Charlie Farley's 350BHP & beyond 2.0tfsi BUL Engine and K03/4 upgrade project, maybe just 300bhp now.

Had an update , it was a lorry fire ,the trailer caught fire whilst parked up and contents have been serverly damaged.
They will be contacting me again in the next few days regarding a claim for my losses.
So I wont be using that engine now.

Back to square one then.
 
I doubts there is any point in me requesting to see the state of the good , clearly fire damage will not be acceptable .
I'll have to see what they offer or don't for that matter, just get a bad feeling i'll be out of pocket on this.
 
Sorry to hear about the utter s**t your going through mate maybe it was meant to be...thats what i tell myself when everything goes tits up anyway, as for ebay i think people brand “ebay” as a make i use it for 90% of my shopping and as long as you check there a reputable company with reviews and possibly a website ect or facebook page your be fine, you can have some good bargains on there (that link being the exception) lol
 
At the moment with my luck Ricky, I could be hacking through the amazon and still get hit by a falling meteorite.
 
Just Rob. said:
At the moment with my luck Ricky, I could be hacking through the amazon and still get hit by a falling meteorite.
Click to expand...
Given how strong these engines are are you not tempted to modify your current lump? A good tuner will never over run it and cause issues or are you set on having a separate engine?
 
I'd rather stick with using a donor engine really as the build up is not reliant on the car that way, if the project hits more issues then the car wouldn't be laid up out of commission.
It does preserve the original engine etc aswell which I think is important.
After a tally up i'm too far into it now to stop , and that would just be giving up without a fight, i'll carry on with the project but just have to make work around's as they happen, hopefully not too many more biggy's .
I'll see what occurs with the shipping company aswell , maybe , just maybe i'll get my cost back but i'll still be out of pocket to a degree as I need to buy another lump which may end up costing more.

Anyway, no point getting more pee'd off about it , it's done so best to move onwards .

have a good one Ricky.

rob
 
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Back to the core subject then.

I was going ship the turbo bits down to turbo dynamics but i'm opting to take them down myself, that way I can get a better idea on what they will do.
An issue they will need to sort out, and they probably have a solution already in mind and that is the wastegate.
On the K04 manifold housing the wastegate arm itself is the other way round and in a different position to the K03 and actuator rod is longer so a different mounting method will be needed.

pic.
K03 complete setup with rod fitted and k04 manifold without rod.

Wastegate1
Wastegate2
 
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****** hell Rob, Things are deffo not going to plan.

I felt sure you'd see 350 as it was since its mostly K04 but then maybe I didn't allow for the fact the K03 compressor housing isn't optimal. To be fair though its pushed you into going further and onto the 400 you would always be coveting.

Fingers crossed you get another lump sorted, that's the route id be taking for all the reasons you've already considered, just makes sense. lets hope you get some money from the courier.
 
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When I started out on this project Matt I knew it would more than likely have issues along the way, so for the most part I was expecting issues, I wasn't expecting quite so many at this early stage, and one being such a major issue.
I've got over yesterdays bad news and now moving forwards to source another donor engine, it was one of things out of my control so need to let it go really, hopefully get some thing back from insurance to offset things.

I've got this thing in my head about 400 or close as now , only way now is to go for those figures or i'll never be content, had I been happy with 300-320 ish i'd have been good to go with your bits.
It's like they say, seize the moment or something and missed opportunities....well that's my thinking.:icon thumright:
 
Hi Rob. It's been a while since I've been on the site. Took me a while to read through your post but I got through it all. Sorry to hear about the engine you lost. I have an extra block in my garage that I have no idea what to do with if you want to drop me a PM. Won't be free but it might be worth the PM. This is what I did, I just had an extra block, built it up, swapped the parts I needed to onto it when I was ready. If you're still looking at other parts, let me know to see if I can help. I've already broken and repaired everything in this engine so I've learned a thing or two along the way.

Rods, pistons, turbo, and injectors is all you really need. I believe you have everything else, upgraded HPFP, upgraded PRV (just get an RS4 one if you don't have it), intercooler. That's it. Simple recipe and hold on to the steering wheel! Well, you'll need a head gasket and I would suggest replacing the oil pickup tube with the revised one since you'll have everything out. It's a few days project but if you have a second car it shouldn't be too bad.

