K04-064 Tfsi turbo to 1.8 20vt engine

Nick_mk2 said:
Be sure that the adapter is made properly at head with exact diameter as the ports because if it isn't the same diametre the flow will be not so good! In our workshop we don't use adapter any more we make the appropriate changes at exhaust manifold of k04-064 and is bolt on! Also we have better space between turbo and the mirror of the car!
Click to expand...

Nick, you don't want exact diameter at the head though! You need a step up in diameter from head to manifold. If you are talking about the manifold ports not lining up with the head ports then I agree it needs work as there is an overlap but if you get the sizing correct on the adaptor you can get a smoother flow transition , I believe from head to manifold which also includes the step . This is why I think our setup made very good power..
 
Nick_mk2 said:
Be sure that the adapter is made properly at head with exact diameter as the ports because if it isn't the same diametre the flow will be not so good! In our workshop we don't use adapter any more we make the appropriate changes at exhaust manifold of k04-064 and is bolt on! Also we have better space between turbo and the mirror of the car!
Click to expand...

lhd cars yours yea?
 
beachbuggy said:
Nick, you don't want exact diameter at the head though! You need a step up in diameter from head to manifold. If you are talking about the manifold ports not lining up with the head ports then I agree it needs work as there is an overlap but if you get the sizing correct on the adaptor you can get a smoother flow transition , I believe from head to manifold which also includes the step . This is why I think our setup made very good power..
Click to expand...
Yeah this is what i mean!We also fitted k04-064 at 1.4 tsi Seat ibiza cupra dsg with stock internals and spools like oem although that have compressor at low rpm!About 300 bhp safe because of stock internals and with no gap between compressor and turbo at 2.500-3000 rpm.Just spools like oem!If you see how this turbo works even at 1.4 tsi motor you will get amazed...The compination with dsg(remmaped) - low weight of car makes it really good!
 
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Nick_mk2 said:
Yeah this is what i mean!We also fitted k04-064 at 1.4 tsi Seat ibiza cupra dsg with stock internals and spools like oem although that have compressor at low rpm!About 300 bhp safe because of stock internals and with no gap between compressor and turbo at 2.500-3000 rpm.Just spools like oem!If you see how this turbo works even at 1.4 tsi motor you will get amazed...The compination with dsg(remmaped) - low weight of car makes it really good!
Click to expand...
Awesome

You guys are ahead of the game!
 
Nick_mk2 said:
Yeah this is what i mean!We also fitted k04-064 at 1.4 tsi Seat ibiza cupra dsg with stock internals and spools like oem although that have compressor at low rpm!About 300 bhp safe because of stock internals and with no gap between compressor and turbo at 2.500-3000 rpm.Just spools like oem!If you see how this turbo works even at 1.4 tsi motor you will get amazed...The compination with dsg(remmaped) - low weight of car makes it really good!
Click to expand...

sounds very cool
nice work
pictures?
 
badger5 said:
sorry.. lhd = left hand drive

a/c pipes and power steering pipes on right hand drive cars and clearing the compressor housing on these?
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i didn't have the chance to work at rhd car because here in greece we have only lhd cars but i think it is possible to fit! I need to see the motor bay to have a better opinion! There is also the way to use the turbo at the opposite site and make another fitment! These are just some minds! Can you upload a rhd motor bay and back to turbo housing to see the fitment?
 
badger5 said:
sounds very cool
nice work
pictures?
Click to expand...
if you are interested i can upload them later and also the dyno of 1.4 tsi! At 1-2 months we think to use aftermarket internals and see how k04-064 work at 1.4 tsi and what bhp produce at its limits and also with hybrid turbo!
 
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Can see this getting copied soon with results that good.
 
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Nick_mk2 said:
if you are interested i can upload them later and also the dyno of 1.4 tsi! At 1-2 months we think to use aftermarket internals and see how k04-064 work at 1.4 tsi and what bhp produce at its limits and also with hybrid turbo!
Click to expand...

Lovely.. thankyou
 
Happy new year...I hope you had a good time from your family these days!Relaxing days but passing so fast:sorry: .Back to work from everyone.
Many updates and photos from our workshop - customer cars.

Ibiza 1.4 tsi with K04-064

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Some other cars Audi S3 GTX3071

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Scirocco R 1st stage approx. 391ps

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Hello from Germany,

im planning to add the K04-023 EGT probe to the K04-064 Manifold. Anyone besides loba welded on this material? I think its D5s metal.
There are some K04-064 @ 1.8t running in germany by the way.

cheers
 
Good job - good numbers!Stock motor?I think that you can have more torgue than 352 lb!This turbo easily produces 400 lbs and more... Do you have pics closely to turbo to see the lhd fitment?
 
rebuilt AGU engine with forged rods :)

Torque is kept back on mine for traction reasons, the car is FWD and used entirely on track, any more torque and it's just too much of a handful.

We had it over 380lbft during mapping, but at the time I was also on a 5 speed 02J box, so we pulled the torque back to 350lbft to get a more linear delivery and save the box / shafts :racer:

Remember our lbft measurement is quite different to Nm also, 352lbft being almost 480Nm :)
 
Yeahh you are right.I was confused :blink:.So its ok in logical numbers!
 
Nick_mk2 said:
Yeahh you are right.I was confused :blink:.So its ok in logical numbers!
Click to expand...

