3 inch TIPs now available for K04's

Discussion in 'Badger5' started by badger5, Nov 26, 2010.

  1. badger5 Club GTI Sponsor and Supporter Trader

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    Hi

    running alongside the k04 hybrid development thread I have been playing with TIP's, and made a 3 inch version.. We saw significant airflow gains from this which prompted me to have a bunch of these made.

    3 INCH TIP Proven for K04 installs and Orders Now being Taken:


    It can fit with OE Airbox if required, but you will need to trim the top 90' silicon elbow. Easier/advised fitment is with cone filter such as FR08001 type


    CONFIRMED PRICES:
    2 x 76mm 90 degree elbows - 35
    Billet K04 Alloy Reducing Coupler - 38.75
    Natural finish Alloy Coupler with ports - 45 (add 7.50 for polished version *special order*)
    4 x 70-90 hi-grip hose clips - 8.12
    Small Hose Stubs for Evap,N75,breather,DV with clips - 10

    Optional:
    FR08001 filter - 45


    Prices are plus vat & Delivery
    9.50 delivery UK Mainland

    Orders Now being taken.
    Colours Available Blue and Black currently. (red on request if elbows are available)

    Turbo adaptor
    [​IMG]
    mocked up
    [​IMG]
    comparison of OE TIP to 3inch
    [​IMG]

    And combined with the hybrid k04..........
    3inch tip airflow, descreen maf
    272g/s max logged compared to before 3 inch tip where max was 254g/s, however on this car (non wideband) the apparent airflow and change to afr's made a difference. Clearly more airflow as it ran leaner.. added 5% fuel and it returned to as before, making slightly more power.

    New 3 Inch TIP log
    Code:
    Sunday	31	October	2010	17:27:07:61786	VCDS Version: Release 10.6.1	Data version: 20100831									
    8L0 906 018 N		1.8L R4/5VT     G   0002													
    															
    	Group A:	'002				Group B:	'020				Group C:	'118			
    		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization		RPM	Temperature	Load	Absolute Pres.
    	TIME					TIME					TIME				
    
    	31.78	3200	191.7	15.99	138.72	32.08	0	0	0	3	31.49	3040	21	95.3	1880
    	32.69	3720	191.7	16.81	145.36	32.98	3	3	0	2.3	32.39	3560	21	82.7	2490
    	33.59	4160	191.7	17.63	181.69	33.89	3	3	0	2.3	33.29	3960	20	85.5	2540
    	34.49	4640	191.7	18.04	207.72	34.79	3	2.3	0	4.5	34.19	4480	19	82.4	2540
    	35.39	5120	191.7	18.04	228	35.69	2.3	2.3	0	4.5	35.09	4920	19	83.1	2540
    	36.29	5520	191.7	18.45	247.61	36.59	2.3	5.3	0	3.8	35.99	5360	20	83.9	2540
    	37.19	5720	191.7	18.45	257.5	37.49	2.3	5.3	0	3.8	36.89	5680	21	87.1	2520
    	38.09	5960	191.7	18.45	258.36	38.39	2.3	5.3	0	3.8	37.79	5880	22	92.2	2520
    	38.99	6200	191.7	18.45	259.67	39.29	2.3	4.5	0	3	38.69	6120	24	95.3	2500
    	39.89	6480	191.7	18.45	265.94	40.19	2.3	4.5	0	3	39.59	6360	24	95.3	2490
    	40.79	6760	191.7	17.22	266.39	41.09	1.5	4.5	0	3	40.49	6640	26	95.3	2470
    	41.69	7040	191.7	16.81	270.44	41.99	1.5	3.8	0	2.3	41.39	6960	27	95.3	2460
    	42.59	7360	191.7	15.99	272.67	42.89	1.5	3.8	0	2.3	42.29	7280	29	95.3	2420
    	43.49	7680	183.5	11.48	266.58	43.79	0	0	0	0	43.19	7560	30	95.3	2430
    
    Previous logs descreened before 3" TIP
    Code:
    Saturday	23	October	2010	17:48:48:61786	VCDS Version: Release 10.6.1	Data version: 20100831									
    8L0 906 018 N		1.8L R4/5VT     G   0002													
    
    	Group A:	'002				Group B:	'020				Group C:	'118			
    		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization		RPM	Temperature	Load	Absolute Pres.
    	TIME					TIME					TIME				
    Marker	STAMP	 /min	 %	 ms	 g/s	STAMP	KW	KW	KW	KW	STAMP	 /min	C	 %	 mbar
    
