yrs).

Even if this goes bust, I have to give three thumbs up to APTuning staff. They always do superior work:

Tom
Dave
Ryan

I'll post again soon come success OR failure. Let's hope it's the former.

Peace.

-Chris

[chinapie2]

I have the first MK6 2.5T

[OldPhart]

I just read that an hour ago.

It sounds like you LOVE your "new" Golf, and that is so awesome.

Your comment about "being patient w/ C2" makes a lot of sense, since we are trailblazers into uncharted territory. It's both nerve-racking and exciting.

My goal has been to create what I call "civilized power." Sort of like the part Golf, part Audi RS.

So how long have you been T'd and do you still spend 12 hours at a shot driving around???

[Justin14]

Wow big project. Not sure if you're in Louisville currently, but I live 10 minutes from C2. Let me
Know if you want some spy pics of the car lol.

I hear they're good guys. I'm thinking about getting my golf flashed.

Anyway good luck

[nothing-leaves-stock]

Wow big project. Not sure if you're in Louisville currently, but I live 10 minutes from C2. Let me
Know if you want some spy pics of the car lol.

I hear they're good guys. I'm thinking about getting my golf flashed.

Anyway good luck

he's not having C2 build it....... cars in pa(not here)

best of luck with it, hope all turns out well....

[thygreyt]

he is using a Blue Water performance kit.. its the t3 version, which is similar to a C2 kit

tuned by united motorsports.

[Anile_eight]

sounds like it could be a lot of fun! I wish I could drop the $ to do the same. Good luck! Can't wait to see the result!

[OldPhart]

This nearly concludes week seven (7) on a project estimated at two (2).

We have the turbo file loaded on the ECU as of EOB Wednesday 8/15. This effort alone has been a 2-week endeavor. The solution required obtaining an ECU from a dealer for the stock file, cracking the ECU, and getting the file loaded.

As of 4:00 PM today, the car starts & runs, but has not been driven. It's been heat and leak tested. No dyno. Tomorrow should be the first test run.

Tuning will not begin until this weekend or early next week. I expect the car will be done, Done, and DONE by Tuesday 8/21, Wednesday at the latest.

I am planning on picking up the car next weekend, 8/25. That will be eight (8) weeks to the day I dropped it off. That's 4x.

Next week is it. Will post again then – come hell or high water.

[Tom@APTuning]

UM Tuned MK6 2.5T =

[Jefnes3]

Runs more than ~3psi boost.

-Jeffrey Atwood

[thygreyt]

just saw a video of this... tis quick

[OldPhart]

As you can read, the car is done. Aside from a tweak on the psi, dyno, tweak, etc., it's done.

So I'll be picking up this Friday early AM. Eager to drive it, feel it, hear it.

Will post impressions within the week. Pics & videos soon thereafter.

As this is the 8th week, my expectations have become damped. Also, I'm wondering
how insane I am to have spent an insane sum. Hopefully, the car will deliver even more
fun than it ever did before. We'll soon see...

[thygreyt]

As you can read, the car is done. Aside from a tweak on the psi, dyno, tweak, etc., it's done.

So I'll be picking up this Friday early AM. Eager to drive it, feel it, hear it.

Will post impressions within the week. Pics & videos soon thereafter.

As this is the 8th week, my expectations have become damped. Also, I'm wondering
how insane I am to have spent an insane sum. Hopefully, the car will deliver even more
fun than it ever did before. We'll soon see...

lol. you will be positively impressed... you'd have to be dead to not enjoy it more.

more fun? thats a given...

[pete@blackforest]

Just watched the video on APTuning's Facebook.
The tires don't last a chance past 5,000 rpm! Ask me how I know..

The video description said 12psi - stock compression?
Good work guys, it's always nice to see another 2.5T on the road.

[Tom@APTuning]

Just watched the video on APTuning's Facebook.
The tires don't last a chance past 5,000 rpm! Ask me how I know..

The video description said 12psi - stock compression?
Good work guys, it's always nice to see another 2.5T on the road.

Customer has other wheels and tires for the car so should get some better grip then whats current. Also he doesnt plan on daily running it this amount of power. He wants it more mellow and balanced, we are simply showing what it is capable of if he chooses to turn up the boost.

We are now at 14psi on stock compression with zero timing pull.

[nickbeezy]

this dyno makes me jealous.
comparison of prior NA set to 14 psi boost
i need me some boost

[thygreyt]

I have the first MK6 2.5T

Dyno sheet?

