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Discussion Starter · #1 · (Edited)
Hey everyone, wanted to get a thread going on yet another turbo build in hopes the information can help others, and so that i can show everyone what im going to be up to.

I posted this in the 3.2 technical forum as well, and tmoura was kind enough to throw a few things at me, really appreciated brother. He mentioned to try and make sure i get all the little parts and pieces ordered ahead of time best i can so the shop doesn't have to wait for parts to show up during install, etc.

Right now i'm basically in the part collecting stage, i've got mostly everything (i think) researched and laid out to what i'm picking up to put this setup together. It's somewhat of a custom build, and i'm looking to be 450-500whp on 15-18 pounds.

Id love for any help as to things i might be over looking or missing, or just general pieces of advice from anyone who wants to add.

Car is currently cammed, 264/260's
Car is running a fluidampr

- Gen 2 PT6266
- .81/AR
-630cc injectors
-46mm Vband precision WG
-8.5-1 headspacer
-Inline fuel pump
-4" MAF
-UM tuning

-Coated rod bearings
-ARP rod bolts
-ARP Headstuds

-HEP SRI
-HEP intercooler

-Custom 3" vband downpipe, with WG return into exhaust, into 3" with a single 100 cell HFC

-DKM MS Series clutch and flywheel

While it's apart:

-SAI delete
-Catch can
-Eboost street EBC
-Crackpipe, waterpump, thermostat and housing
-All new timing chain components

So, that's my layout. The install work and custom plumbing is all being done by a fantastic shop in NH and by a guy that has done these types of builds many times.

I just saw in the 3.2 sub forum a post by a guy with essentially the same setup in a 3.2swapped mk3, made 420whp on 14psi with the stock intake mani.

I would be plenty happy hitting those numbers on low boost (14psi) but i have a feeling with the cams, damper and SRI, low boost might make closer to 450? Then high boost (18-20psi) id like to see where that brings me... My entire goal is to keep this build south of the transmission threshold. I don't really have a definitive answer on what that is on these cars but i know you get into it much more the more north of 500 you go. I don't track the car, it's my fun weekend car, and will be daily driven on low boost.

Anything i'm over looking or missing on? Any and all advice is welcome. I want to make sure i try and cover everything because i only wanna do this once. Reliable, simple and clean turbo build that can make upper 400's whp.

pics of said car!











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Discussion Starter · #4 ·
Had one just like cant wait to see what you do with the car

Thanks man, excited for it too

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Clean f'n car. I like the carbon fiber work and the blue spark plug coil covers. Where did you get those?
Thanks brother, very much into the clean and functional. The carbon parcel shelf is an old school piece made by Freedom Designs. Never seen another one come up for sale, sold unborn children for it at the time haha. Blue coil caps i picked up off of ECS


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Discussion Starter · #6 ·
I'm running that turbo with the .81 AR housing. I chose that to try to soften the midrange torque spike when boost comes on for the engine and trans. Peark tq is around 4300. IIRC 500ish whp for me is ~17 psi but different cams and intake manifold. I'd definitely recommend doing whatever you can for heat management. Ceramic coating/heat wrap/turbo blanket/low temp tstat and fan switch if thats an option.

Don't forget spark plugs I don't think you mentioned that. I'm running DCPR9EIX. OEM coilpacks are fine.
Awesome man, thanks for that info. I've been dying to hear some real world feedback on this motor with this turbo.. I've been leaning towards the .81 because of that torque spike. Just don't wanna dig into the trans right now. Really impressed with those numbers, what cams are you running? And just a different brand SRI?

Have thought about some heat management, I think ceramic coating the downpipe would be wise, at the very least using DEI titanium like i have on my headers now. Any idea how well the turbo blankets do real world?

Def gunna do plugs. Thank you for that part number as well. I'll note the low temp thermostat as well


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Discussion Starter · #8 ·
Sorry I misread and thought you were going to be running the OEM plastic manifold. Yes just a different brand of SRI and running 268/272 cams as opposed to 264/260.

I went with a PTP blanket and haven't had any issues with it yet after ~3 years but the car isn't driven that often.
Great to know about the blanket. I think that with some DEI around my downpipe will help keep those temps down at least. I also don't drive my car super often, last year (i hate to say this) i think i put on ~1500/1800 miles... granted here in VT 5-6 months is garbage undriveable, and it rains a lot in summer and i hate having to wash the car all the time anymore.. Sounds like that will suit my setup.

