K04 Turbo

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At Ebay won an Audi TT K04 turbo from Borg Warner ( KKK group ) 

 

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Also won at Ebay a GSXR600 throttlebody kit from a 2001 model.

 

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From http://www.800bhp.com/ bought an adjustable blow-off valve.

 

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XS racing has a nice wastegate. This one equiped with a 3.6 psi spring.

 

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Fuel pressure regulator with a small meter and is adjustable within

the needs of the pressue and also has a turbo pressure reference input.

 

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Tubekit for the airtube with silicon hoses.

 

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Testing the bodies and measuring to try it fitting on the heads.

 

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Topview of the testing.

 

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Special thing has to be done like making the axle 68 mm longer than stock.

Welded on with a TIG torch and placed the notch at the end.

 

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Had to make a plenum for the intakeside. Calculated the size by the manual of Corky Bell.

 

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Here a friend welding the plenum together.

 

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Welded the box together. Now have to polish it.

 

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Topview of the plenum on the bike.

 

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Airtube fitting and searching for the right angles and way to route it.

 

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Sideview of the air tube.

 

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Right view of the body connection wheels.

 

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Shortened the output of the compressor housing by 4 inches and

welded a new exactly 2 inch output on it and polished the housing.

 

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Bling factor !
Will fine polish when ready with Belgom.

 

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Fuel distributorblock and gauge mounted on the pressure regulator.
Separate fuel lines for each injector.

 

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Vacuum/pressure lines for the fuelpressure regulator and blow off valve on the manifold.

 

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Bought at www.uitlaten.com a set of bent tubes to make the exhaust made of stainless steel.

 

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Started sawing and trying to fit the piping.

 

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After a lot of time Frans and I got this pipe to the turbo ready.

 

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Other side of the piping.

 

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The downpipe and wastegate connection started to get some shape.

 

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Underside of the engine fits tight.

 

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Rear part of the pipe fits smoothly to the underside of the frame.

 

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Exhaust exiting the frame to the rear of the bike.

 

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Full view of the exhaust pipe ready welded.

 

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Copper gasket sawed with a jigsaw to tighten the pipe to the turbo.

 

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Desgined my mufflers and I like the shapes it is now !

 

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Connection side to the pipe.

 

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Rear view of the bike with the mufflers mounted. Color will be changed when the bike is finished.

 

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My bike at the Dutch www.motor-forum.nl megameeting in Veenendaal

 

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Have to finetune the bike and will fit a boost controller solenoid to regulate the pressure.

Now boosting with 5 psi pressure and it runs great and the frontwheel starts lifting till 4th gear !
Designing heat shields and water catchers to prevent burning my pants and cracking the turbo from water.
Will post some results soon after a dyno day...


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