Sent from my HTC Sensation 4G using Tapatalk 2

[Tom@APTuning]

Dyno sheet?

Sent from my HTC Sensation 4G using Tapatalk 2

I think his was running a couple weeks ago, but only a couple psi as its an auto. I think he was planning a manual swap

[pete@blackforest]

... We are now at 14psi on stock compression with zero timing pull.

I'd be weary of running this on a daily (I know the customer isn't), but I applaud nonetheless. Very cool.

[thygreyt]

I'd be weary of running this on a daily (I know the customer isn't), but I applaud nonetheless. Very cool.

I agree on that this is an awesome result. Ap tuning and united motorsport deserve a clap on their backs.

With zero timing pull at 14psi, and seeing stock engines on ~400 whp (andre did this. as well) I don't understand why to be wary other tha k speeding tickets!

Sent from my HTC Sensation 4G using Tapatalk 2

[Jefnes3]

I'd be weary of running this on a daily (I know the customer isn't), but I applaud nonetheless. Very cool.

~14-15psi boost is limited only by the injectors. This turns out to be a decent
setup: enough power to be worth the effort, yet not at the motor's limit.

-Jeffrey Atwood

[pete@blackforest]

~14-15psi boost is limited only by the injectors. This turns out to be a decent
setup: enough power to be worth the effort, yet not at the motor's limit.

Excellent.
14psi is awfully tempting, but I must resist the temptation.
Good work.
I'll stop clogging the thread now.

[thygreyt]

Excellent.
14psi is awfully tempting, but I must resist the temptation.
Good work.
I'll stop clogging the thread now.

last post: why must you resist temptation??

just crank the boost and those 550s to 14 psi and have fun!

[Vegeta Gti]

so the BW400 kit, SRI and 870cc on whatever turbo is included in the kit..at say 17/18psi..is looking at 400whp. will the crank/rods hold this for real on a daily car on pump(92)?

is anyone running meth? i would def prefer to do meth since the temps here are static 85-90 year round here with avg humidity 55-65% as well.

[thygreyt]

so the BW400 kit, SRI and 870cc on whatever turbo is included in the kit..at say 17/18psi..is looking at 400whp. will the crank/rods hold this for real on a daily car on pump(92)?

is anyone running meth? i would def prefer to do meth since the temps here are static 85-90 year round here with avg humidity 55-65% as well.

550cc

as i said, the turbo depends on the project.

at 14 psi you are looking at around 340 whp. (as little as 330 whp or as much as 360whp)
at 20psi +400 whp

no meth yet

[Vegeta Gti]

i know it comes 550cc, and that above dyno is 550cc.

i am saying..with 870cc or larger the sri and bw400 is capable of this. the details on the site are vague and when a turbo is mentioned, it is worded as the turbo was a personal choice, not the kit included unit.

lots of tech, loving it. can't wait to my first 5cyl turbo..that isn't a 4000qt

[thygreyt]

i know it comes 550cc, and that above dyno is 550cc.

i am saying..with 870cc or larger the sri and bw400 is capable of this. the details on the site are vague and when a turbo is mentioned, it is worded as the turbo was a personal choice, not the kit included unit.

lots of tech, loving it. can't wait to my first 5cyl turbo..that isn't a 4000qt

the next "drop in" injectors are 1000cc. 850s or 870s would need some modifications to fit.

you may also need a fuel pump upgrade... that why most customers stop@ 550s

[Vegeta Gti]

injector adapters are everywhere, fuelpump upgrade is already in the books with the kit.

just searching as to see if anyone is actually doing it. not just shop cars. someone said in a post that jeff verified that the 870's make a huge difference to go over 12/13psi.

just sorting through a lot of posts from dreamers, and get results from the doers so i have a better plan of attack. prefer to do it in a day and not be surprised too much.

[Tom@APTuning]

870cc were done for testing and have done 400awhp on a stock motor. However the 870cc tune wont be the finished consumer product. The bigger injector tune will be a little while longer. Just do the 550cc's awhile, if you buy that tune from me now and when you get past the 550cc capabilities I will give you 100% credit towards the next tune, just pay the difference.

[thygreyt]

870cc were done for testing and have done 400awhp on a stock motor. However the 870cc tune wont be the finished consumer product. The bigger injector tune will be a little while longer. Just do the 550cc's awhile, if you buy that tune from me now and when you get past the 550cc capabilities I will give you 100% credit towards the next tune, just pay the difference.

so i'll have to wait with ONLY 355 whp?

this sucks.

lmao.