Edgar
 
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Thanks for the reply Edgar, I had noticed you've been offline recently.
I've been trying to source another worth while engine but not having much joy thus far, there's a few around but i'm not 100% happy with them to be honest.
I have most of the uprated bits , just need the rod's pistons and bearings , I have the turbo and I need to drop it off asap to be built up.
If I go the bare block build I will of course need to source other bits as my donor BUL was complete with the ecu , but it maybe a route to take rather than having to rely on the quality or should that be unknown quality of another donor engine.
My original plan to build around another engine still stands , it maybe that I have to use separate parts now to get the same overall effect.
I'll drop you PM shortly .

thanks for the help .

rob
 
I suppose doing a totally new build from the ground up with known parts will be a better plan from a reliability point of view.
Given It doesn't involve laying up the old bus either.
 
Just Rob. said:
Thanks for the reply Edgar, I had noticed you've been offline recently.
I've been trying to source another worth while engine but not having much joy thus far, there's a few around but i'm not 100% happy with them to be honest.
I have most of the uprated bits , just need the rod's pistons and bearings , I have the turbo and I need to drop it off asap to be built up.
If I go the bare block build I will of course need to source other bits as my donor BUL was complete with the ecu , but it maybe a route to take rather than having to rely on the quality or should that be unknown quality of another donor engine.
My original plan to build around another engine still stands , it maybe that I have to use separate parts now to get the same overall effect.
I'll drop you PM shortly .

thanks for the help .

rob
Click to expand...
You don't need a separate ECU at all. That will likely make things more complicated to be honest because you'll have to get it cloned and all. The block is all you need and will reduce cost drastically. You can use your existing head and swap it over once the block is complete. The only thing a complete separate engine saves you is time since you can drop it in when it's done. If you look at your engine the code is stamped on the head, not the block so you'll keep the existing BUL code. The crank is the only thing different on most of our cars and that's due to the transmission mainly. A block and crank with main caps is where I would recommend you narrow your search to. Not trying to be pushy, just provided some recommendations to save a little cash that you can put elsewhere.

Sent from my ONEPLUS A6013 using Tapatalk
 
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I see your line of thinking Edgar, my main reason for getting as much of a complete engine for the project is so I can preserve my original BUL and its ECU .
If I need to change back at some point, not that I was planning to but it would cover all bases , I could refit a known very good engine and ecu without issues to follow.
Once I start messing with the original ecu etc and it setup to the new engine it wont be such a straight forward swap backwards to the original BUL lump.

Yes its a more costly route but I've learnt the hard way over the years that sometimes it is a good idea to keep somethings as original and keep parts just in case.
Its probably an old guy thing.:yes:
 
i3oricua said:
You don't need a separate ECU at all. That will likely make things more complicated to be honest because you'll have to get it cloned and all. The block is all you need and will reduce cost drastically. You can use your existing head and swap it over once the block is complete. The only thing a complete separate engine saves you is time since you can drop it in when it's done. If you look at your engine the code is stamped on the head, not the block so you'll keep the existing BUL code. The crank is the only thing different on most of our cars and that's due to the transmission mainly. A block and crank with main caps is where I would recommend you narrow your search to. Not trying to be pushy, just provided some recommendations to save a little cash that you can put elsewhere.

Sent from my ONEPLUS A6013 using Tapatalk
Click to expand...

What crankshafts will fit for manual boxes Edgar.
 
Just Rob. said:
What crankshafts will fit for manual boxes Edgar.
Click to expand...
I don't know that there is a specific code or part number for them. The donor block just need to not have been mated to a CVT or auto transmission. I really don't know much more about it beyond that. Quattro or non Quattro doesn't matter.

Sent from my ONEPLUS A6013 using Tapatalk
 
A quick search shows there are three part numbers for 2.0TFSI crankshaft : 06A105021E, replaced with 06A105021S, and current P/N number 06A105021AR.
For below.

manual gearbox/automatic infin. gear+
BGB,BUL,BWE,
BPG,BWT,BYK,
BPJ
 
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Just Rob. said:
A quick search shows there are three part numbers for 2.0TFSI crankshaft : 06A105021E, replaced with 06A105021S, and current P/N number 06A105021AR.
For below.

manual gearbox/automatic infin. gear+
BGB,BUL,BWE,
BPG,BWT,BYK,
BPJ
Click to expand...
Hmmmm. Interesting. I wonder if I've been wrong all this time about the different cranks.