    	48.83	1440	82	5.33	23.17	49.13	0	0	0	0	49.43	1640	24	95.3	1100
    	49.73	1760	87.2	5.74	28.94	50.03	0	0	0	0	50.33	2040	23	95.3	1190
    	50.63	2200	106.8	6.97	45.83	50.93	0	0	0	0	51.23	2440	21	95.3	1370
    	51.53	2560	122.6	7.79	62.06	51.84	0	0	0	0	52.14	2800	21	95.3	1670
    	52.44	2920	171.4	12.3	102.92	52.73	0	0	0	0	53.04	3240	21	77.6	2370
    	53.34	3440	191.7	15.58	141.31	53.64	0	0	0	0	53.93	3680	21	81.6	2500
    	54.24	3840	191.7	16.81	154.53	54.53	0	0	0	3	54.84	4120	20	83.5	2510
    	55.14	4280	191.7	16.81	179.42	55.44	3	0	0	3	55.74	4560	21	82.7	2530
    	56.04	4720	191.7	17.22	198.17	56.34	3	0	0	3	56.64	5000	21	83.9	2520
    	56.94	5160	191.7	17.63	222.33	57.24	2.3	0	0	2.3	57.54	5440	21	85.5	2500
    	57.84	5520	191.7	18.04	236.33	58.14	2.3	0	0	2.3	58.44	5760	23	89.4	2450
    	58.74	5840	191.7	17.22	243.58	59.04	2.3	0	0	2.3	59.34	6040	24	95.3	2430
    	59.64	6080	191.7	16.81	246.5	59.94	1.5	0	0	1.5	60.24	6240	25	95.3	2420
    	60.54	6320	191.7	16.81	247.31	60.84	1.5	0	0	1.5	61.14	6480	27	95.3	2400
    	61.44	6560	191.7	16.4	251.61	61.74	1.5	0	0	1.5	62.04	6760	28	95.3	2360
    	62.34	6840	191.7	15.58	253.64	62.64	1.5	0	0	0.8	62.94	7040	30	95.3	2340
    	63.24	7160	186.5	14.76	254.83	63.54	0.8	0	0	0.8	63.84	7360	31	95.3	2300
    	64.14	7480	178.2	13.94	252.33	64.44	0.8	0	0	0.8	64.73	7240	32	0	1750
    
    3inch tip and screened maf
    Code:
    31	October	2010	17:49:37:61786	VCDS Version: Release 10.6.1	Data version: 20100831									
    	1.8L R4/5VT     G   0002													
    
    Group A:	'002				Group B:	'020				Group C:	'118			
    	RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization		RPM	Temperature	Load	Absolute Pres.
    TIME					TIME					TIME				
    STAMP	 /min	 %	 ms	 g/s	STAMP	KW	KW	KW	KW	STAMP	 /min	C	 %	 mbar
    
    	30.89	1480	32.3	2.46	9.14	31.19	0	0	0	0	30.59	1520	26	0	1010
    	31.79	1480	78.2	5.33	23.08	32.09	0	0	0	0	31.49	1440	26	95.3	1000
    	32.69	1600	84.2	5.33	25.92	32.99	0	0	0	0	32.39	1480	24	95.3	1060
    	33.59	2000	92.5	6.15	37.08	33.89	0	0	0	0	33.29	1880	23	95.3	1130
    	34.49	2360	109.8	6.97	50.78	34.8	0	0	0	0	34.2	2240	21	95.3	1270
    	35.39	2760	134.6	9.43	74.44	35.69	0	0	0	0	35.09	2640	21	95.3	1470
    	36.29	3200	191.7	15.99	139.39	36.58	3	0	3	3	35.99	3040	21	95.3	1910
    	37.18	3680	191.7	16.81	144.22	37.49	3	0	3	5.3	36.89	3520	21	82.7	2490
    	38.09	4120	191.7	17.63	169.94	38.39	2.3	0	2.3	5.3	37.78	3960	20	83.9	2540
    	38.99	4640	191.7	18.04	199.56	39.29	2.3	0	2.3	4.5	38.69	4480	20	82.4	2540
    	39.89	5120	191.7	18.04	225.11	40.19	2.3	0	2.3	4.5	39.59	4960	20	83.5	2540
    	40.79	5520	191.7	18.86	238.06	41.09	2.3	0	1.5	4.5	40.49	5400	21	84.7	2530
    	41.69	5760	191.7	18.45	244.83	41.99	1.5	0	1.5	3.8	41.39	5680	21	87.8	2510
    	42.59	5960	191.7	18.04	247.31	42.89	1.5	0	1.5	3.8	42.29	5920	23	93.3	2490
    	43.49	6200	191.7	17.63	251.94	43.79	1.5	0	1.5	3.8	43.19	6120	24	95.3	2470
    	44.39	6480	191.7	17.63	253.22	44.69	1.5	0	1.5	3	44.09	6400	25	95.3	2480
    	45.29	6760	191.7	16.81	255.36	45.59	1.5	0	1.5	3	44.99	6680	27	95.3	2430
    	46.19	7040	191.7	15.99	258.58	46.49	0.8	0	0.8	3	45.89	6960	27	94.9	2420
    	47.09	7360	185.7	15.17	260.78	47.39	0.8	0	0.8	2.3	46.79	7240	29	95.3	2400
    	47.99	6960	12.8	1.23	0	48.3	0	0	0	0	47.69	7640	30	0	2500
    

