PrecisionAutoWorks 1.8t 20v GT28

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PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Fri May 04, 2018 2:48 pm

Hi Guys

So I thought I'd post this.

Another friend bought a 1.8t 20v A3 last year. Was in decent condition.

Drove it stock for a while. And then we did a run to sun city and a the car broke.

So we decided to rebuild it and then play.

What happened was the chain tensioner wore due to probably never servicing the car as the head was black on the inside, so all the plastic bits got caught in the pick up and then ya disaster.

So we went about rebuilding it. It bent 5v, so we replaced that, I Ported and polished the head and gas flowed. Rebuild the Ko3 and did all the other parts that needed replacing.

And with that the car was up and running.

We also change the cam chain tensioner from hydraulic to manual. As well the vacuum delete. As well as a joey mod.

I then started mapping the car, Anti lag, over run, hard limiter and so on pushed the boost to .8 bar but whenever it would get higher in the rpm the car would pull timing hard, and hesitate even on stock map, couldn't figure it out. Replaced coils, plugs, maf, lamada, and and and eventually after making sure air and spark where not the colprit we did the fuel pump and sorted. Car was running like a monster.ImageImageImageImageImageImageImageImageImage

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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Fri May 04, 2018 2:52 pm

More pictures. There was a lot of pictures taken but over time I've misplaced some.ImageImageImageImageImageImage
2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Fri May 04, 2018 3:07 pm

So... the car was running perfect.

Not sure what happened but hit the hard cut limiter and all of a sudden no power car cuts out. Like the cam belt snapped. However it was a brand new cam belt so I knew it wasn't that. Towed the car back. Turned the motor swung fine but no firing.

I new it was valve train related could just here no compression. So compression tested, 3 cyclinders were fine one was low.

Open the tappet cover and low and behold the exhaust cam snapped on cylinder one.

So we set about stripping the head off again and checking for valve damage and piston damage.

3 bent valves. Nothing else.

So made missions got a set of s3 cams from a guy in durbs. Then we decided on a new turbo set up. Gt28 with external gate.

So the work began

Will add more pictures later ImageImageImage

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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by ZiF_k » Fri May 04, 2018 3:42 pm

Another BT build! Nice to see more of these around these days.

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by Dinner » Fri May 04, 2018 3:55 pm

Quite a bumpy road so far, do you have any idea what caused the camshaft to fail like it did?
Good luck with that new route however, should be a handful.
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Fri May 04, 2018 5:37 pm

DCmk3 wrote:Quite a bumpy road so far, do you have any idea what caused the camshaft to fail like it did?
Good luck with that new route however, should be a handful.
Yeah look, the price he got the car for and the people im not surprised about the stuff.

And the plan was to build a project car so yeah.

My best guess was from the previous lack of oil supply and the anti lag and heavy bangs on these valve trains are alot of strain. But the cams were not in great shape either. ImageImage

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2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Fri May 04, 2018 5:45 pm

We discussed a normal even length tubular manifold.

Then decided if we going big turbo we go with a different kind of mani so I made something different. ImageImageImageImageImageImage

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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by Ashveer03 » Fri May 04, 2018 6:18 pm

Fabrication works out so smoothly with pie cuts.. nice welds bro

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Sat May 05, 2018 9:29 am

Ashveer03 wrote:Fabrication works out so smoothly with pie cuts.. nice welds bro

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Thanks man.

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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Sat May 05, 2018 9:30 am

So last night got the timing done and fitted the new cams aswell as finish all the new oil and water lines.Image
2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by PapaJo » Sun May 06, 2018 9:15 pm

Very good job and great updates and upgrades.
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by Stu » Mon May 07, 2018 7:23 am

very nice
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by MarshallGTi » Mon May 07, 2018 2:31 pm

keen to hear what this sounds like at full tilt
It is an ingenius solution to a problem that should have never existed in the 1st place...

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by PapaJo » Mon May 07, 2018 2:36 pm

Watching these updates with some popcorn.
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by Unobeat » Mon May 07, 2018 7:17 pm

What an epic build, loving this build.
THANAS wrote:Mix them together to create Shellstrol, and then mix that with Winstrol to create the ultimate, maximum performance oil for your engine.
panic-mechanic wrote:When I build engines and do stuff like this I do it when there is nobody else around, No distractions, No phone nothing so that you don't forget what you should be doing. It's the little things that make them run right. Anybody can slap a basic bottom end together. that is the easy bit. It's all the little things that makes these builds a success or not.
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Sun May 13, 2018 12:09 pm

So I've been in durbs the past week and a bit.

Got some graft done on the car yesterday.

Cars is fully running, turbo is in, all the lines are done, timing is spot on, no oil leaks or water leaks, car starts first turn, got a video of start up with no exhaust just down pipe so sound is a bit rough will post it when I get a gap.

Finished up on the cold side boost pipe all purged, need to finish the hotside boost pipe and new recirculating/blow off valve then the rest of the exhaust at the rear and finish the 100mm aluminium intake then the car is complete. Air fuel gauge is also fitted and working.

Didn't take much pictures as we still cleaning up vacuum lines and so on will try snap some. We car also going to redo the catch can lines at some point. ImageImage

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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Sun May 13, 2018 12:18 pm

A few more shots.

Excuse the engine bay shot quality not so great and still got line to sort out and odds and ends. But it's getting there. ImageImageImageImage

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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by PapaJo » Sun May 13, 2018 1:09 pm

Like the update.
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by seleb » Sun May 13, 2018 11:36 pm

In for updates...
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Wed May 16, 2018 2:42 pm

Thanks alot for the comments guys. Sorry I can only update now and then. Time is not my Ally.



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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Wed May 16, 2018 2:48 pm

Only update I have for now that I took pictures of was the hotside boost pipe is almost complete. All mocked up and half way welded all purged.

Need to weld in the fitting for dump / recirculating bov.

Also intake is almost done it's not exactly how I want it but until we battery relocate then it will have to do. I am keeping maf and just going to rescale it. I'm not a fan of speed density on me7.

On to the last little bits and pieces.ImageImage

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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by Unobeat » Thu May 17, 2018 7:32 am

Awesome work on the car and loving those welds.
They look tops.
THANAS wrote:Mix them together to create Shellstrol, and then mix that with Winstrol to create the ultimate, maximum performance oil for your engine.
panic-mechanic wrote:When I build engines and do stuff like this I do it when there is nobody else around, No distractions, No phone nothing so that you don't forget what you should be doing. It's the little things that make them run right. Anybody can slap a basic bottom end together. that is the easy bit. It's all the little things that makes these builds a success or not.
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by PapaJo » Thu May 17, 2018 4:18 pm

Unobeat wrote:
Thu May 17, 2018 7:32 am
Awesome work on the car and loving those welds.
They look tops.
:iagree:
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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by farrell15 » Thu May 17, 2018 5:02 pm

Tack plates with my company logo
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2009 Hyundai Tiburon FL2 GTv6 (Big turbo project)
2009 Golf MK5 GTI dsg (SOLD)
1979 Golf MK1 2L (SOLD)
2007 Polo 1.9 TDI (BEEEEEEG turbo) (SOLD)
1998 Jetta MK3 ABF 2.0 16v (SOLD)
1990 Jetta MK2 ABF
1968 Baja bug 2.0 Kombi project ABF (SOLD)

Precision Auto Works

2003 Audi 1.8t 20v GT28
2002 Polo 9n 1.9 tdi PD100

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Re: PrecisionAutoWorks 1.8t 20v GT28

Post by Tman21 » Fri May 18, 2018 11:39 am

Kak Lekker!
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