On a side note, this one is still being run on the small OEM charge pipe, hopefully when a better sized one is fitted we can get a bit more out of it..
 
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Any news on your hybrid Dan? That charge pipe is what I was thinking about recently.. I'd love to get one over to bill so he could measure one up. If all looks well I'd be up for a hybrid build on mine :)
 
I have an K04-064 waiting for Dan, my car it's LHD and I'm rebuilding engine and swapping to wideband already have the ECU, just need to deal with imo stuff...
So as son as Dan got news about the hybrid and all the parts needed come around I'll do something in the LHD version. Also got one LEON Cupra LHD doing the same, but that one as onr 2.0l stroker kit.
 
Hah, a lot of people waiting here for Dan. I also have Leon Cupra 4x4 LHD and I am waiting for the whole kit including downpipe.
 
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I am driving K04-064 on 1.8T Leon 4x4 for 3 months already. It is pushing solid 204-205 gr/s with the stock MAF and injectors. I have prepared 3 inch MAF and 630cc injectors and we will see the results after remap.
 
audi upgrades
Not 630cc Siemens Dekas I hope... worst injector in the world... for ME7 at least...

<tuffty/>
 
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I bought Genesis 630cc from the US, they should be decent...
 
There are lots of people working on them (myself included!). I think it will be a bit of a race to see who can get finished the first in the UK. At the minute (that I know of, other than Prawn), there is myself, Aaron Marsh, Chris Carse, and Dan @BBT working on K04-064's on 1.8t's. I'm sure there are several more under the radar though! Looks like its a lot more popular overseas though.
 
I have sold 8 adaptor plates, 6 in the uk and 2 to portugal..
Other than the ones listed Marks and 1 other are all thats around at present. My TT has sat collecting dust for the last 8 months unfortunately as had no time to do any work on it. hopefully that'll change in the next month or so. Other than mine which is a full hybrid and marks which is a stage 1 hybrid the rest I believe are all stock..

I have 1 adaptor kit left, but unfortunately I found out this week the machine shop I use is closing down as they are retiring so need to hold onto it until I find another one to do the work..
 
(ohps, Dan beat me to it! post directed at George!)

Bit late for that old boy :laugh:

Marks has already been up and running, I believe it's only offline due to an engine rebuild at present.

There's also Adam Forbes, who's made it all himself and got it running on a mk4 golf already. been up and running for a few months now :)

I think it's easier for the overseats lads due to less clearance issues on that side of the bay!
 
Ah yeah, forgot about Mark (sorry!). His engine is the wrong way round though, so he doesn't count :p Tabs's Bora is another one too I guess.

Didn't know about Adam, that's good to know. Handy to pool information from everybody that has taken it on.

Not overly looking forward to the brakeline/power steering line clearance issues, but have read a bit of coldside clocking helps a bit.
 
Here is mine up and running :)
The only one in Bulgaria with this setup.


Anyway what blades are you using for Stage 1 hybrid and Full hybrid on k04-064?
 
Stage one is running the 7+7 stock sized compressor with the larger K16 turbine.. Its' basically what's in the 1.8t hybrids I've done. No idea how it'll fair on the TFSI but that's why mark is trying it.

Full hybrid is a 2480 compressor with the K16 turbine. On the 2ltr TFSI has run 400bhp and 415Lbs but again on the 1.8t untested fully.

Also Prawn is now running a stock TFSI turbo but with the 7+7 compressor to help surge and I have a new clipped TFSI turbine and 7+7 compressor ugrade CHRA to test as well at some stage..
 
I have Mylo's kit, which I believe to be the same compressor wheel as Nick's. Also has a 63mm outlet welded onto the coldside rather than the stock outlet, so hopefully that will flow a bit better
 
There are some running in germany. I would say more then ten. My mapping isnt done at the moment and no im not using dekas. there is some strange "knock" which isnt real knock in my logs. i think there is something touching, maybe exhaust or so.
What would be a good air mass with stock k04-064 on a 1.8t?
 
You should be looking towards the 280g/s region with around 1.5 bar of boost on a good setup working well. Sadly I can't give comparable figures from mine as I have a different ECU and crazy MAF scaling
 
I have a real k04-064 and dont see those airflows when I've looked on the TFsi leon of mine
18-20psi boost max is what I run it on.. 360-370bhp/320lbft badger torques
 
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Hey guys,

Short introduction, I'am a student mechenical engineering in holland owning a audi tt mk1 225 quattro for over a year now.
Remap is fun but 260 bhp gets used quickly so preparing for a tfsi k04 turbo conversion. Did some research and CAD designed a adaptor plate to mount the K04-064 turbo to the 1.8t head. Both 20V and tfsi heads have 40mm exhaust ports.
The 20V head to manifold gasket (058 253 039 L) has exhaust ports diameter of 41mm so nice step up. The adapter will also have exhaust ports with a 41mm diameter. But the tfsi head to manifold gasket (06F 253 039 F) has exhaust ports diameter of 37mm and the runners of the exhaust manifold are even smaller 35mm.
What did you guys like Prawn and beachbuggy do with this decrease in diameter?
I can port match the exhaust manifold to 41mm but what to do with the tfsi gasket?

I appreciate you guys help

Daniel
 
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