K04 Upgrades!!

[GaryM]

Must be a Cupra 180, he would have made more torque in an R.
Im very interested in what you have done to a K04 to hit 278bhp.

[RobDon]

Engine mods are:

Hybrid K04 turbo from Star.
3" Milltek downpipe with 100-cell race CAT, 2.5" exhaust system.
AEM CAI
APR FMIC
Samco TIP
Forge 007PA with blue spring
Denso iridium plugs
Neuspeed engine pulleys
4-BAR fuel pressure regulator
5-point grounding kit
Sun-Auto voltage booster/regulator
Custom map by Star
NX N-tercooler halo spray kit (not plumbed in yet)

Standard N75, MAF, injectors, etc. That's it! With the APR map my car only made 245BHP @ 1.45 BAR, but after having the 3" downpipe and pulleys fitted, Jim custom mapped it to 278BHP @ 1.2 BAR, lower boost than the APR map. Mapping in all the mods makes a massive difference compared to a generic map.

[RobDon]

USED to be a 180 Cupra yes ... now it is SO much more! R was never made in blue.

[GaryM]

I thought the standard injectors were only good for 250 - 255bhp.
Im not openly doubting your plots but have you had your car on an idependant RR?

[redbaron]

std injectors maxed at 250ish at 3 bar... will push up to 300 at 4bar...


there was a thread somewhere...

also you can get more with a bit of head work to improve the burn/efficiency...

bizarrely mine always ran rich.... even with boost at stupid...

[RobDon]

Stock 180 injectors are good for 300BHP with the 4-BAR FPR. I have all the VAG-COM data from the 278BHP run as well if you want to see it, nothing funny going on to make big numbers. I don't need independant verification of these numbers, I trust Jim implicitly and if anything, Jim's rollers always tend to read on the low side.

It was a case of either 225 injectors and 3-BAR or stock 180's at 4-BAR, Jim's choice. The fuelling is spot on with the 180's @ 4-BAR.

My turbo is not a K04-001 - it's a hybrid which is higher performing than the stock K04 - I don't know the specs you'd have to ask Jim - I'm blown away and VERY pleased with the results.

[RobDon]

Thanks for verifying that ffelan.

[EddyH]

I'd be interested to know what they do to 'modify' the K04 to acheive this. Mine and 2 other Golf's I know of with K04's got nowhere near this when setup by Jabba. Mine acheived 254bhp at Jabba but in reality it was much less.

[GaryM]

Originally Posted by RobDon

Stock 180 injectors are good for 300BHP with the 4-BAR FPR. I have all the VAG-COM data from the 278BHP run as well if you want to see it, nothing funny going on to make big numbers. I don't need independant verification of these numbers, I trust Jim implicitly and if anything, Jim's rollers always tend to read on the low side.

My turbo is not a K04-001 - it's a hybrid which is higher performing than the stock K04 - I don't know the specs you'd have to ask Jim - I'm blown away and VERY pleased with the results.

It sounds very nice indeed, bet it goes well too!!

[GaryM]

One more quick question, you only have 219.5 WHP yet make 278.5 BHP - why do you have such large losses?

At JBS a couple of weeks ago (A RR know for its accuracy) I made more power at the wheels than you - 224 WHP but only 245.3 BHP.

It seems strange to me.

[RobDon]

That's what I mean about reading low, JBS must put a very light load on their rollers for you to only lose such a small amount to the wheels, if the same load was applied to mine, I would be making around 250 to the wheels.

[EddyH]

JBS have the largest rollers of any RR in the UK AFAIK hence high inertia and less drag, not necessarily light load. However this setup is proving very accurate so far on the 3 RR days they have run to date.

I have to agree with Gary though, 59bhp seems a big loss 44kw is a huge amount to be losing through heat and noise in the drivetrain.

[RobDon]

I'm agreeing with you guys, my car definately makes more to the wheels - out on the road it feels phenomenal, even Jim couldn't believe how hard it pulls! You'll have to ask Jim as to why their is such high losses to the wheels, I don't know.

[EddyH]

It does sound like a nice setup, I see the classic K04 lag hasn't been modified out though as not much seems to happen until 3krpm. It's always good to see folk taking different routes and I look forward to seeing a few more with this setup for comparison.

Any luck with info on how the K04 is modded?

[RobDon]

Thank you (bit of support at last!), you'd have to quiz Jim about his hybrid K04, I know nothing! This week my NX nitrous intercooler halo spray is being fitted, so we'll see how much extra is added on top of the 278/269 with the intercooler frozen!

[wilsonan]

I look forward to seeing the results RobDon, and that's a great website you've set-up BTW

I've got a question, will the halo spray add any extra power? I thought that cooling the air with an FMIC just enabled you to keep a consistent high boost - does it just mean you'll be able to run at maximum efficiency, as in the cold, damp morning effect?

Andy

[RobDon]

Yes, the spray should add power, in general I've seen and heard of around 15BHP extra as a result of freezing the intercooler (intake temps should drop to single figures), reports from around the web seem to back this up. We'll soon find out as Jim is testing mine today or tomorrow with a dyno run after freezing the intercooler - watch this space!

[Jimmy]

Rob, Just to echo what Andy has said re: your website. The car looks the mutts nuts aswell

I'm also very interested to know your before / after inlet temp results with the NOS system. BTW do you know what temp the NOS is as it exits the spray bar?

[RobDon]

Cheers!

I believe the NOS comes out at -80 or something like that, the halo ring goes frosty that's for sure! I'll post the results regardless if they're good or bad within the next couple of days. I get my car back on Saturday.

[RobDon]

Well the deed has been done today ... dyno run with nitrous sprayed onto the intercooler was carried out today ... the results are in and I have the dyno graph in front of me ... did it improve on 278BHP and 269lbft ... ?