2004GS

iTrader: (1)

Hey all, just wanted to introduce my project to the forum. I have been a member on here for a long time and learned a lot over the years, been slowly building the car and my parts inventory. Thanks to everyone for all the great knowledge shared.

I have owned the car since new, first thing I bought after finishing University, didn't even have a job the day I picked it up. Dailey drove the car for the first two years, including the first winter while living in Toronto. My goal with the car and this project is a fun weekend car, putting together my own turbo kit is part of the fun. My power goals at first are very conservative, later on I plan to build the engine as you can see from my list of parts.

Here is a pic of the car last fall before it was put away for the winter.

At this point here is what I have installed on the car
6ul 8x15 with 225 RS4
gen 1 xidas
boss frog roll bar
boss frog frog arms
dual feed fuel rail
supermiata engine mounts
Energy diff mount
Energy suspension bushings
Rtheory motorsport ss frame rails
MS3basic (ran NA all last summer)
Innovative wide band
SS brake lines
fluidamper harmonic damper
Erg delete
VTCS delete (butterfly's still in place)

Here are the parts I have
Kraken low mount manifold and down pipe
spun 3" cat
the big magnaflow muffler
3" ss straight section of pipe pile of v bands
arp head studs (PHASE 2)
arp main studs (PHASE 2)
DW200 fuel pump (PHASE 2)
CSF radiator and cap
supermiata coolant reroute
manley rods (PHASE 2)
boundary oil pump (PHASE 2)

My plan right now, let's call it phase 1. Get the car running on boost using the low pressure waste gate and a conservative tune, if possible make it through the summer on the stock clutch... fail?
Here's where I'm at, everything that had to be removed is gone. manifold and turbo are fit up so that I can get the water and oil lines sorted as well as the rest of the exhuast.

oil lines -6an supply line, oil sourced on the passenger side of the block, kraken supplied a brass BSP adapter for this. Also supplied 5/8" silicon hose for drain.
Water lines, my local hydraulics supplier will custom bend me ss lines form 5/16" tubing, I'm going to provide them the profile using some metal coat hangers. I will run hard line close to the mixing manifold and water pump return then run short length of hose.
Also need to get the water pump inlet modified or flipped to work with my setup.
From this pic you can see how close the turbo inlet is to the back side of the power steering pump. would love to get some advice from anyone on how to retain power steering with this setup..


If all goes to plan this winter (phase 2) I plan to pull the engine and tranny, new pistons to drop the compression, the much needed clutch, bigger injectors and the other phase 2 parts.. Will also have a shop do a little bit of work on the block to make sure it all good with the ARP mains.

I know this is more of a cat space but here's a pic of my dog for completeness

HowPrayGame

Curious to see how long the stock clutch lasts on that amount of boost.

Nice dog & car!

Dr.Sep

With an EFR? It'll hold probably right up to 6psi MAYBE...

c3hutson

iTrader: (2)

Do you have e85 available up there? I just did a very similar build but retained my 10:1 pistons since e85 is readily available here.


320/290 whp/wtq

2004GS

iTrader: (1)

No E85 for me, you can buy it by the barrel but that's $$. Nice numbers, so you just did rods?

I should add I also have an ebay intercooler and piping setup, bought a number of years ago. Unsure of the quality, its bar and plate from what i can tell.

Just looking to get the car on the road and sort things out for reliability then start with the power build.

c3hutson

iTrader: (2)

My build is very similar to yours.
Manley rods
ARP mains/head studs
ACL bearings
BE oil bump
OEM pistons (new rings and hone obviously)
ID1050x
DW200
FM happy meal

320/290 @ 15psi

allofit

Exciting! Another fully paid up member of the Kraken low mount EFR master race. All aboard.

Low pressure wastegate can and EBC is the right choice for stock engine. I'm putting 8-10psi through my bone stock VVT engine at low rpm. Ramps up to 13-14psi by redline. EFR 6258.

I'm using stock clutch at the moment without issues. I don't know what clutch is in my car as I bought it with 106,000 miles. I don't launch the car or otherwise abuse the clutch and it's been fine for 2000 miles while I build my spare motor.

For the water pump inlet, you can flip it, or you can chop it down and weld to fit. I opted for the latter as it allowed me to keep the heater core (nice to have in our lovely British summers/winters).

The Kraken low mount & EFR does fit with the power steering pump and lines in place. It is a tight fit, but it does fit. I've got Kraken's intercooler kit and I did have to 'delete' my power steering cooling pipe to make space for the intercooler.

I can probably find some pictures of the modified water pump inlet and the (lack of) space between the EFR and powersteering stuff if it would help you.

2002 NB2 6 speed
ME221
Kraken low mount & full 3" exhaust
Kraken intercooler kit
EFR 6258 & low boost can
640cc FlowForce
DW200

2004GS

iTrader: (1)

Allofit, pictures would be appreciated. I was messing around with some options today, super tight. Wondering if you ran low and then came up in front of the power steering pump.

allofit

I'm attaching some pictures of my water pump inlet modification, and how it fits up so you can see what you're working with.

My instructions to the guy who chopped and welded it for me weren't quite clear enough and he didn't cut it down as much as he should have. Ideally you want to cut it down more than mine, otherwise your water inlet hose is perilously close to the EFR's compressor housing. 0.25" - 0.5" shorter would make all the difference for clearance.

I'll also get you some pictures of my EFR & power steering arrangement later today.

allofit

Ok here’s some pictures of how the EFR fits/doesn’t fit with the power steering in place. It’s really tight.

If you were more motivated than me you could probably make a neater job of it.

The silicone 90 degree elbow coming off the EFR’s air inlet is literally touching the pump.

Kind of have to wiggle it all in there when you drop the manifold and turbo into the car.

2004GS

iTrader: (1)

Thanks for that, it is very tight. Pretty much what I have planned.
The line going from the power steering reservoir to the pump inlet. I was able to clean that up a bit if you wanted some clearance on the bypass valve.

I just cut the inlet tube on the power steering pump back about an inch so that the "stop" bead is now the bead holding the hose clamp on. Then I trimmed the hose about 3/4" off each end. This allows you to slide the hose towards the front of the car by about 3/4" and gives some more clearance to the turbo cold side.

Are you currently running the oem heat shield on the header?

2004GS

iTrader: (1)

Quick update on this project, I was able to get the car put back together by end of September and did a few low load test runs around the block. Still on stock clutch and without proper tune so it was just to get a feel for how the exhaust would sound and that it would hold together.

So far
-efr 6258 with kraken low mount
-modified water pump inlet
-ebay intercooler
-ms3 basic
-coolant reroute
-diy 3" ss exhaust, spun 3"cat and magnaflow muffler

Here's a pic of the car back together, ss heat shield for header not shown



my new welding skills




Videos at idle (attached)


Plan to swap the clutch over the winter then a safe tune in the spring running on the low boost efr waste gate.

Winter after that will be phase 2
-boundary oil pump
-upgrade injector and fuel pumps
-rods and pistons
-arp mains and head studs
-required block machine work
-medium erf waste gate and ms3 boost control