k04 Hybrid for 210/225 owners, LCR/TT/S3 etc-Now achieved 344bhp!302lbft with XS Mani

Hi
there's a lot of interest in these k04 hybrids.. so to help people visualise whats being talked about I have taken some time to take pictures of on install going on for speedy_steve's S3 which is with me for this upgrade

First of all comparison side by side showing different compressor wheels.. k04 vs billet k06 wheel

k04's std comp wheel

Hybrids billet k06 comp wheel


hot sides comparison

turbine size comparison, rs6 wheel vs k04 wheel


std k04 turbine wheel


hybrids larger turbine wheel (RS6)



Mocked up with PiperWerx 3" downpipe on engine and stock manifold



Essential mods imho are going to include rods, downpipe, fmic, intake to support what this thing is potentially capable of.
Steve's gone for rods which we have fitted (IE rods), FMIC will be required, and mapping to suit to realise its potential.

more when we have buttoned it back together and test driven it and logged what it does
watch this space folks
regards
bill

 

also...
this is what CR have said in respect comparisons to Turbo Dynamics units

the one pictured is the stage 4

and for TD's specs and claims - see below reference

My personal opinion is the power figures claimed by TD are unrealistic, so we will have to see..
A high flow mani such as JBS are shortly making available should make a nice contribution to increased flow.

 

some install pictures of it in place with the now wrapped PipeWerx 3" downpipe




116k mile engine.. next to now lip in the bore and factory hone marks still very apparent..
just cleaned up pistons and refit them as they came out. (its not an endless budget)

getting there...

 

do you have any idea when this manifold will be finished, i only ask you as you seem to know, will you also be putting up any graphs of this once you map it?

 

no idea re jbs,... who knows.. supposed to be soon, but i've heard that before..

i will post dyno once it returns for mapping early may.
customer is fitting fmic, tip before returning for mapping.
initial log on its "unkown" map showed 206g/s airflow at 4200rpm, and >1.5bar boost at 3krpm so it spools like a regular k04, just more of it in airflow terms

watch this space

 

that sounds good then, i will be watching this space for more updates, good work bill

 

Bill, a workmate a LCR and is interested in a hybrid - is it ok If I bring him down one evening for a chat?

 

sure.. mon-thurs from 7pm-10pm and weekends..
I am there thurs/Fri & monday all day - lots to do

 

very nice

 

has this come back for mappping yet? any updates?

 

comes back to me in June for mapping

 

Interesting set up. Nice alternative keeping it mostly OE too....will be nice to see results.

Ian

 

right done...
no doubt some debate will ensue over this.. lol as always.

yesterdays runs i got 281bhp, today after fixing the boost leak, we peaked 315bhp/250lbft, with airflows logging 275g/s or more occasionally.
now this does'nt all add up..

heat kicks in rapidly, and only ever get one peak reading which is the 313bhp-315bhp range, then drops to 305-308bhp, then down to 296bhp, 292bhp as it gets hotter.. A definate candidate for wanting wmi installed to my mind.

the torque reading does look low to me, but the spool is more akin to BT, spooling 3.5k-4krpm full chat to 25psi tapering to 23psi at 7krpm

now, caviats apply... new dyno to me, maybe i am driving it wrong.. (dont think so, but training is next saturday on it) and thus far, stock cars hav made stock power, and remapped one of wellys S3 made 254bhp, but with apparent low torque which i dont believe. same dyno same day, steve's hybrid 04 has made 60bhp more than a k04.... with huge airflows.. no scaling done to maf at all.

i dont think the dyno is a happy dyno, it certainly is'nt being optomistic on cars i have run so far, presuming i am not being a numpty using it **** about face or owt..

on the road, steve's s3 is rapid, and makes me very much believe the things producing 300bhp power.

let the debate begin

 

Code:

Sunday	18	July	2010	14:17:51:61786	VCDS Version: Release 10.6.0	Data version: 20100630							
8N0 906 018 J		1.8L R4/5VT         0004											

