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Discussion Starter #1 (Edited)
My project is nearing completion yet again, so figured I would assemble another build thread to show the world what I did to my poor little 1.8T and what it yielded. If I don't mention it, it's stock AWP 1.8T. I won't get into any of the body, suspension or brake modifications here since it is the 1.8T forum, but the car is very light and is specifically built for SCCA FP Solo competition as well as HPDEs.
For more information on the non-engine modifications, take a look at this thread I started in the autocross forum: http://forums.vwvortex.com/showthread.php?6126117-My-MK4-GTI-Setup-Thread

NEW BUILD

Engine:
-ITG 3" cone filter
-VR6 MAF housing with an AWP MAF sensor
-FFE custom aluminum turbo inlet pipe
-N75 J valve
-Forge Evo 7 diverter valve
-GonzoTuning/GTS GTTx K04-02x Turbo, port matched to manifold by FFE (https://www.gonzotuning.com/hardware/mk4/gtt/)
-Forge adjustable wastegate actuator, customized for the K04 by FTD Motorsports and FFE
-High flow cast exhaust manifold, ported and machined by FFE
-42DD MK4 K04 downpipe with test pipe and 3 O2 bungs
-FFE custom 3" side exit aluminum V-banded exhaust with 3.5" Vibrant aluminum muffler
-FFE custom aluminum intercooler charge pipes
-BSH FMIC core
-SEM small port passenger side intake manifold
-OEM R32 throttle body
-iABED Industries 5.7L motorsports baffled oil pan
-830cc Siemens injectors
-Hitachi bolt-down "E" coil packs
-NGK BKR7E .028" plugs
-AMSoil 5w40
-E85 fuel (also maps for 93 and 100 octane)
-DeatschWerks DW65v in-tank high flow fuel pump
-Integrated Engineering Deleted SAI/N249/EVAP + AC
-GonzoTuning Stage 4 software
-Valeo 3 row radiator, custom plumbing and flanges to delete heater core
-Mocal 19-row oil cooler with -10 Aeroquip braided hoses and fittings (factory exchanger deleted)
-eBay 500cfm fan behind oil cooler
-034 Motorsports catch can
-Eurojet lower PCV hose
-IE connecting rods
-Fluidampr crank pulley
-Shine Racing Service custom solid aluminum upper motor mounts, FFE Racing motor plate to replace the factory dogbone mount
-Prosport gauges for oil press/oil temp/boost/EGT and an Innovate MTX-L wide band air:fuel

Transmission/Drivetrain:
-2005 02J with a Peloquin LSD
-Raxles axles
-ClutchMasters FX400 6-puck clutch kit with steel lightened flywheel
-DieselGeek Sigma5 short shifter
-billet shifter mount bushings



PREVIOUS BUILD
Engine:
-ITG 3" cone filter
-VR6 MAF housing with an AWP MAF sensor
-some crappy silicon TIH
-N75 J valve
-Bailey's DV
-GonzoTuning GTT Turbo (https://www.gonzotuning.com/hardware/mk4/gtt/)
-Godspeed high flow cast exhaust manifold
-Godspeed 2.5" downpipe
-TT/Borla 2.5" exhaust
-Alamo Autosports hard boost pipes
-EvoMS FMIC
-830cc Siemens injectors
-Hitachi bolt-down "E" coil packs
-NGK BKR7E .028" plugs
-AMSoil 5w40
-Walbro 255lph inline pump w/ USRT harness
-Integrated Engineering Deleted SAI/N249/EVAP + AC
-GonzoTuning Stage 4 software
-Valeo 3 row radiator
-Setrab 19-row oil cooler with -10 Aeroquip braided hoses and fittings
-eBay 500cfm fan behind oil cooler
-Eurojet PCV hoses
-IE connecting rods
-Fluidampr crank pulley
-034 track density motor mounts
-Prosport gauges for oil press/oil temp/boost/EGT and an Innovate MTX-L wide band air:fuel

Transmission/Drivetrain:
-2005 02J with a Peloquin LSD
-Raxles axles
-ClutchMasters FX400 6-puck clutch kit with steel lightened flywheel
-billet shifter mount bushings and brass cable end bushings
-TT short shifter


New Dyno:

Still at 27 PSI with a little more timing up top than before. Performed on a very hot and muggy day at FFE Racing.



Old Dyno:

Was done at 27 PSI with relatively conservative timing. In a couple weeks I'm going to run the same setup on the Dynojet at ForceFed, then from there bring the boost up a little bit (~30) and dial in the timing more. I'm super happy with the fat powerband and driveability of the car so far, just what I was shooting for when I took the leap from stock turbo.

 

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Nice numbers man...Gonzo does it again! Congrats!
 

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When i get my turbo back im switching to gonzo :thumbup:
 

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Great numbers Jeff! Aren't you happy you listened to me and hopped on the rollers? With a bit more boost, and your timing fully optimized for E85, the car will shread the auto-x courses this year. (We have to set up a schedule of solo events we can all go) :thumbup::thumbup:
 

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Looks like an awesome setup and #'s!!!! How is that clutch with this setup? I'm running Gonzo's Stage 2 tune on 93 octane and my OEM clutch is slipping hard! :banghead:
 

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Damn, them are impressive #'s:thumbup: Did Gonzo do this via E-mailed logs or was he there to tune it??
 

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Discussion Starter #17
All without a bigport head, cams, intake manifold, water meth, etc. !!!

Just imagine what a set of cams an AEB head and a SEM manifold would do. Can we say 400whp possible ;)

:peace:
...and the original wastegate actuator that came with the turbo! I have no plans to touch the head or IM, not saying this is the end though...

That's how it's done Jeff! Amazing dynojet numbers! :thumbup:
Thanks Max! Did you have a chance to dyno with your new downpipe on today?

Damn, them are impressive #'s:thumbup: Did Gonzo do this via E-mailed logs or was he there to tune it??
Thanks! It was all done over email.
 

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I hope to make some good numbers with my F21 and E85. These numbers are awesome! :beer:
 
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