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KR 16V G60 BBM lysholm charged

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KR 16V G60 BBM lysholm charged

Post by Flusted on Thu Oct 23, 2008 12:20 pm

ok easier for me to post lots of pics but basic idea was, get standard KR, stack the headgaskets and build a 16v g60, i then had major g-lader problems and ended up buying a bbm lysholm.

heres the pics

Heres the engine straight out of a 16v corrado 1.8 139bhp

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This is where i need to drill the block for oil return from the charger

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oil return fitted

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The 8v lumps last few moments before being taken out

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Charger off and slam panel etc

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And its out!

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pic of the mk3 1.4 bottom pulley, i think it might actually sit in too far?

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My belt arrangement using a vr6 alternator mounted under the charger then a few cam belt tensioners here and there

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when the original tensioner is pushing down on the belt, it does actually spin the water pump pulley, although it doesnt look like it in pic.

picked up a CTN code gearbox from passat TDI, should allow much better traction and higher top speeds in every gear
heres the block with gearbox fitted

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got it sat in the bay

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had to cut the rad support for clearance for alternator

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Stacked head gaskets

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Head on

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Got my flipped inlet, here it is

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I decided to cut up an old manifold i had, and cut the logo off to then glue on the new manifold so it looks more oem

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Where the top part of the manifold has been flipped over and welded, the throttlebody flange needs re-shaping as the small and big butterflys are now different sides. heres what material needs taking off

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I also took out this large lump that looks very restrictive for number 1 runner, and then match ported the throttlebody to the manifold

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Here it is fitted

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need to move the coil down slightly to add more clearance for the throttlebody pipe.

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Just got to route the boost hoses then put the front back on

heres a mongoose cossie front box, i welded a cat flange to it, and a joiner the other end

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Then i welded in another lambda boss for my AF gauge

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Not bad for the second time ive ever welded something Laughing

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440cc injectors yummy
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440cc injectors yummy
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Then this turned up

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Mocal oil cooler with braided lines

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New front mount

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Going standard airbox with panel filter and BBM inelt adaptor

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trial fit of charger

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with intake on

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Then my DIY cold feed for standard airbox

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Cold feed

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Heres the cold feed taped into the brake duct for trial fit

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My mate made me the breather blank with oil return

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heres a few pics of intercooler and plumbing

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wedged a bit of random pipe i found into the cut down duct and fibreglassed it in place
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Then glassed it in on the inlet

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Then filler

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cold feed filler smoothed

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painted

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made some brackets for my slimline fan out of bike stabilizer brackets Laughing

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with 50mm inlet

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and its in this, but thats another story lol

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Ive recently fitted a 55mm pulley to the bbm and its flying
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Re: KR 16V G60 BBM lysholm charged

Post by mrbeige on Thu Oct 23, 2008 12:38 pm

What sort of power are you seeing from it?

From this pic it looks like the upper and lower manifolds don't really mate up very well, you don't get any leaks there do you?
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£300 Corrado 1.8 16v
The good lady wife's Golf VR
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Re: KR 16V G60 BBM lysholm charged

Post by dirtytorque on Thu Oct 23, 2008 2:12 pm

Looks wicked.
You have introduced alot of new variables into the engine mate.More boost better lungs,Higher fuel flow rate etc.
The car deserves a custom MAP to really get the most out of it.
Great skills thus far.
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Re: KR 16V G60 BBM lysholm charged

Post by mrbeige on Thu Oct 23, 2008 2:16 pm

dirtytorque wrote:Looks wicked.
You have introduced alot of new variables into the engine mate.More boost better lungs,Higher fuel flow rate etc.
The car deserves a custom MAP to really get the most out of it.
Great skills thus far.
I was thinking that. Is it running G60 management, with a different chip?

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"Take one old performance car, modify it so that it is as good, if not better, than a new performance car"

£300 Corrado 1.8 16v
The good lady wife's Golf VR
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Re: KR 16V G60 BBM lysholm charged

Post by Flusted on Thu Oct 23, 2008 11:59 pm

Yeah digi 1 with g-werks chip which i guess was written by steve psd.

That mani pic was trial fit and i think the coil lead was under it, notice no nuts done up!
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Re: KR 16V G60 BBM lysholm charged

Post by mrbeige on Fri Oct 24, 2008 3:41 am

Flusted wrote:Yeah digi 1 with g-werks chip which i guess was written by steve psd.

That mani pic was trial fit and i think the coil lead was under it, notice no nuts done up!
Ahh right Laughing

Have you considered going standalone? Or are you happy with the performance of the digi-1 chip?

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Stu
"Take one old performance car, modify it so that it is as good, if not better, than a new performance car"

£300 Corrado 1.8 16v
The good lady wife's Golf VR
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Re: KR 16V G60 BBM lysholm charged

Post by saysomestuff on Fri Oct 24, 2008 4:50 am

Yikes, there's alot of work gone into that, proper ghetto-charged motor Cool. How are you getting on with the whine? And to echo Stu, how much power is it kicking out?

