2008cc 8.75:1 CR 3A G60 build.

A lump hammer and a steel pin punch I used something else also but can't remember?? Anyway you have to swing the hammer real close to the charger!!!

Right decided to get my arse in gear and get this had fitted sooner than later. Can't wait till October! Plus it's cold then and I always end up doing stuff in the rain and dark! So I'll be sorting out some bits and pieces within the next week or so!

And will be gathering cash for the remap.

Things I need or need to do:-

1. An ABF headgaset!
2. mk3 8v Exhaust gaskets
3. Gonna make another custom matched intake gasket for future reference.
4. Coolant take off gaskets n seals
5. Decide whether to go with the lucas/denso type disc injectors I have and if so get them tested. Or get bosch greentype or the new type 3's, can't decide!
6. Sort out the bottom end breathing which is currently as standard.
7. Throttle body Gasket
8. New u-bend boost pipe
9. Possibly a new distributor just incase it is inaccurate.
10. What ever else I've forgotten! Oh yeah make some time and think of an excuse to tell the missus for me messing around with my car again!

11. Fit the new head?

Oh, and good to see you getting your arse in gear....

Tis a rather exciting prospect!


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Be cool to blow that bluejoe/Berno engine out the water, it's never been right since the day it was born that one. And to climb that Top20 list on Vortex.

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Currently in 5th.! with a stock head!!!!

I'm so competitive, it's not healthy!

ctwg60 wrote:Be cool to blow that bluejoe/Berno engine out the water, it's never been right since the day it was born that one. And to climb that Top20 list on Vortex.

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Currently in 5th.! with a stock head!!!!

I'm so competitive, it's not healthy!

Of course it's healthy

I agree about BlueJoe's engine. As you said, it never was right. I wonder whether it was a little OVER engineered....

The CR is too high I'm sure that's the issue. I've done the maths and a 92.8 mm crank and 144 mm rods and a capacity of 2031cc does not leave enough room to have a piston that will give you a low enough CR. Bernos upped the boost with a ported charger and 62mm pulley but still on reds with a 3.5 bar fpr so he's made the situation worse, he's just recently slapped in some 440's without a remap and it still pinks so god know where he's going with it now. Keeps blaming the valve timing and wayne at chipwizards more recently. Berno's not the right guy to sort out that engine, he needs to take the head off and have a good look at the Combustion Chamber Volume. Anyway it's entertainment to say the least, but I digress.

Out of interest, where is chipwizards, and how much for a remap? Currently thinking about options for getting the VR mapped...

Toad wrote:Out of interest, where is chipwizards, and how much for a remap? Currently thinking about options for getting the VR mapped...

For VR mapping I would say Stealth were the people to use mate. They are off the M40 just before you get to Birmingham on the way from london.

tell the wife it's either play around with cars or get a mistress.

Those injectors are fine mate.

dirtytorque wrote:tell the wife it's either play around with cars or get a mistress.

Those injectors are fine mate.

Can't really afford new injectors so I'll probably just use them, I'd like to have them tested first. Just don't like the fact they were sold to me as new and came unprotected from dirt or damage! I don't like things with a question over their function. You know me Rob! I'd rather spend the money just incase than spend time and money I don't have later to figure out what's wrong. We'll see!

Chipwizards is up by way so quite a way for you, it's not far from Manchester.

Oh and cost offered him cash and he did mine for £350!

ctwg60 wrote:The CR is too high I'm sure that's the issue. I've done the maths and a 92.8 mm crank and 144 mm rods and a capacity of 2031cc does not leave enough room to have a piston that will give you a low enough CR. Bernos upped the boost with a ported charger and 62mm pulley but still on reds with a 3.5 bar fpr so he's made the situation worse, he's just recently slapped in some 440's without a remap and it still pinks so god know where he's going with it now. Keeps blaming the valve timing and wayne at chipwizards more recently. Berno's not the right guy to sort out that engine, he needs to take the head off and have a good look at the Combustion Chamber Volume. Anyway it's entertainment to say the least, but I digress.

yeah it makes 4 interesting reading thats 4 sure/
I would lurv to know what compression it is running.
A unique engine,will have to wait and see if it has a happy ending.

bollox I'm going with the lucas disc injectors untested! fluck it! let's live dangerously!!

ctwg60 wrote:bollox I'm going with the lucas disc injectors untested! fluck it! let's live dangerously!!

umm who ever that is you don't fool me for a second.
Please put chris back on.



seriously though I have a nice idle with those injectors and i'm slowly dialing in the fueling.Once I have my VE table setup up I have no doubts it will hit the targets.
get them cleaned if it will stop you ringining your hands.


