**new custom induction kit.. inc photos

[ifbravadoasks]

Hi all,

after attending Vag vs Ford day and going on the rolling road my standard air intake hose was collapsing under the hybrid turbo at full load

So I sourced the proper parts individually to make my own pipes and filter set-up including a new cold air feed

If anyone is interested in the parts and prices let me know and ill post them up

All in I was probably around 100 quid and 3 hours labour

I used 5mm gauge stainless tubing

heavy gauge silicone couplers

decent hose clips. British made

Flexi cold feed with brackets

Mushroom filter

kept maf incorporated and also added and drilled to fit vacuum pipe from existing into filter.

hopefully the pictures explain the process

I also cleaned up engine cover with a touch of paint.

This may not be every ones taste nor may you like the filter idea but it wasn't done for any performance gains it was purely done to maintain a steady flow of dense air into the intake without collapsing under the turbo pressure.

probably small pics shown but clicking them should resize hopefully... Steve...

 

[sepulchrave]

Ok, but could you not have just used the stainless pipe and silicon couplers to simply replace the standard plastic parts while retaining the standard airbox?

 

Also consider fitting a Honda S2000 paper cone filter instead of that dreadful foam mushroom which simply sifts out fine gravel before firing it at your delicate alloy impeller, if the mushroom is oiled it will go hard on your MAF as well.

[ifbravadoasks]

I appreciate your comments

mushroom is un oiled As foam filters don't need oiled

Yes I could have used pipe and couplers to use standard box although running a hybrid I personally don't think standard box and pd130 intake delivers enough air as I had it on diagnostic before

changing and it should be drawing 800 micrograms of air and mine was only drawing 350 micrograms approx figures

I may change mushroom for a cone filter as I ordered one as well but it's not here yes so mushroom went on first

I will dyno it with each filter and see which is better, maybe I should have explained this in my post better but didn't.....

And I ran the same dreadfull foam mushroom on my scoob sti for 2 yrs with no power loss or reported issues.

 

And yes I could have used pd160 and upgraded panel filter with new pipes but this was my choice. Ill try to post up my figures after rolling road visit.

[sepulchrave]

I appreciate your comments

mushroom is un oiled As foam filters don't need oiled

Yes I could have used pipe and couplers to use standard box although running a hybrid I personally don't think standard box and pd130 intake delivers enough air as I had it on diagnostic before

changing and it should be drawing 800 micrograms of air and mine was only drawing 350 micrograms approx figures

I may change mushroom for a cone filter as I ordered one as well but it's not here yes so mushroom went on first

I will dyno it with each filter and see which is better, maybe I should have explained this in my post better but didn't.....

And I ran the same dreadfull foam mushroom on my scoob sti for 2 yrs with no power loss or reported issues.

 

And yes I could have used pd160 and upgraded panel filter with new pipes but this was my choice. Ill try to post up my figures after rolling road visit.

 

All perfectly fair, but your reasoning is flawed since your boost is capped and electronically controlled, unlike your scoob which used an FGT, your VRS uses a VNT with a solenoid controlled vacuum actuator to prevent overboost.

 

I'll be interested to see the dyno results nonetheless, could you not rig up the standard airbox with a fresh paper element for a run as well, I'm quite sure everyone else will be very interested to see the results as well, don't worry about the PD160, just use the standard snorkel and don't worry about fitting the airbox in the car just rest it on there while you do a quick power run.

[ifbravadoasks]

All perfectly fair, but your reasoning is flawed since your boost is capped and electronically controlled, unlike your scoob which used an FGT, your VRS uses a VNT with a solenoid controlled vacuum actuator to prevent overboost.

 

I'll be interested to see the dyno results nonetheless, could you not rig up the standard airbox with a fresh paper element for a run as well, I'm quite sure everyone else will be very interested to see the results as well, don't worry about the PD160, just use the standard snorkel and don't worry about fitting the airbox in the car just rest it on there while you do a quick power run.

ok, which part is flawed? in fact don't bother .As for preventing over boost....

As I always thought sticky vanes causes over boost on these if I am not mistaken?( and actuator length)

And as my intake was collapsing the technician advised me on a better set up for air intake as it was causing the car to over boost when it collapsed under intake(his words)

My standard intake box is in the bin as I am happy with my current set-up

All I posted up was a simple changeover pics guide that I done, like it or don't I am really not fussed

thanks anyway for your comments which ill take on board... St

I will try to post results this week to see the difference in filters as It was reaching 180hp when collapsing under load and that was with a jetex panel filter and a mann standard filter too.