Sent from my ONEPLUS A6013 using Tapatalk
 
I've read so much conflicting info on parts , i'm just as confused now as I've ever been, would be nice to get a deffintive answer.
 
The brakes are on for this project now.
I'm having issues with the courier of my destroyed donor engine and getting compensation , also to get to 400 I do need a Ko4-064 hybrid so a whole new assembly will be required and all that goes with it .
So all on hold for a bit while I think on it, I wasn't expecting such big problems so early on .
 
What predictions were you getting for the power from what you have with a hybrid core? It's like anything in that you get to a highish figure quite easily but then it gets harder (and more expensive) for smaller and smaller increases, The law of diminishing returns in F1 speak.
I'm just thinking that even 350bhp will get you down the road quite nicely and you will rarely get to give it full beans unless you track it, and I'm certain you'll see more than that out of it even if its not the 400 you're looking for but that's just a number after all.

What I'm saying is don't get too hung up on the final figure and end up not doing anything because you will end up with a great weapon with what you already have planned.
 
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Just Rob. said:
The brakes are on for this project now.
I'm having issues with the courier of my destroyed donor engine and getting compensation , also to get to 400 I do need a Ko4-064 hybrid so a whole new assembly will be required and all that goes with it .
So all on hold for a bit while I think on it, I wasn't expecting such big problems so early on .
Click to expand...
Id just do the ko4 upgrade will keep cost down significantly and your be getting around 320-350bhp with a more significant torque increase by the sounds of it you have mostly everything you need for the conversion and your already have the ko4 there for when you wish to do the ko4 hybrid and aim for the 400 mark.
 
Maybe i'm just getting a bit despondent with it, I was hoping things would move along nicely and it would be a job done situation without too many issues.
The donor engine issue has been the major blow as I cant find another suitable complete lump and add in the courier company are not playing ball with my compensation claim.
Going the parts route is possibly going to cost even more.
I knew there would be possible small probs along the way with the build but I don't even have the base engine now to start the project.
 
Just Rob. said:
Maybe i'm just getting a bit despondent with it, I was hoping things would move along nicely and it would be a job done situation without too many issues.
The donor engine issue has been the major blow as I cant find another suitable complete lump and add in the courier company are not playing ball with my compensation claim.
Going the parts route is possibly going to cost even more.
I knew there would be possible small probs along the way with the build but I don't even have the base engine now to start the project.
Click to expand...
Doing the ko4 route will only be adding the s3 injectors, hpfp core, fmic and re routing some bits isn't it? I wouldn't get a doner engine just for that Rob unless you plan on forging things and going for 4-500+
 
Ricky Burrows said:
Doing the ko4 route will only be adding the s3 injectors, hpfp core, fmic and re routing some bits isn't it? I wouldn't get a doner engine just for that Rob unless you plan on forging things and going for 4-500+
Click to expand...

Agreed Ricky but I made the descision that if I was going this route I would use a donor engine , I just don't want to mess up a very good working engine .
It may sound a bonkers way to go but from previous experience with engine upgrades projects ,I have learnt never start messing with a perfectly good running lump., use a spare unit and if it doesn't work out or blows up, which is allways possible , there will allways be the original to put back in.
 
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Keep at it Rob. Chin up because these projects rarely go as planned. You've watched my build take some good lumps along the way but I shrug it off and move along. There's been one or two instances where I contemplated abandoning it all but that was mostly because I felt that the cost want going to be worth it but but it turned out not being too bad at all.

If 350bhp is your goal then the K04 is the route but I would argue that you should think about at least doing forged rods. You'll thank yourself in the long run. The torque in those K04s when you can bring it in early in the rpm band is pretty insane otherwise on a stock block a tuner is just going to delay the torque onset and keep the torque figures low to not hurt the engine.

Sent from my ONEPLUS A6013 using Tapatalk
 
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Kicking myself now, I was going to take @maxdrz400 's damaged B7 with a good engine back in October but just didn't have the space at the time, sod's law or what as it would have been ideal, oh well that's life.
 
