MkV GTi DSG GT2860RS Conversion

[Chipmunk]

Hi guys and girls, on my K03 setup the most power I ever made was 204 kW/274BHP, mods : Software, 76mm Evolution Downpipe, Devils Own WMI, Forge DV,BSH PCV Fix. I then broke the engine   and decided that its a good time for a turbo upgrade aswell, wanted to go K04 but its so common these days     went a little bit bigger with a Garrett GT2860RS     ball bearing turbo as I still drive my car everyday.

Here is the list of parts for the repair and turbo upgrade :

Pistons
Intergrated Engineering Conrods
ARP Conrod Bolts
Rings
Bigends
Mains
Valve stem seals
Bush
Sleaves
Garrett GT2860RS Turbo + Manifold
Injectors
DV Relocate Kit
Custom 76mm Cold Air Intake
GIAC ECU Software
GIAC DSG Software
GIAC Handheld controler
76mm Exhaust
Bigger Intercooler
Eibach Lowering Springs
Then theres still some small things like gaskets and so on that I didnt mention.

We estimate around 270 kW/360 BHP.
Build started on monday 19 March 2012, completion date hopefully 30 April 2012.

[Chipmunk]

Pics of my ride





Pics of my Garrett GT2860RS Turbo + Manifold






Engine Removed

[Chipmunk]

Some pics I took of the stripped motor.

Cracked Piston on the left



Head removed

[Chipmunk]

Block with the new sleeves installedand IE Conrods. I also ordered Eibach lowering springs as I plan on fitting 19" wheels. Some pics I took.

Block



Integrated Engineering Conrods



Pistons



Eibach Lowering Springs

[Chipmunk]

Some pics I took of the motor being assembled.

Seeing as I use the car daily I thought it would be nice to have 3 different maps, cos during the week I spend alot of time in traffic and the lady is already heavy on juice, below is the GIAC handheld controller, I must still order it but it has 3 modes, stock, pump and race mode.

[Chipmunk]

Pics of motor finally back in the car. I decided to order a custom made 76mm Cold Air Intake as my current one is 63mm and also bought a boost guage.









Boost guage looks similar to this one below

[Squeeguk]

Very nice man. Where did you get the manifold for the Garrett Turbo from? I work for Honeywell at the moment, and as Garrett is a Honeywell company, was wondering if I could get one of them turbo's and put it in my car rather than a K04.

[Chipmunk]

Very nice man. Where did you get the manifold for the Garrett Turbo from? I work for Honeywell at the moment, and as Garrett is a Honeywell company, was wondering if I could get one of them turbo's and put it in my car rather than a K04.

Thanks, the workshop thats doing the conversion for me ordered it with the turbo from Turbo Direct, just remember im from South Africa 

[Squeeguk]

Yep, me too originally, lol. Recognised the Western Province plates. Keep us posted on how it goes ok?

[Chipmunk]

Yep, me too originally, lol. Recognised the Western Province plates. Keep us posted on how it goes ok?

Oh okay  yes if all goes well we will start her up saturday, then next week start running the engine in for 1000 km's and after that she will be tuned again.

[DanGB]

With WMI you should get quite a bit more than 360 

suprised you went for a GT2860RS as as far as i know they are very similar size to the k04 twinscroll

[Chipmunk]

With WMI you should get quite a bit more than 360 

suprised you went for a GT2860RS as as far as i know they are very similar size to the k04 twinscroll

Yes true, as 360 BHP was achieved with a car that didnt run WMI, I chose the GT2860RS as they made more power than the K04 and I wanted something different to the normal K04 route.

[Chipmunk]

Update: Turbo fitted on Thursday, 76mm exhaust going on today (see pic).

[Hurdy]

Nice mods

Good to see another build car but going a different route.

[Chipmunk]

Ordered these carbon fibre look DSG paddle shifters today.