Hopefully be reaching 200hp now (md345 stage 1 hybrid and remap by bedrock veedubs)

I know  mushrooms are not favoured And I am not getting into technical disputes either

it was a simple solution as my cone was not delivered today

At least the car breathes  well for now So THANKS for the comments and ill look forward to the rolling road...

[sepulchrave]

ok, which part is flawed? in fact don't bother .As for preventing over boost....

As I always thought sticky vanes causes over boost on these if I am not mistaken?( and actuator length)

And as my intake was collapsing the technician advised me on a better set up for air intake as it was causing the car to over boost when it collapsed under intake(his words)

My standard intake box is in the bin as I am happy with my current set-up

All I posted up was a simple changeover pics guide that I done, like it or don't I am really not fussed

thanks anyway for your comments which ill take on board... St

I will try to post results this week to see the difference in filters as It was reaching 180hp when collapsing under load and that was with a jetex panel filter and a mann standard filter too.

Hopefully be reaching 200hp now (md345 stage 1 hybrid and remap by bedrock veedubs)

I know  mushrooms are not favoured And I am not getting into technical disputes either

it was a simple solution as my cone was not delivered today

At least the car breathes  well for now So THANKS for the comments and ill look forward to the rolling road...

 

Whoa there, wait a minute, I wasn't knocking you, I am genuinely interested in the results of a fair test.

 

It is common knowledge here that the standard intake and exhaust systems on the VRS do not cause any restriction until ~220bhp, if your hybrid is pushing that then fair enough.

 

Had you considered that the RR tech might have been talking *******s instead of having a poke at me for trying to enlighten you!

[ifbravadoasks]

My apologies if you thought I was having a poke...

I don't think I am quite near the 220 barrier, I did see the intake pipe collapsing on the RR, so in hind sight maybe I should have just changed the pipework. The purpose of my original post wasn't to run a filter results test but as I am going back to RR I will try to run both cone and mushroom, I think ill just stick to the cone filter.

Ill attach my original RR result when intake was collapsing

Thanks again for the input...St

[felicia16v]

Can anyone explain how the the intake pipework collapsing would cause it to over boost ?

[ifbravadoasks]

Taken from pistonheads forum " It would be worth posting this in the VAG subforum too, you will probably get some more in depth answers. If it's the 1.8L 20VT engine, I had the same in my Cupra R so I know it a bit. Off the top of my head, a few things that can cause overboosting:

• A bad remap overstretching the boost ability of the car
• A faulty wastegate actuator on the turbo causing it to stick shut and not vent boost pressure as the throttle closes
• Aftermarket dump valves that have too strong a resistance spring for the boost pressure of the engine, the pressure is insufficient to force them open, so boost pressure does not fall quickly enough on a closing throttle and the ECU registers and overboost. Poorly maintained dump valves can stick shut too, they need to be serviced rountinely with cleaning and lubricant
• Turbo intake pipe collapsing under boost, this causes an intake pressure spike which can be registered as an overboost. The TIP degrades and gets softer over time and becomes more prone to collapse under high pressure. Most Cupra R owners fitted the aftermarket Forge or Badger5 TIPs, which were much stiffer and more robust.

While you are at it, look at all the pipework and tubes from the turbo system (there are loads on the 20VT engine) and check for holes, splits, blown-off hoses etc.

 

Source : http://www.pistonheads.com/gassing/topic.asp?t=1085762

[coskev]

Your above post is talking about the petrol eng, boost control etc is totally different.

 

I too would like to see back to back rolling road filter tests please

 

As above, the airbox is a restriction on larger turbos/powers, ie GTB's.

[sepulchrave]

My apologies if you thought I was having a poke...

I don't think I am quite near the 220 barrier, I did see the intake pipe collapsing on the RR, so in hind sight maybe I should have just changed the pipework. The purpose of my original post wasn't to run a filter results test but as I am going back to RR I will try to run both cone and mushroom, I think ill just stick to the cone filter.

Ill attach my original RR result when intake was collapsing

Thanks again for the input...St

 

Those figures look awfully low for a hybrid setup, who did the remap?

[ifbravadoasks]

Hi my apologies in being late, having some issues. but i'd like to reply to this those figures are low because the intake is collapsing at that point(180)original intake is collapsing at this point, hence the need for more air.( and my desputable custom intake ) :-)

the remap and hybrid was done by bedrock veedubs in motherwell who have a good reputation.

My radiator has now failed and a glow plug issue hence a slight further setback in getting to the RR for testing

[ifbravadoasks]

here is my receipt from when it was done...

[ifbravadoasks]

My radiator has failed  as well as my emissions light on  (diagnostics done) Glow plug fault cylinder 1

Hence my setback in testing air filters.

new radiator is ordered.