	Group A:	'002				Group B:	'112		Group C:	'118			
		RPM	Load	Inj. On Time	Mass Flow		Temperature	Load		RPM	Temperature	Load	Absolute Pres.
	TIME					TIME			TIME				
Marker	STAMP	 /min	 %	 ms	 g/s	STAMP	C	 %	STAMP	 /min	C	 %	 mbar
	31.06	1880	87.2	6.8	33.89	31.37	450	0	30.77	1760	35	94.5	1060
	31.97	2400	109	7.48	53.75	32.28	470	0	31.67	2280	33	94.5	1240
	32.88	2920	150.4	10.54	94.89	33.18	500	0	32.57	2760	30	94.5	1520
	33.78	3600	191.7	15.3	139.94	34.08	545	0	33.48	3320	30	70.2	2300
	34.69	4400	191.7	16.32	196.06	34.99	620	0	34.38	4120	30	65.5	2440
	35.59	5280	191.7	18.02	250.53	35.89	680	0	35.29	5000	30	73.3	2540
	36.5	5800	191.7	18.7	266.72	36.8	750	0	36.2	5720	33	80	2540
	37.41	6160	191.7	18.36	272.92	37.7	785	0	37.1	6000	36	80.4	2540
	38.31	6400	190.2	17.68	271.75	38.62	820	0	38.01	6320	38	82.7	2540
	39.21	6600	191.7	17.34	275.42	39.51	835	0	38.91	6520	41	87.1	2540
	40.12	6720	191.7	17	279.11	40.42	855	0	39.82	6680	45	89.4	2540
	41.03	7040	191.7	16.32	279.64	41.33	870	0	40.72	6920	48	90.6	2540
	41.93	7400	191.7	15.3	281.22	42.23	890	0	41.65	7280	51	91.4	2540
	42.83	7160	12	1.36	89.28	43.14	920	6.3	42.54	7600	55	76.9	2540
	43.74	5600	13.5	1.7	12.64	44.04	930	0	43.44	6080	50	0	1210

some logs from along the journey this weekend..

Code:

Sunday	18	July	2010	14:03:50:61786	VCDS Version: Release 10.6.0	Data version: 20100630							
8N0 906 018 J		1.8L R4/5VT         0004											

	Group A:	'002				Group B:	'031		Group C:	'020			
		RPM	Load	Inj. On Time	Mass Flow		Lambda Factor	Lambda Factor		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization
	TIME					TIME			TIME				
Marker	STAMP	 /min	 %	 ms	 g/s	STAMP			STAMP	KW	KW	KW	KW
	16.6	1760	60.9	5.44	24.47	16.91	1.016	0.992	16.29	0	0	0	0
	17.5	2280	97	7.14	46.39	17.81	0.992	0.992	17.19	0	0	2.3	2.3
	18.41	2760	131.6	9.18	75.61	18.71	1	0.992	18.11	0	0	2.3	2.3
	19.31	3360	191.7	13.6	167.28	19.62	1.094	0.992	19.01	0	0	2.3	2.3
	20.22	4400	191.7	18.36	216.39	20.53	0.875	0.875	19.92	0	0	1.5	1.5
	21.12	5240	191.7	18.36	243.17	21.43	0.821	0.836	20.82	0	0	1.5	1.5
	22.03	5600	191.7	18.36	255.08	22.33	0.805	0.813	21.73	0	0	0.8	0.8
	22.93	5880	191.7	18.02	257.06	23.24	0.797	0.813	22.63	0	0	0	0
	23.84	6080	191.7	17.68	261.06	24.14	0.789	0.813	23.54	0	0	0	0
	24.75	6360	191.7	17	263.89	25.06	0.805	0.813	24.44	0	0	0	0
	25.65	6640	191.7	16.32	266.31	25.95	0.805	0.813	25.36	0	0	0	0
	26.56	7000	191.7	15.98	269.19	26.86	0.797	0.813	26.26	0	0	0	0
	27.46	7280	178.9	15.3	270.22	27.76	0.891	0.922	27.16	0	0	0	0
	28.37	5720	12.8	1.7	6.53	28.67	0.867	0.945	28.06	0	0	0	0

 

I like the look of this turbo, so you reckon rods are essential?
Do the standard pistons have to be machined to accept forged rods or do they already accept them?

 

for me, I would only advise peeps fit rod... they have to take at their risk otherwise..
its not a bolt on turbo... its spiking at 30psi as a bolt on, only mapping it back to tame it down, and on a car which already has rods fitted in prep

20mm IE rods bolt onto stock pistons yes. thats what we did on this one. 113k engine this one too. perfect bores, it was lovely inside

 

torque looks very low, thought it would have been higher than that?...

 

yea I know.. not sure if its my rollers or software, but the ecu's torque monitor on block 122 shows very similar torque also to the dyno run.
more sympathetic to the running gear/clutch tho. no huge spike/dollop of initial spool torque spike

 

Hi Bill

Can you slow the ramp rate down on your dyno and see if the torque reading increases !!! i normally find the slower the ramp rate the higher the TQ but lower BHP and a faster ramp rate gives lower TQ and higher BHP?? worth given it ago.

JIM

 

cheers for that, so as far as the rods are concerned its just a case of removing the head and sump, take the bearing caps off to detatch from the crank and push the rods and pistons out through the top? I know theres alot more to it than that but it sounds like they can be changed with the engine in situ?