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BBT hybrid with New Badger5 high flow k04 exhaust manifold first tests look promising

Discussion in 'A3/S3 Forum (8L Chassis)' started by badger5, Jan 4, 2014.

  1. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 4, 2014]
    K03 hybrid on Lupo compared to the BBT K04 hybrid on my new test K04 high flow exhaust manifold...

    Looks promising power/temp wise.
    [​IMG]

    [​IMG]

    EGTs max on the plotted run 825'c measuring in normal k04-023 position factory stylee.

    I need a stiffer actuator.. This run was on 9psi actuator cranked to give 10psi actuator only boost.. Swapped to a forge one I had on shelf with white spring, and it ran less boost.. doh! 15psi BBT actuator to get asap and then continue with this and find the actual limit as I am not sure I'm there yet. EGTs being my guide, there's some left in it if I can hold more boost up top.

    Very pleased with the result so far.
    More mods to come to see what we get.

    Manifold works fine :)

    :)
    #1
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  3. Brodster
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    Brodster Shark Performance In Scotland Regional Rep Site Sponsor VCDS Map User

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    [Jan 4, 2014]
    OOooOO.........Matts gonna be happy as hes waiting for this mani to complete his S3 build. Running on stock mani just now but waiting for your manifold Bill..............any ideas of timescales????
    #2
    hoffmanvp3 likes this.
  4. daz-20vt
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    daz-20vt Well-Known Member

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    [Jan 4, 2014]
    Ohh very interesting. Not having a desent reliable mannifold on the market is so annoying. Especially when you cant diy. I couldnt afford to do this job twice. Any idea on prices etc? How easy are they to fit? Any info would be awesome
    #3
  5. Gops
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    Gops 6th gear @7000rpm

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    [Jan 4, 2014]
    I can vouch this manifold is great, I have it on my car! Adds more growl if anyone is interested in sound! Good work bill! Seems so tempting as its only a turbo swap away from me!! Haha!
    #4
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 4, 2014]
    I am testing the upsize bore version which should have a badger5 modified hotside to suit. Gops has run the std sized version on baby hybrid to 315bhp fine.
    #5
    jitvv and Gops like this.
  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 4, 2014]
    I painted the cam cover :D



    <tuffty/>
    Last edited by a moderator: Aug 15, 2014
    #6
    Sam_, badger5 and Gops like this.
  8. daz-20vt
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    daz-20vt Well-Known Member

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    [Jan 4, 2014]
    Gops do you have a build thread?
    #7
  9. chaz20vt
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    chaz20vt Member

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    [Jan 4, 2014]
    Excellent results so far ............
    #8
  10. superkarl
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    superkarl MAN OF STEEL

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    [Jan 4, 2014]
    That's an awesome result
    Which hybrid?
    I notice the vid is titled k16/2283, but I though the big daddy bbt was tfsi turbine now?
    #9
  11. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 4, 2014]
    The spec was my choice which Dan kindly made for me. The hotside I have significantly reworked to assist flow, which seems to be helping keep Egts relatively cook for the power output from this framesize turbo.
    #10
  12. chaz20vt
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    chaz20vt Member

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    [Jan 4, 2014]
    Any ideas when this manifold will be complete for sale
    #11
  13. daz-20vt
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    daz-20vt Well-Known Member

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    [Jan 4, 2014]
    And how much change we get from a one'er ?
    #12
  14. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 4, 2014]
    292.67+vat is manifold price which will include stainless steel turbo bolts, nordlocks, and gaskets where applicable.
    #13
  15. chaz20vt
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    chaz20vt Member

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    [Jan 4, 2014]
    When will they be available bill?Also hows fitment compared to "other" manifolds? Not a head of job I take it
    #14
  16. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 4, 2014]
    Having seen these manifolds today, they look fantastic!

    Fitment will be very easy too from what I saw when compared to other nasty fitting aftermarket things!
    #15
  17. Gops
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    Gops 6th gear @7000rpm

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    [Jan 5, 2014]
    Better made, won't crack like others, ports align, better fitting - just to name a few. It feels so much better made than others I've seen! Larger port ftw
    #16
    AVLO and russwuss like this.
  18. AVLO
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    AVLO Active Member

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    [Jan 5, 2014]
    There is obviously going to be a big market for this manifold bill as reliability and fitment are what matters as well as flow. Just one question are they all going to be large port or will it be an optional extra??
    #17
  19. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 5, 2014]
    largeport version might be a little dearer but not much if at all, but it will require a hotside to match it.. The Genuine BW hotsides might have an issue with their inserts if they protrude at all, as the bore is close to the mounting holes for the bolts. Largebore is run gasket less also, so new "flat and smooth" flange face is required to ensure a seal.

