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Hybrid K04 R&D

Discussion in 'A3/S3 Forum (8L Chassis)' started by beachbuggy, Sep 17, 2012.

  1. wild willy
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    wild willy Member

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    [Jun 13, 2013]
  2. beachbuggy
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    beachbuggy Well-Known Member

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    [Jun 13, 2013]
    I've got one..
    Its basically the ttrs compressor wheel. It's too big for the 1.8t comp housing.. And the current 2283 is more than capable of flowing more than the 1.8t turbine housing can take.. And in the k04 tfsi hybrids the comp housing will easily take a 2480 wheel if not larger so again this isn't needed.. I don't know know what application this wheel could be used in tbh.. I know the guy who made them up and think he hasn't sold many....
  3. beachbuggy
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    beachbuggy Well-Known Member

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    [Jun 13, 2013]
    I agree, there is a step/ridge inside the turbine housing lip on the outlet which I always port smooth but I think it might be there either as its badly designed or as a kick to get the gases flowing over the lip of the dp flange, flow is about turbulence and reducing it. Also you'd only need to de restrict one side of the dp as the gasses come out one side and shielded from the waste gate gasses on the other. Also as the gasses come out of the turbine and energy is taken out the gasses slow and in so increase in volume. If I be a chance I'll take my dp off and try match porting the dp to turbine housing. You can buy 4"-3" reducers so you could cut one down to get the larger Id to 3" existing dp.
  4. wild willy
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    wild willy Member

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    [Jun 14, 2013]
    That would be interesting if you did, i recon it would be worth the effort. Still a few tweaks to be added to get the very best out of this tubby.
    Have you had any figures back from your latest k04 Hybrid builds. They do look very well engineered and specified.
  5. wild willy
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    wild willy Member

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    [Jun 20, 2013]
    I was looking at my stock K04 last night and was amazed how restrictive it is where it continually reduces down from the exhaust mani flange to the turbine wheel. I can barely get my finger down there. How much scope is there for porting that area immediately before the turbine wheel and due to it being ubber restrictive and how can we say that it is probably the exhaust manifold that is limiting power when the turbine inlet is many times smaller. This restriction is also causing big manifold back pressures.
    What is the dimensions of the custom K16 turbine wheel.
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 20, 2013]
    lupos hybrid pending fitment is ported a lot in that area.
    we shall see.
    manifold is also ported equally as large
  7. wild willy
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    wild willy Member

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    [Jun 20, 2013]
    This is going to be very interesting. Any chance you could take a picture of how much porting has been achieved, one of my biggest concerns for porting in this area is to know how much is too much with regards leaving enough meat there for the turbo to retain reliability.
  8. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 20, 2013]
    no one knows that answer carl
  9. beachbuggy
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    beachbuggy Well-Known Member

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    [Jun 20, 2013]
    I have the same porting on mine which is now running, you only need to take metal away from the meaty bit between main port and wastegate .

    That shoulder looks like it takes a lot of direct heat and gas on it but once its opened up there less of a face/restriction into the turbine. When you you open the wastegate up to stop creep you remove a fair bit already. I guess time will tell on whether it affects the housings and if its prone to crack more.
  10. wild willy
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    wild willy Member

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    [Sep 30, 2013]
    Have you had a recent spec upgrade on these as there seams to be a bit of a buzz on facebook regarding a Super sized version.
  11. wild willy
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    wild willy Member

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    [Nov 24, 2013]
    Bill, BBT, anyone fancy making an adapter plate like the tapered ones used for throttle boddies on the various intake manifolds but only this time used for tapering the exhaust housing in a ko4 turbo to fit the smaller typical 3 inch down pipe. Ie 83mm to 73mm (ported turbine exit on exhaust housing necking down to internal downpipe diameter.Maybe 12mm thickness.see post 198
  12. beachbuggy
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    beachbuggy Well-Known Member

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    [Nov 24, 2013]

    Just port or tout the inside of the downpipe flange, most have the downpipe welded to the outside of the flange, then you just need to smooth the inside lip of the turbine housing, which I do..

    Port match the turbo housing, gasket and down pipe..
  13. beachbuggy
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    beachbuggy Well-Known Member

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    [Nov 24, 2013]
    I've just had flanges made that are identical to the k04, so you only need to flow the actual downpipe pipe inside the flange..

    line the inner edge on the side of the turbine and the other side, heat and knock out, or fill weld it so to make up the gap, less important the other side as it's the waste gate.. I've done this same principle on the tfsi..
  14. wild willy
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    wild willy Member

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    [Nov 24, 2013]
    Unfortunately mines a blueflame where the pipe enters the flange. I did consider getting it built up with a heavy weld and grind it away with a die grinder, the adapter plate will ad volume though.
  15. beachbuggy
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    beachbuggy Well-Known Member

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    [Nov 24, 2013]
    how about an flange, 3.5" reducer cut to fit the flange and the cuts to butt weld up to you dp, with the old flange cut off?

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