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Re: KR 16V G60 BBM lysholm charged

Post by Flusted on Fri Oct 24, 2008 7:29 am

digi 1 seems ok, would like a psd live remap. Power wise i have no idea, it feels like my old 8v (which shoulda been 240ish) but alot more torque at 5k so maybe 250ish?

Its only standard 1.8 kr with stacked gaskets and ABF cams

55mm bbm pulley
FMIC
440s
Flowed throttlebody
Water injection

The standard 1.8 16vg60s made 210bhp?
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Re: KR 16V G60 BBM lysholm charged

Post by dirtytorque on Sat Nov 22, 2008 2:01 pm

where did you take your oil feed for the charger from flusted ?
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Re: KR 16V G60 BBM lysholm charged

Post by Flusted on Sun Nov 23, 2008 7:27 am

I took the feed from the top of the oil filter hosuing for the lysholm but i think if you do this with a g it blows the oil seals.
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Re: KR 16V G60 BBM lysholm charged

Post by dirtytorque on Sun Nov 23, 2008 8:18 am

cool,but when you ran the g-larder where did you run it from then mate?
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Re: KR 16V G60 BBM lysholm charged

Post by Flusted on Sun Nov 23, 2008 11:30 pm

From the back of the head using the g60 t piece
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Re: KR 16V G60 BBM lysholm charged

Post by saysomestuff on Mon Nov 24, 2008 3:05 pm

mate, did that used to be red?

If it's that same car that's amazing what you've done, looks really good.

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Re: KR 16V G60 BBM lysholm charged

Post by mrbeige on Mon Nov 24, 2008 3:39 pm

saysomestuff wrote:mate, did that used to be red?

If it's that same car that's amazing what you've done, looks really good.
I'm pretty sure it was, Cole Suspect

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"Take one old performance car, modify it so that it is as good, if not better, than a new performance car"

£300 Corrado 1.8 16v
The good lady wife's Golf VR
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Re: KR 16V G60 BBM lysholm charged

Post by Toad on Mon Nov 24, 2008 3:41 pm

And I think it was white once too?
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Re: KR 16V G60 BBM lysholm charged

Post by Flusted on Tue Nov 25, 2008 12:02 am

yes it started off white, then i chavved it up and painted it red, then i got a life and painted blue lol
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Re: KR 16V G60 BBM lysholm charged

Post by saysomestuff on Tue Nov 25, 2008 11:42 am

Flusted wrote:yes it started off white, then i chavved it up and painted it red, then i got a life and painted blue lol

mate, you've done a great job on it now, looks really tidy.

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Re: KR 16V G60 BBM lysholm charged

Post by dirtytorque on Wed Nov 26, 2008 10:54 am

me again.

So they say to compensate fot the wider belt cam belt of the 16v setup you have to take off 6mm from the g60 crank pulley.
The g60 crank pulley doesn't have 6mm to give.
I'm a tad confused..

Unless they are talking about the crank sprocket,but then your supposed to use a 16v one of those so that makes no sense either.
Bang head
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Re: KR 16V G60 BBM lysholm charged

Post by mrbeige on Wed Nov 26, 2008 12:57 pm

dirtytorque wrote:me again.

So they say to compensate fot the wider belt cam belt of the 16v setup you have to take off 6mm from the g60 crank pulley.
The g60 crank pulley doesn't have 6mm to give.
I'm a tad confused..

Unless they are talking about the crank sprocket,but then your supposed to use a 16v one of those so that makes no sense either.
Bang head
ABF crank pulley?

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Stu
"Take one old performance car, modify it so that it is as good, if not better, than a new performance car"

£300 Corrado 1.8 16v
The good lady wife's Golf VR
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Re: KR 16V G60 BBM lysholm charged

Post by Flusted on Wed Nov 26, 2008 11:40 pm

Yeah i stumbled across this. I used a crank pulley from a golf 1.4 mk3 and spaced it out slightly by cutting another pulleys centre out.

I think they mean the ABA bottom pulley
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Re: KR 16V G60 BBM lysholm charged

Post by mrbeige on Thu Nov 27, 2008 12:18 am

Will the ABA not have the same problem as it is an 8v engine as well?

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£300 Corrado 1.8 16v
The good lady wife's Golf VR
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Re: KR 16V G60 BBM lysholm charged

Post by Flusted on Thu Nov 27, 2008 11:19 am

yeah but i think thats the pulley to shave, i checked a 2E puley and that wasnt easily shaved either
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Re: KR 16V G60 BBM lysholm charged

Post by dirtytorque on Thu Nov 27, 2008 11:28 am

Flusted wrote:yeah but i think thats the pulley to shave, i checked a 2E puley and that wasnt easily shaved either

as long as there is enuff material there i'll give it to a machine job to do.
Do you think the 2e or the abf's will do the job then?
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Re: KR 16V G60 BBM lysholm charged

Post by Flusted on Fri Nov 28, 2008 2:48 am

Nope otherwise id of gone that route. they only have a thin piece of mating material like the g pulleys.
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Re: KR 16V G60 BBM lysholm charged

Post by dirtytorque on Fri Nov 28, 2008 4:07 am

Crying or Very sad
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Re: KR 16V G60 BBM lysholm charged

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