Glad you decided to put the head on now.Makes sense to do these things in the light and the warmer weather,especially without a garage.

Things I need or need to do:-

1. An ABF headgaset! - ordered n paid for
2. G60 8v Exhaust gaskets - ordered n paid for
3. Gonna make another custom matched intake gasket for future reference. - ordered n paid for
4. Coolant take off gaskets n seals - ordered n paid for
5. Decide whether to go with the lucas/denso type disc injectors I have and if so get them tested. Or get bosch greentype or the new type 3's, can't decide! Going with the Lucas injectors untested
6. Sort out the bottom end breathing which is currently as standard.
7. Throttle body Gasket - ordered n paid for
8. New u-bend boost pipe - £100+ not going to happen, current one will hold for now.
9. Possibly a new distributor just incase it is inaccurate. - £80 not going to happen
10. What ever else I've forgotten! Oh yeah make some time and think of an excuse to tell the missus for me messing around with my car again!
11. Head Bolts - ordered n paid for
12. Fit Head
13. Get mapped

I like your style.
The bottom end breathing isn't too much of an issue tbh as you have the engine breathing just as it would on a g60,vie the head.
So you could probably go ahead and tick that off too.

dirtytorque wrote:I like your style.
The bottom end breathing isn't too much of an issue tbh as you have the engine breathing just as it would on a g60,vie the head.
So you could probably go ahead and tick that off too.

YEs I thought that as I looked down the list! So what's left, yep get some cash together change the head and get it mapped!

Things I need or need to do:-

1. An ABF headgaset! - in my possession
2. G60 8v Exhaust gaskets - in my possession
3. Gonna make another custom matched intake gasket for future reference. - ordered n paid for
4. Coolant take off gaskets n seals - in my possession
5. Decide whether to go with the lucas/denso type disc injectors I have and if so get them tested. Or get bosch greentype or the new type 3's, can't decide! Going with the Lucas injectors untested
6. Sort out the bottom end breathing which is currently as standard. - NO
7. Throttle body Gasket - in my possession
8. New u-bend boost pipe - £100+ not going to happen, current one will hold for now.
9. Possibly a new distributor just incase it is inaccurate. - £80 not going to happen
10. What ever else I've forgotten! Oh yeah make some time and think of an excuse to tell the missus for me messing around with my car again!
11. Head Bolts - in my possession
12. Fit Head
13. Get mapped

11a. Fit new fuel pump - Might do this one this weekend!

Have you tackled 10. yet?



When since have you needed a new fuel pump?

dirtytorque wrote:Have you tackled 10. yet?



When since have you needed a new fuel pump?

Probably don't need the fuel pump but I have a new bosche one and it only cost £25, so better safe than sorry with those big boy injectors. No I haven't tackled 10. I think I'll say the injectors just need cleaning or the head gaskets gone, and then say it's turned into a bit of a nightmare and I had to remove the head. She'll be all supportive and sympathetic.

ctwg60 wrote:She'll be all supportive and sympathetic.

Until she reads this!

mrbeige wrote:

ctwg60 wrote:She'll be all supportive and sympathetic.

Until she reads this!

She isn't a forum member!

OK had another idea lately. I've never been very happy with the g-werks manifold, as it set fire to my steering boot uj grease etc. etc. etc. Performance wise I have no complaints but it's been a major compromise in daily driving due to the farty, turbulence, sounds like it's blowing at idle but believe it's due to turbulence in the manifold. Also the lack of flexi has caused me no end of problems with exhaust system movement. So... I was thinking the standard downpipe isn't that restrictive so why not send off the standard cast manifold to somewhere like this...

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And have them use it as a template for a 1.5-1.75 inch primary replacement with reinforcement for the heavier downpipe?

Expensive probably but sounds like a plan, it would still be a 4-2-1 mani but with shorter primary runners.

I know that JMR had some good results running a flowed standard exhaust manifold....or was that on his 16vG??

I'd love to go back to a stock exhaust system but I think it might hurt performance a little too much. Maybe once I've proved my engine design I'll fit a new VAG exhaust system and downpipe and think about what to do for an exhaust manifold!! Hmmm. I just hate unpleasant noisy exhausts...