Several on Facebook marketplace Rob with suspected Oil pump failure, shouldn't be an issue if you are rebuilding it, and you could use/part out the rest of the car to cover costs of paying more.
 
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maxdrz400 said:
Several on Facebook marketplace Rob with suspected Oil pump failure, shouldn't be an issue if you are rebuilding it, and you could use/part out the rest of the car to cover costs of paying more.
Click to expand...

Thanks for the info chap, worth a look then but one problem , what is facebook market place, that's all new stuff to me.
 
You will need a facebook account to use it, but its a buying/selling platform through Facebook.
Imagine gumtree but through a social media site and that's basicly it, seems to have taken a lot of business away from gumtree as it's so simple to use and the majority of people have access to Facebook, so gets a lot more exposure.
 
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Looks like the project is moving forward once again.
Still no further with the planks at the courier company and I've written that side of thing off now, if I get something back that will be nice and increase the project piggy bank a bit but i'm not really expecting it now, i'll see how things go.

I've made a descision on what turbo route to progress the project with aswell.

I now need to source a new donor engine , either by going with the parts or buying a complete B7 and stripping it for the parts.
 
Just Rob. said:
Looks like the project is moving forward once again.
Still no further with the planks at the courier company and I've written that side of thing off now, if I get something back that will be nice and increase the project piggy bank a bit but i'm not really expecting it now, i'll see how things go.

I've made a descision on what turbo route to progress the project with aswell.

I now need to source a new donor engine , either by going with the parts or buying a complete B7 and stripping it for the parts.
Click to expand...
Good to hear Rob
 
Ok chaps, I'm changing direction on this for a while.
I'm not aborting the 350-400 project , just putting back for a while until I have sourced everything and made a final descision on which turbo assembly to complete the project.
Upon considering the options and what parts I have ready to use i'm going with a revised route .
I'm going to go on with rebuilding the K03/4 parts I acquired from Beardy matt , nothing close to 350 -400 , more 300-325 ish for now, utilize the FMIC and parts and fit it all to my current fitted BUL engine.
Having thought about it, the old bus is already at 270 , so fitting the uprated turbo and few parts will not be that excessive and will at least give me something to show for it all, I just hate sitting on project parts and them not being used, waiting to get the big figure project completed will just end up taking longer than I want to wait now.
I'll get it done but i'd rather have all the bits here in one go then go for it rather than it dragging on .
So its onwards for a few more ponies at least, better than zippo for the moment.

I need to get to the bottom of these random epc issues while i'm at it .
 
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I've a few hours to spare tomorrow so its out with the sand blaster and clean up some of the bits prior to modifying and re- assembly.:yahoo:
 
Just Rob. said:
Ok chaps, I'm changing direction on this for a while.
I'm not aborting the 350-400 project , just putting back for a while until I have sourced everything and made a final descision on which turbo assembly to complete the project.
Upon considering the options and what parts I have ready to use i'm going with a revised route .
I'm going to go on with rebuilding the K03/4 parts I acquired from Beardy matt , nothing close to 350 -400 , more 300-325 ish for now, utilize the FMIC and parts and fit it all to my current fitted BUL engine.
Having thought about it, the old bus is already at 270 , so fitting the uprated turbo and few parts will not be that excessive and will at least give me something to show for it all, I just hate sitting on project parts and them not being used, waiting to get the big figure project completed will just end up taking longer than I want to wait now.
I'll get it done but i'd rather have all the bits here in one go then go for it rather than it dragging on .
So its onwards for a few more ponies at least, better than zippo for the moment.

I need to get to the bottom of these random epc issues while i'm at it .
Click to expand...
I know what you mean mate im in the same awkward position Rob, i had the funds there to get a full 3” cat back, hpfp, uprated clutch, uprated turbo actuator and custom remap at rtech then these suspension issues happened and mot taking away an unexpected bill of just over a thousand pound which was the money towards a very good spec stage 2+ but as I'm now saving up again and dont want to leave parts sat in boxes for a while I'm going to fit the fmic, sports cat and 3” downpipe and get a custom map from a local company (performance remap) to tie me over and have something to enjoy while i save up again to finish my original goal.
 
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Do you know if the standard BUL injectors are ok for 300-325 bhp or will you need the high flow variety from the s3?
 
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