UK-POLOS.NET - THE VW Polo Forum

Hi Guys,
I am Michael and live in Holland.
Driving a customized mk4 gti turbo.
large history of changes made to the engine and will highlight the most important ones.

It was a lot of work for the one who did the rebuild, with loads of new components.
unfortunately the 085 gearbox is not strong enough and the 5th gear is doing nothing at all at this moment.
so should be changed with a corrado g60 gearbox, with loads of work left to fit it on the smallblock engine.

Specifications:
- KW mk2 coilovers (lowered at about 9cm)
- 288mm Zimmermann brake disks and G60 pads.
- 16 Inch BBS RC rims with 195/40-16 Toyo T1-R tyres
- debatched trunk
- removed rear wiper
- raceland rollbar
- wiechers strutbrace
- autostyle bucket seats with sparco belts.
- removed the airco
- removed backseats and all unneeded plastics in the trunk

For sure the car has got a brake upgrade to 288mm drilled disks and brake pads of a golf mk2 g60.
future plan is to convert to a bigbrake solution with 304mm disks and 6piston caliper.



a list of the engine modifications:

- refurbished cilinderhead, with all new components
- custom 8,3:1 wiseco pistons
- custom g60 h-profile rods.
- balansed flywheel and crankshaft.
- Garrett GT2056 turbo
- Bosch 650cc injectors
- 20 vT throttlebody
- Cabledriven throttlepedal
- Bosch 044 fuelpump
- Custom exhaust manifold
- custom 3 inch downpipe and 2,5 inch exhaust
- KMS (kronenburg) mp25 stand alone engine management
- KMS Widelamda incl controller
- KMS Exhaust Gas Temp meter with display
- Verhoeven tuning front mounted intercooler

and loads of small parts.

Hulsen turbo tuning realised the build-on of the electronics.
It has been measured on a dyno and produces 273HP
Torque is 371NM @ 4900rpm.

for those who like pics... i will place some of them.

former turbo setup with garret gt2554 turbo (189hp) broken pistons


2 gti engines in a box ARC and AJV


refurbished cylinderhead:


crank and rods


piston oil cooling:


piston pen cooling inside the rod:


new and shiny!


turbocharger:


almost ready to be back in the car:


removed half of the interior:


downpipe


finished


engine (filter is placed after the pic)


interior:


small warning for upcoming wannabe traffic-light sprinters.


Nice HDR pic made on a meeting:


and last but not least... the dynorun

(url= http://i54.tinypic.com/wmh10w.jpg for a bigger pic)

Welcome to the Forum Mate What an Awesome car you have there!

270+ BHP is crazy, looks like you have put some serious time & effort on this car and you deserve credit for it.

How much has all this cost you to put together?

Benm

well done.

How does it pull with all that power going through the front wheels?

Wow thats quiet a build. Very nice dude.

And welcome to the forum. Chris

What an impressive build you have there dude.As mentioned how much in total did the work cost yourself?.

Get some more pictures up and maybe a sneaky video if possible .

Needs a stubby aerial

Godderz23 wrote:Needs a stubby aerial

If i was running 275bhp out of my polo i wouldn't even care if i had a NATS Mast on the top of my car.Plus i would be pretty skint and have no pennies for a stubby lol.

Its the little things i notice bradley

If i was running 275bhp out of mine....i'd be dead.

all the work is done by others, so all credits to:
- Richard, a clubmember of vwpolo.nl and currently building a 1.6 16v G60 in his polo 2F
- Hulsen Turbo Tuning, for all the electronics
- Mark, a friend which has a golf mk4 1.8 20v T @ approx 430bhp

i did the hardest job.. paying the bills lol!
when i look back... i can say that the rebuild costs more than expected.. don't know the value in GBP, but in euro's it is at least over the €7000.
and major things as Sachs Raceclutch, full stainless steel exhaust, intercooler were done in the past, so it should be a lot higher.

the aerial can be removed.. as the radio is removed also.. the only noise in the car is the sound of the engine, and.. when i have to go for a long distance a ipod shuffle

at my youtube channel (username: Coolkast) there is a vid which we did a testdrive on lowboost.. all the parts needs to be settled so, rev limiter was at 4000rpm, and boost at about 0.4bar.

as i mentioned earlier, the gearbox is not in a good condition so.. the car is standing in front of my home, and waiting for the new transmission.
unfortunately i didn't make a vid on full boost, but can tell all of you that on a sad day my smile always returns when pushing the throttle pedal.

Will search for more pics.. has plenty of the rebuild, i only needs to organise them

coolkast wrote:
the aerial can be removed.. as the radio is removed also.. the only noise in the car is the sound of the engine, and.. when i have to go for a long distance a ipod shuffle

Yeah i guessed as much, only kidding, silly british humour.

Didnt think it would be cheap to put together, stunning car regardless of cost.
I could only dream of having that power from my GTI.

I want to see more pics dude

Wow! Another Polo to put mine to shame...

I need a turbo, just so I can get one of those stickers - Amazing!

thanks all for those great replys!

Shame on me that i till now only react on my onw threath.
will read/reply some of your topics when i am at work (nice to read all the stuff next to my work)

Was it worth the stress and cash?

Honest

bradley1983 wrote:Was it worth the stress and cash?

Honest

273bhp..... ofcourse it was worth it its now a proper Sleeper