    The std size bore version is +1mm over stock but the maximum a factory gasket is which sets the max size. Turbo hotside obviously as std and normal hybrid are the same bore entry size.
    #18
    Gops likes this.
  20. antwan64og
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    antwan64og Member

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    [Jan 5, 2014]
    Bill, if I'm reading the data right and you set max boost to 20psi it would reach it @ 4500rpm and could hold it till redline.
    It produces 240hp at 4500rpm but have you any idea what the peak would be @ 20psi
    #19
  21. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 5, 2014]
    15psi actuator now sourced and fitted and on dyno again now..........
    updates will be on our facebook page

    https://www.facebook.com/Badger5Ltd

    I want to see what the trade off with boost, flow, egts is vs power/torque... Testing continues.
    #20
  22. russwuss
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    russwuss Active Member

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    [Jan 5, 2014]
    Very interested to see the difference the 15 psi actuator makes... may invest in one of these myself :)
    #21
  23. Jersey
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    Jersey Member

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    [Jan 5, 2014]
    Hi guys,
    Just a quick question, please don't slate my lack of knowledge!
    Would this new Badger5 manifold be beneficial to a stage 1 revo mapped car? Or would it need to be custom mapped?
    Cheers,
    Jordan
    #22
  24. antwan64og
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    antwan64og Member

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    [Jan 5, 2014]
    if you get a chance pretty please do one run at 18 or 20 psi, interested to see how smooth the power is at what i'd run on the street
    #23
  25. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 5, 2014]
    when you change hardware mods, I would always suggest custom map to make benefit from improved hardware.
    It would help, but I would not expect by much.

    I would be putting my ££ on other mods first to improve flow, cooling etc... intake, downpipe, fmic... then the slippery slope takes hold :)
    #24
    Westy likes this.
  26. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 5, 2014]
    [​IMG]

    and it continues..........
    #25
    s3dave likes this.
  27. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 5, 2014]
    ******* :sign_unfair:

    That's my bonfire well and truly pissed on them :lol:

    I think gear based boost will be required for this one!
    #26
  28. s3tt
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    s3tt New Member

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    [Jan 5, 2014]

    Just build it it bigger then...
    #27
  29. Pedrosousa
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    Pedrosousa Member

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    [Jan 5, 2014]

    It's time for the hybrid version of yours...
    #28
  30. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 5, 2014]
    firmly off for MrsB.. 288bhp/235lbft(273lbft) badger torques for her daily.

    Its max has been reached from this hardware..
    Smallport head. Stock AUM motor and we're pushing it hard and its pushing back now.. Edge reached.
    A little more left in the turbo, but we need to encourage the engine to use it - lol

    Plans for this ready, but they will wait a while, whilst MrsB enjoys her car back after many many months of me buggering about with it.. and it sat patiently in the "to do" queue

    Its reached/suppased my expectations without the additional mod planned.. so we shall see what that does in due course..

    manifolds working well. egt's nice 845-855 max on the 23psi level

    I do wonder what a largeport head would allow it to do, but thats just a 'thought' I will park for now.

    Tired now.. as is poor ickle lupo I bet. poor thing.
    #29
  31. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 5, 2014]

    I already did :laugh: but I was hoping my 353bhp record would stand for a little longer, it lasted 13 months before being beaten by Bill :)
    #30
  32. Gops
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    Gops 6th gear @7000rpm

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    [Jan 5, 2014]
    Epic results these are! I was hoping it would be record breaking! I wanna upgrade my turbo now ;)
    #31
  33. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Jan 5, 2014]
    Just waiting on a fresh batch of hot sides with egt to come in for Dan to swap out with my exsisting BBT KO4 hybrid Which Will Be Getting The B5 mani.
    Bill, Dan said you'd be doing the large port mod on my mani and Dan would send over my Hybrid hot side to match up:)
    #32
  34. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 5, 2014]
    do you know of any others who were your figure prawny? Were they large or smallport jobbies?
    #33
  35. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    fine.. I need to figure out time/costs for this bit.
    #34
  36. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Jan 5, 2014]
    Kool bill, might be a while until those pesky hot sides turn up. If they take to long I'll just weld on the bung for the egt probe and send that hot side to you but will let you know before hand.
    #35
  37. superkarl
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    superkarl MAN OF STEEL

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    [Jan 5, 2014]
    you're forgetting gazz
    #36
  38. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 5, 2014]

    Nope, I'm not. 352 is less than 353 where I did maths!
    #37
  39. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jan 5, 2014]

    Niki had one make 352 on large port with an SEM also, but dialled it back to 335 before leaving, Gaz saw 352 also on a dyno somewhere up north, on a worked large port.

    Mylos once saw 348 on the ko3 frame thing at Nikis, but from a monster boost push and low down, realistic was closer to 300-310 long term.

    Not aware of many others getting much over 330 though anywhere.
    #38
  40. superkarl
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    superkarl MAN OF STEEL

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    [Jan 5, 2014]
    Deeply truly sorry prawn. I thought it was more
    #39
  41. lovemelongtime
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    lovemelongtime Member

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    [Jan 5, 2014]
    Sounds awesome at last a manifold built to last compared to the relentless.
    #40

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