    rule of thumb calc applied.. airflow divide 0.8 = power
    we get 260g/s = 326bhp

    Logged airflows - gains & comparison - REMEMBER this is a Silicon TIP vs the new 3inch TIP... gains from OE would be greater difference.
    [​IMG]

    and fitted to another S3.......
    Now its worth mentioning this prototype was done for a car which had open cone induction kit.
    Its going to be tight on an OE airbox, but not having tried that I cant confirm how well it will fit..
    wellys S3 bung it in to check install below to show you what Io mean:
    [​IMG]
    [​IMG]

    Comparison to an already good flowing silicon TIP which was what welly was running before swapping to the 3 inch jobbie
    [​IMG]
    [​IMG]
    [​IMG]
     
    Last edited: Nov 26, 2010
  2. badger5 Club GTI Sponsor and Supporter Trader

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    and soem more on OE airbox
    to prove the 3inch tip can go onto std airbox (not that this is what I would reccomend) I fitted the version 2 to a car with std box last night. It fits, is tight and fiddly to do, but is doable.

    pictures:
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  3. badger5 Club GTI Sponsor and Supporter Trader

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  4. rallye1.8t Forum Member

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    just wondered how the adapter fits on the turbo?
     
  5. badger5 Club GTI Sponsor and Supporter Trader

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    2 x m4 grub screws which locate onto the turbos intake groove, loctited to keep em from rattling out, and a smear of sealer to make gas seal (they're a good fit but this is belt and braces)
     
  6. badger5 Club GTI Sponsor and Supporter Trader

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    okies...
    tests from today on stage 1 map from rtech on an s3 of danes.
    car has no mods at all.. aside from rods i fitted for its upgrade path planned by the owner Dane

    before any change, run on dyno on its std airbox and silicon tip, with k&n filter element. airbox had been drilled with big holes in its base by previous owner.
    logs:
    Code:
    Saturday	18	December	2010	11:43:30:61786	VCDS Version: Release 10.6.3	Data version: 20101206									
    8N0 906 018 J		1.8L R4/5VT         0004													
    															
    	Group A:	'002				Group B:	'020				Group C:	'115			
    		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization		RPM	Load	Absolute Pres.	Absolute Pres.
    	TIME					TIME					TIME				
    Marker	STAMP	 /min	 %	 ms	 g/s	STAMP	KW	KW	KW	KW	STAMP	 /min	 %	 mbar	 mbar
    
    	409.24	1520	85.7	8.16	27.28	408.52	0	0	0	0	408.83	1520	80.5	1640	1100
    	410.35	1800	94.7	8.84	33.89	409.63	0	0	0	0	410.04	1680	92.5	1690	1200
    	411.45	2320	121.1	12.24	57	410.73	0	0	0	0	411.07	2160	108.3	2250	1350
    	412.66	2840	172.2	17.68	104.86	411.86	0	0	0	0	412.27	2680	146.6	2340	1830
    	413.89	3400	190.2	19.72	127.64	413.07	0	0	0	0	413.49	3240	185.7	2340	2320
    	415.08	3920	191	19.72	142.39	414.27	0	0	0	0	414.67	3720	190.2	2340	2310
    	416.31	4400	188	19.72	157.31	415.48	0	0	0	0	415.89	4240	188.7	2330	2320
    	417.49	4880	183.5	19.72	172.33	416.71	0	0	0	0	417.09	4720	186.5	2310	2300
    	418.69	5320	176.7	19.38	181.17	417.89	0	0	0	0	418.31	5160	180.5	2340	2220
    	419.91	5760	173.7	19.38	188.36	419.09	0	0	0	0	419.52	5600	172.9	2340	2190
    	421.1	6160	163.2	18.02	190.53	420.31	3	0	3	0	420.7	6040	166.2	2290	2110
    	422.34	6600	155.6	17	196.14	421.54	3	0	3	0	421.92	6440	157.9	2210	2090
    	423.53	7000	145.1	15.98	193.72	422.75	3	0	6	3	423.11	6880	148.9	2080	2020
    	424.77	7040	26.3	1.02	4.89	423.93	3	0	6	3	424.32	7240	128.6	1530	2260
    
    then 3 inch tip ws fitted along with the FR08001 filter
    dyno'd again... no other change
    Code:
    Saturday	18	December	2010	13:36:18:61786	VCDS Version: Release 10.6.3	Data version: 20101206									
    8N0 906 018 J		1.8L R4/5VT         0004													
    															
