K03/K04 wastegate actuators from Forge

[Hurdy]

I've been looking at a thread over on Golfmkv's and subscribed to the teaser thread for the actuator development.

It looks rather tasty and for the K03 guys who have already modded to include a HPFP, intake and TBE it is going to hopefully rock your world.

The standard actuators on K03 are letting boost past at around 4psi which increases the N75 duty cycle, which basically reduces overall power and torque attainment across the rev range.

On a typical test they simply swapped the OEM wastegate for the Forge version and the car made these increases.

Standard Correction Factor:


SAE Correction Factor:
[/

Yes guys you read right, that is a gain of 42whp and 48lbft

Now the not so good news. The guy in question had a leak that was present before AND after the dyno's. This means that possibly if he hadn't had the leak he would have "only" seen an increase of around 15whp and 15lbft. Still amazing though.

Here's hoping that a K04 version gives similar results

[Hurdy]

Just in case you want to read the full 20+ pages, here is the link.

Angel@Forge has the main posts to look out for if you want to skim read the important bits

http://www.golfmkv.com/forums/showthread.php?t=80971

[iainalpine]

Interesting read and very interesting results. Think i will be keeping an eye on this one.

Iain

[RedRobin]

....

Nice 1, John! - Very interesting mod.

[GTIjames]

its already available in uk, forge develop everything here in good old blighty before they release it to the yanks!

http://www.forgemotorsport.co.uk/content.asp?inc=product&cat=260303&product=FMACVAG05

quite reasoable too, not sure if it fits ed30 though

[dan.payne]

Hurdy why dont you try it out for us, and if its any good, Group buy? 

[john_o]

that looks like a nice mod.
For me though I'd want to know how much the OE K04 tends to open.
If the K04's prove to have the same issue , then yes Im in. although my spool is already very hard so I dont really need it any sooner/harder  (or maybe I dont have much wastegate blowby in the first place)
The raising of the default min boost also 'slightly' bothers me, which is there as a safety guard.

Seems very much based on the position of the car prior to the mod, which as far as I call tell isnt that easy to ascertain before changing...

looking good though 

give some time for the pioneers to sort out any issues 

[SteveS]

nice stuff!!

[Hurdy]

Hurdy why dont you try it out for us, and if its any good, Group buy? 

The K04 actuator is different. I'm hanging on for the results of any K04 trials before I jump on it.

[nick-barnes07]

ill be getting one for the k04 as soon as i find one cheap enough with some injectors 

[Tfsi_Mike]

Will be keeping an eye on this! Good find!

[jonnyc]

I have been watching this over on the other forum on and off..

So are they just saying that the standard actuator is allowing wastegate creep so you loose boost top end?? If so a stronger actuator would for sure be the answer.. It must be pretty easy to test for this??

Im going to look into it and see if I can get something on mine to test, so long as your logging whilst testing then it should be fine!

Jonny

[Top Cat]

I asked Bacillus about this a week or 2 back and he said one of his friends is currently testing this, but he has the stage2+ and uprated fuel pump, He doesnt know what if any benefit can be gained by cars not at the stage2+ 

[john_o]

that wasnt my take on the reason.  i took the following :
above x psi  the wastegate is opening to a small or large extent before its even reached a point where the boost should have been bled...
therefore at all points in the rev range whilst under boost there is potential bleed through the wastegate that hasnt been requested by the ECU......
in theory the stronger actuator prevents any bleed , thereby spool is much faster and all flow is controlled by the ECU and N75 rather than constantly having a x psi bleed as part of the equation....

if your car doesnt bleed psi then this mod isnt gonna give you any gain BUT
if it does (and it appears that most K03 cars do!) then it will give you a gain.
It remains to be seen whether VW improved the design for the K04.

remember the way the the OE DV has been changed
1. VW design fails in OE and tuned applications
2. Forge produce a replacement
3. VW eventually come out with a DV that solves the situation that may even be better than the original forge solution to the problem...

please correct me if Im wrong 

John

[Tfsi_Mike]

Is it here?

http://www.forgemotorsport.co.uk/content.asp?inc=product&cat=&product=FMACVAG05