Its good to have the old girl back

[skud missile]

Well look what turned up while I was in Saudi:)

BBT Hybrid KO4

Just waiting for a Relentless V3 exhaust manifold to come up for sale if any one knows one:)

[missingmyvrs]

Wait for v4

Testing at mo ;-)

[skud missile]

Well I've been assured V4 I crap and the V2 flows best but V3 lasts longest before cracking

[missingmyvrs]

That's funny I'm the only one in the country that has a v4 and it's not ona car yet lol

V2 flows but falls apart very quickly and a complete and utter biatch to fit

[missingmyvrs]

If anything get badger 5 new k04 manni looks awesome

[skud missile]

when did Bill come out with his?

[missingmyvrs]

Think it's about to be released in the next few weeks

[skud missile]

Bill says early next year:( but will hold off fitting the Hybrid till then

[skud missile]

Well a little update.

B5 V2.2 TIP install and replacing the old OCC system.

And all finished

[skud missile]

Well its been a while since i updated this Thread so here is the run down.

 

Ive put the RS4 alloys onto the Skud missile (Mk1 octavia 4x4 1.8t on Shark stage1 map) for those who dont know it and got me some Rota Grid Drifts 9.5X18" all round with 225 yokohama Parada Spec2 rubber and it stretches bang on for the Stance point of view.

 

Needed spacers tho running a 9.5 lol

 

Also fitted Bills High flow cast mani with large port mod and BBT stage4 hybrid KO4 also with large port mod.

Here is the large ported stage4 Hybrid vs oem 

The large port Mod on the KO4 hotside

 

And Bills large ported mani vs oem

[skud missile]

 

Did have some problems with the EGT port not being machined correctly, basically the port was drilled too deep and didn't allow the crush washer on the egt probe to be held tight so a M5 copper washer takes up the slack and holds the probe secure.

 

 

You can fit the turbo and mani with the head on but seeing as i run the ARP stud kit for the main and head it`ll only cost me a gasket to pull the head as you can reuse the stud kit and its a ****e load easier to complete.

 

And a small tip...make sure the wells are dry for the head bolts as if there's fluid like oil or coolant in the well the bolts when torqued down will pressurize the fluid and crack the block, with a stud kit its not so much a problem as the stud is only screwed in hand tight.

[skud missile]

So the Blocks back together.......for now lol (bigger plans to come)

 

Now to replace that tiny front mount intercooler as its way way to small for the flow i`ll be producing lol.

 

 

Most people mount the fmic on the slam panel but looked shoody to me so made a custome frame to carry the new Monster fmic

 

And then to pressure test for leaks.

 

Custom boost system testers 

 

And the frame made fitting the bumper back a piece of cake but did take a while with finding the best position.

[skud missile]

Still to fit the Water Meth Injection tho, half way through it now but off shore in Saudi doesn't help :(

 

Also vcds flagged up a DTC not supported or comms error with the Haldex coupling for the Quattro system and found this, a snapped Haldex earth strap due to corrosion.

 

Easy to fix with a batt earth cable wrapped in electrical tape.

 

A surprise surprise the Skud missile had the same error message and snapped earth strap, once sorted the DTC clears:)

[missingmyvrs]

How's your manni ??

[skud missile]

Don`t Know yet as i`m still needing a mapper to be available next month, Bills booked up till June:(

[skud missile]

Also heat wrapped the 3" down pipe and sports cat, even tho i soaked it in water over night it still itched the ****e outta me lol

[skud missile]

Haven't updated my Briskoda in quite a while so here goes..

 

Just before the Badger5 trip was thinking it'll be wise to uprate the brakes as the standard ones are ok if your grannies driving but not for what I have in mind lol

So that being said a nice set of D3 360mm 6pot set up shall suffice:)

 

#

 

 

 

 

 

 

 

 

 

Didn't take long to bed in, running fast road pads as not planning on sending her into a track day gravel trap lol

And coming from my Mk1 Octavia 4x4 1.8t20v which already has the S3 brake upgrade I almost put myself through the S3 wind shield when using the new brakes for the first time lmao.

And when I go back to the Octy I barely stop due to the little brake travel required in the S3, so a little caution required me thinks.

[skud missile]

In addition to installing the wmi kit i've installed a pressure gauge post solenoid valve to confirm what pressure the water meth pump is running at for tweaking during mapping as standard setting iirc is 200psi. it can go as low as 150psi or as high as 250psi.

 

 

 

[skud missile]

So the Badger5 trip begins, now most people would drive there car down for mapping but due to fitting the Hybrid KO4 without a map I was running off actuator pressure as I've disconnected the N75 valve as I didn't want to damage the motor but this almost makes the car very difficult to over take etc etc so hired a self drive transporter and used there clutch so to speak lol

 

 

 

Took the missus with me as I had booked us a nice little hotel in the Cotswolds as I was due to treat the missus from all the time I spent away off shore and working on the S3 car and other customers so quite literally 2 birds with 1 stone, as this'll give Bill plenty time to up rev his mani and map and do some making up to the missus 

 

 

 

Very happy with the end results, but wasn't easy due to the rr being 30+C and having to wait for the motor to cool, even with water meth and 3 massive fans and Mark spraying water on the huge fmic. Very interesting point Bill pointed out was the brand of water meth I was using which is just VAG concentrate screen wash which claims to be up to 49% meth 49% water and rest cleaner and fragrance. Not idle due to the heat of the rr so Bill made up his own water meth mix which is virgin grade meth 99.85 or there about's and a little of the stuff I had supplied for colour and she accepted another 2 more degrees of timing and another couple bhp but lowers ait's egt's respectively. 

Consequently I know make up my own mix from a local supplier of 99.85% meth and it really does make a difference running proper meth.

By no means am I slagging the company that supplies lots of people across the UK with there own water meth mix as it does do a good job but there's always room for improvement but at the end of the day its a compromise.

 

 

 

 

 

 

 

And here is the proof of Bills v mani producing the goods...low egt's VS power on the highest map 347BHP 

 

 

 

 

865-885'c typically peak and after 3 back to back runs, just crept into 900'c compare that with other set-ups and stage 1&2 std k04 cars which will be getting to the egt protection threshold if 920 frequently whilst making considerably less power, all credit to Bills mani:)

 

So 347BHP and 296FtIbs which i very pleasing from all the hard graft, particularly that the BAM is still on standard bore @ 116K just with new rings.

Bills rr is very conservative with power, in particular the torque which looks a little low but on the road there's no shortage of it lol.

 

So I leave with 5 map selectable software and really makes this a proper B road weapon

 

Edited 21 August, 2014 by skud missile

[Jimbling]

Great build bud bet it's a weapon now would love to do this to the skoda bus and be a total sleeper

[skud missile]

Cheers fella

well the plan was to fit the old KO4 to the skud missile but the hotside is cracked so there would be too much build effort to go in with a defective turbo:(

[Bowders1]

Fab read and update buddy.....well done..  

[skud missile]

Hope its to every ones enjoyment:)

[Silver Bullet]

Superb project and build quality 110%

[kidology]

Fantastic build thread top marks to you looks the dogs