But your cams should account for some more power at the same pressure, so i would think i can see around that 500whp with a few more psi, maybe up to 20. Heard a few other guys say head studs should be done. This the case in your build? Or did you pass them


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Discussion Starter · #12 ·
Here are the numbers I made with almost the exact same parts you want to run and a .68AR. The only real difference is I'm running stock cams..


The gauge on the dyno was low by 3psi. The maxes should be 14psi and 21psi. The numbers are also FWD since I'm still a GTI.


Here is Stock manifold vs SRI, there isn't much of a difference. The main thing was probably the several months between dynos.
In my first post, your post was exactly the one i was referring to, with that 420whp number on stock manifold. Thanks so much for posting this here. Do you feel like the .68ar housing was perfect for this motor? did it feel like maybe it could have been pushed up the band more? I know you weren't using an 02M tranny but a similar 6 speed. Really curious how much of a difference those two make in terms of feel on the street. At least now i've got a couple guys in this thread alone that have run both.

Not much of a difference between the manifolds, but regardless gunna go with the SRI, love the layout of the plumbing as well vs. the stock manifold.

All this leads me to believe i should fall somewhere right in that 450-500whp number with this setup, and that's perfect for me thanks so much for your help, truly appreciate it


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Discussion Starter · #14 ·
Oh, Nice! You said MK3 so I didn't know you were talking about me. Mine is a MK4 that is a AWD swap away from being a R32.
The trans is still an 02M, the R32 is an 02M GQV where mine is the 02M FZR. It just a different bell housing because of the transfer case mounting and different gear ratios.

I can't speak to much on the AR. I haven't ridden in any other comparable turbo cars or seen any dynos from a 6266 .81. If you're worried about the trans go bigger. You can always by a 68 housing later.
Right on brother, i apologize not sure why i thought mk3 swapped haha but that's rad. How's she running? I think ive made the choice to go .81.. and you're right, that can always be changed if i hate it but i have a feeling i won't. I'll see how it goes for my driving and if for some reason i wish it was a hair snappier i'll go to .68, but sounds like i'll be happy. Thanks so much for the feedback


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Discussion Starter · #16 ·
That's a great graph. That's honestly perfect for what i'm shooting for.. shows nearly 600chp, and 440-460whp if i'm reading it correctly. which is plenty for me. Where did you dig that up from? I've searched high and low and havnt come across that dyno yet.


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Discussion Starter · #18 · (Edited)
It's my graph (I posted earlier) but you're reading it incorrectly. The Avg HP is the average across the pull. 600 is whp.
No that's great, saw you've been posting just didn't know it was your setup! But wow, that's some serious power haha.. but i like where that torque comes in.. do you have a lot more fueling and boost pressure to bring the power to that level?

edit: nevermind.. doing this on my phone is confusing me, i'll get onto the computer. But that's at around 17psi for your setup right?

I think i'll be right in the wheelhouse of where i wanna be with a max boost pressure of ~20psi.



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Discussion Starter · #20 ·
That graph was ~21psi. I have the ProMAF and 870cc injectors.
Ok, awesome to learn all of this. Thanks so much for sharing with me. I know variables in builds always change things but i’m feeling confident in my part choices with everything you guys are sharing. Huge help


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Discussion Starter · #21 · (Edited)
Not entirely turbo related but, few parts showing up the last few weeks... wheels and brakes will be on soon for this year.. hoping fronts don’t need spacers but we will see.. 17z 6pot fronts, 4pot rears.. all done by Rob @ Rotorlab.. rear aluminum brackets fabbed by Riaz @ RizPizDesigns







Then got an HEP bumper rebar from Vito @ Exit9...



also a CTS turbo manifold and super DV from DJNastie on the forums hopefully showing up soon..

and Howie @ HEPerformance is fabbing up my 10” intercooler for me



ball is rollin!



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Discussion Starter · #23 ·
You will certainly need spacers to run that brake/wheel combo

I am guessing in the 20-25mm to clear the front calipers, not as much to clear the rears, but they will be needed
I hope i don’t need anything that size up front.. New wheels are ET35.. Right now I run 10mm up front with Aristos.. i think that puts me flush without spacers at almost the same exact ET with the wider wheel.. was hoping at most i would need a 3mm up front

Am putting my 10mm from up front out back on the rears, so shouldn’t see any problem there


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Discussion Starter · #25 ·
they’re 17z’s.. however the width i didn’t think was much different from the 18z’s.... if that’s the case i might have to look into the wider front fenders.. did a lot of talking with guys from europe with the same wheel and brake setup and i got the impression it wasn’t too far off.. But that’s what we get i guess haha, thank you very much for the heads up.. btw, you know a guy in the Greenville area named Andrew? Just sold him my S8!


