APR/Race Developments Stage 4+ 700hp+ TTRS Build

[graeme]

Lets hope that you get that crach bar back on it 

Looks good tho  cant wait to see it stage 4 

[Poverty]

Yeah there were a few differences between our builds to begin with mainly in regards to the cylinder head but jonny is updating his so we will both be running the same spec. His car will be about 200kg lighter than mine when finished though, he's one crazy guy lol

[AndrewJB]

i want a passanger ride once this is done!

[Bignod00]

Subscribed!

Glad to see this finally in a Readers Ride thread mate, great work!

[Poverty]

Some more exhaust porn. Gotta give massive props to Forge Motorsport/scorpion exhaust for making a Ti exhaust for the TTRS! Aero Space Grade 1 Titanium with 1mm thickness!

[Poverty]

At this point I decided that I would move away from Revo software, and paid a visit to APR.

They wrote a stage 2 map for the car, I was hoping for great things after having tested their new 2.0TFSI software and I wasnt dissapointed. The power holding that the map provided at high rpm map was just crazy. Its pulls and pulls all the way to the redline. The way the power doesnt drop off and it keeps on just pulling leaves you smiling from ear to ear.

Now after the forge intercooler was installed, the car was dynoed at 420hp at revo stage 2 and  about 400lbft of torque, I cant remember the exact figure.

I decided I wanted to dyno this new map to see what the car was making now.





The APR map gave me a nice gain, 430hp and 450lbft! The power curve is just beautiful aswell!

So now we are at 430hp and just about reaching the limits of the stock turbo with the limited size intercooler and no WMI.

However, still hungry for greater power, so on I plod.

[Poverty]

Performance Vbox figures now

Some vbox gps data from stage 2.

0-60mph in 3.4 secs. 30-60mph in 1.9 secs. 0-100mph in 8.4 secs.

30-130 time is 12.x something seconds irrc.

[Obese]

The ttrs is one of the few cars that really gets my attention. its good to see a few are getting properly played with

[Poverty]

The ttrs is one of the few cars that really gets my attention. its good to see a few are getting properly played with

Thanks, always wanted to do a BT conversion on something, and I think the TTRS fits the bill perfectely.

Anyway earlier this year I was at the pod, was struggling all day trying to get the gear into third on every run, as was shown in the results of all my runs being slower than stock at times. One run too many as I attempted my usual ninja shifting into third, but selected 1st gear instead 

Quick scan with vagcom showed the engine revved to 8800rpm, the engine still ran, but didnt sound too healthy. So off it got towed to nearby APR in milton keynes.

It was a weird feeling having just broke your engine. I took it better than I thought I would, albeit all I was thinking at the time was of the possibility of a 15k bill for a new motor. 

The car sat at APR for a while as I was away on holiday, which gave me 2 weeks to think about which steps I wanted to take next, and gave APR a chance to strip down the engine to see what damage there was.

Turns out a few of the valves kissed 2-3 pistons, but other than that the motor was fine, so about 1-1.5k to put right. However as I had ambitions for big power and the engine being out already I decided that I might aswell build the engine.

Engines out!






So after asking around for recommended engine builders I chose Race Developments to spec and build the engine. These are the guys who built the skoda bonneville record holding 700hp 2.0TSI, time attack evo cars and race engines for british superbike racers to name a few.

And so the engine build begins!

How it looked partially stripped down






And some progress pics.


Stripped down head



Port moulds and the ferrea valevtrain

[Poverty]

]Rings gapped, parts balanced, ready for assembly. High temp, low friction thermal coating.


Old VS new



The cylinder head getting race developments renowned expertise applied to it



Superfinished Crank

[Poverty]

Attention was then turned to the gearbox.

More isotropic superfinishing treatment.

What is superfinishing?



Isotropic Superfinishing increases horsepower by reducing friction in the engine, gearbox and drive train components. Testing has shown this process increases the functional life of motor and gearbox components by an amazing 300%!
Isotropic Superfinishing is not a coating, polish, oil treatment or additive of any sort. This technology is dyno tested and track proven. It gives the added advantage every competitor is looking for. It is effective on all metal components involved in the production and delivery of horsepower.
Manufacturing cannot make a perfectly smooth surface. All new surfaces, even when coated, have surface asperities (micro peaks). When metal cutting begins, these asperities are producing friction and affecting the life and performance of the product. In a closed system, as metal components mate and shear, every component in the oil/coolant stream is exposed to these particles carried in the lubricating fluid.
Isotropic Superfinishing creates a surface with low surface roughness (skew). Bearing properties improve, heat from friction is reduced and engine/gearbox life is extended. Most importantly, performance is improved! It is used extensively in F1!


Gearbox internals before:




Internals after

[chrisr763]

This car jut keeps getting better and better!

[Statller-Stevo]

Jason this is Sweeeeeeeet!!
Loving it, what comp ratio and who's pistons are you going for & rods etc? I Had a lengthy conversation with Aaron @ Arrow yesterday regards specs and we're probably going to run custom in our two, only a wee bit more expensive but a long 5 weeks wait  
Did you have any of the parts Cryo treated or was it part of the super finishing anyway?
BTW I was on V max face book last night there's a Porka 9E's just built & its just run 213mph @ Brunters on road fuel!!!   looks like we all got our work cut out for next year! Hah !

[DaveB@Vagbremtechnic]

looking good Pov. You still on stock rotors??

@steve

Longer final drive on the golf!

[Poverty]

It's custom JE pistons and IE rods. I don't have the final compression ratio to hand, but during the spec o the build it was decided to keep the CR as close to stock as possible. What features are you going for on your pistons?

Cyro was talked about but I dont think it was specced in the end.

213mph that's just mad. I'll leave you and the brabus to try and beat that. My car will just about do over 200mph thanks to a raised limiter! Should get there bloody quick though mind!

Still on stock rotors Dave, only a matter of time till I order a upgrade with you. Need to get the car back on the road first and then I will set about on sorting the brakes and chassis!