    	Group A:	'002				Group B:	'020				Group C:	'118			
    		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization		RPM	Temperature	Load	Absolute Pres.
    	TIME					TIME					TIME				
    Marker	STAMP	 /min	 %	 ms	 g/s	STAMP	KW	KW	KW	KW	STAMP	 /min	C	 %	 mbar
    
    	153.79	1720	40.6	4.08	13.56	154.11	0	0	0	0	154.52	1560	15	0	1020
    	154.9	1600	45.1	4.42	13.83	155.33	0	0	0	0	155.7	1640	15	92.5	1060
    	156.11	1640	82.7	7.82	27.97	156.53	0	0	0	0	156.92	1640	15	94.5	1200
    	157.32	1760	93.2	8.84	32.92	157.74	0	0	0	0	158.14	2120	15	94.5	1370
    	158.53	2320	126.3	12.58	60.11	158.92	0	0	0	0	159.34	2680	15	94.5	1940
    	159.72	2880	187.2	18.7	106.94	160.04	0	0	0	0	160.43	3200	15	83.5	2110
    	160.85	3360	178.9	18.36	116.39	161.26	0	0	0	0	161.63	3680	16	83.1	2130
    	162.03	3880	186.5	18.36	138.17	162.46	0	0	0	0	162.84	4200	17	83.9	2160
    	163.16	4320	188.7	18.7	155.36	163.56	0	0	0	0	163.94	4640	18	87.5	2180
    	164.29	4800	191.7	20.06	177.11	164.67	0	0	0	0	165.06	5120	21	87.5	2210
    	165.48	5280	191.7	20.4	194.58	165.87	0	0	0	0	166.28	5600	24	93.3	2260
    	166.67	5720	190.2	19.72	208.86	167.08	0	0	0	0	167.5	6000	27	92.9	2250
    	167.88	6160	183.5	19.04	209.19	168.29	0	0	0	0	168.69	6400	31	94.5	2190
    	169.1	6520	174.4	18.02	215.28	169.51	0	0	0	0	169.93	6800	36	87.8	2120
    	170.32	6960	159.4	16.32	210.36	170.72	0	0	0	0	171.12	7200	39	74.1	2100
    
    bolt on g/s gains of from an intil best 196.14g/s to 215.28g/s = gained 19.14g/s of airflow :)

    and the before & after dyno is.....
    [​IMG]
    [​IMG]
    [:D]
    Pretty conclusive to me... and I was surprised to be honest in the difference.. on stock k04, on a stage 1 map, with no other performance mods on it, just changing the tip's and filter. wow!

    Also, after this we did some playing with the mapping to see if there's any more left in it, for its lack of mods.. so did a custom map for it.. and eaked a little more bhp out of the girl.
    comparison below of silicon tip, rtech stage 1, 3inch tip rtech stage 1, and a Badger5 map on it
    [​IMG]
    [​IMG]

    This has ended up the most powerful std k04 car i have run so far on my dyno..
    started with 251bhp from its map, then rose to 270bhp, then to 278bhp with some tweaks

    There was no side effect to installing the 3inch tip on th stage 1 std k04 turbo at all... just more airflow and top end sustained torque = more power.

    Well please with this result. surpasses my expectations

    ...in stock to buy folks ;)
     
  7. jimk04 Forum Member

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    Bill did you get me email RE these.?

    I just need the 2 ally parts.

    I have N75, breather and DV so the other one (about15 - 20mm inner diameter could be omitted)

    Thanks
     
  8. badger5 Club GTI Sponsor and Supporter Trader

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    sorry, I dont recall it
    could you resend it?
    bill@badger5.co.uk
     
  9. Gup16v Forum Member

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    Hi Bill

    Have you got anything like this but for a K03s set up?

    Thanks
     
  10. badger5 Club GTI Sponsor and Supporter Trader

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    sorry no.. Very little space on K03 fitment with water pipes and gear cables in the way.
    I have made one off's but they are costly and involve moving water pipes and gear cables... Our lupo has such a bespoke setup on it.
     

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