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Discussion Starter · #27 ·
No worries at all, check out my build thread, you can see where i ran the OZ Superleggaras, with 205/40 tires, then ran the OZ RSI cup wheels with 225/40 (low) and have run both 235/40 and 255/35, but those wheels 18x9 et10 require the wider SRS fenders...

Yeah, I know Strom, lives right down the road from me! :thumbup: :beer:
awesome man, i’ll definitely check your thread out again (i know i’ve looked at it serveral times) but i do mix up people’s cars and setups with all these rad builds everyone has. So so cool, he’s a great guy, glad the car went to someone like him


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Discussion Starter · #29 ·
You will need to run pretty big spacers up front. I just put 17z's on the front of mine. 17 x 8's 245/40 ET38 - a 20mm may have worked but I did ECS 22's. I also ordered the new wider fenders that you see everyone with. I've yet to get the rotors on the rears since I basically just finished installing the diff and refurbishing all mounts. Hope my 2cents helps.


yup, looks like all my diggin got me nowhere.... hahahaha mannnnnnn. Well it is what it is. This will throw a wrench in the works a little bit since i’ll have to get those fenders and have them painted.. luckily have a good buddy of mine that’s a body man and can do it much cheaper than huntin, but golly.. I can’t believe i was that far off. All your guys help and info is beyond appreciated, that’s why i love this community. Got a new route for this summer


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Discussion Starter · #31 ·
my pleasure... it's painful. If you expect it to cost x - triple it. Your calipers look great though.
i’m a big believer in sharing everything i go through... I know that in parts alone for this build (turbo stuff only) i’m at 10k.. I don’t have hookups in the industry so i pay full boat for all my stuff.. buy used if or where i can depending on the parts.. but to do a build on these cars right, it’s 15-20k no matter how you slice it... and when you add in unseen stuff like this, keep adding.. but you’re exactly right.. but like all of us, we love these cars so much we will do anything to make them what we dream of. Luckily i have an awesome fiancé who believes in what i’m doing and wants me to enjoy it.

I think the calipers came out awesome too.. I just hope i can get everything looking good and running better hahaha. Awful life we live with these things!


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Discussion Starter · #32 ·
Got the rest of my brake and wheel setup here.. once i get the rubber mounted, gunna see what i need to run up front with a mock up.

Intercooler is being made as we speak.. Talked with Fred @ UM, and will be running 550’s for this setup, he said it’s good for up to around 480whp so it’ll keep me where i wanna be for now. Maybe down the road look into beefing up the trans, maybe rods and turning it up a little.

CTS manifold showed up yesterday, along with diverter valve. thinking of sending it out for coating at some point.

Once the intercooler is here, I think next step will be getting the meat and potatoes of the turbo setup ordered from CTS. Won’t need any piping from them, manifolds or intercooler. So glad i’m going with custom plumbing.

Also gunna go with the gen2 6266 Ball bearing, .81ar.. starting to realize how much more capable this setup will be versus where i’m gunna be running it. For now anyway!


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Discussion Starter · #34 ·
I am thinking of a 6266 as well. What led you to make this decision. I also have 550 setup with um tune.


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I just think that it’ll put the power band a little more where i want it, and not be as peaky as it would be with a 6262.. Sounds like it’ll give me the drive that i’m looking for.. and the larger AR should help with how the power is delivered to keep the trans a little more safe


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Discussion Starter · #35 ·
not so much a turbo update but got new wheels thrown on finally.. might drop the rear a hair but not sure yet.. brakes are going on next week.. will see how the fronts go. Census is im gunna need more room but, read so much from the UK of guys making these work so we will see.

currently on 5mm in front with these ultraleggeras, ET35 18x8, and 10mm rear












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Discussion Starter · #36 ·
fronts are on.. didn’t realize i needed to pull hubs and bearings for the rear dual caliper setup to go on so need to order those. Gunna actually run 20mm out back now and get a real fat and meaty look goin with 18’s. I moved my 10mm up front to clear, and there are a few mm to spare for sure. 8mm might possibly work but i’m not gunna bother cause of how awesome the fronts look right now, so stoked. The pedal feels f*ckin awesome, and holy **** do these things stop. Can’t wait to get the rears on to match. Gravity bled both sides before pumping, and they came out perfect. Thought it would be a nightmare based on everything i read but, my guy felt confident we would be all set, was dead on.














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