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

Who’s doing the build?

I always like Stacey who runs
https://prorace-engineering.co.uk/

he can do you a package on anything internal related but you’ve probably ordered already by now.

Clutch wise its about preference, for the road I only like full face.
I’m too old for SMF paddle clutches and bunny hopping at traffic lights
 
I have SMF and I'm quiet fond of it. It's a clutch masters fx350. It's stuff but very street drivable.

Sent from my ONEPLUS A6013 using Tapatalk
 
Sygh2k said:
You should really get your crank checked before ordering shells as it might need a polish/grind so altering your size requirement. Dont assume std will be ok

Also you probably want the rods rifle drilling, standards are
Click to expand...

I'm going with the rifled ones , I've factored in a rebore for pistons etc but as I've not sourced a lump yet I don't know what the crank condition will be like, I suppose I could make an allowance for any remedial crank work and go a size up.
As i'm ordering all the IE bit in one shipment I need to make allowance for these things.
 
antwan64og said:
Who’s doing the build?

I always like Stacey who runs
https://prorace-engineering.co.uk/

he can do you a package on anything internal related but you’ve probably ordered already by now.

Clutch wise its about preference, for the road I only like full face.
I’m too old for SMF paddle clutches and bunny hopping at traffic lights
Click to expand...

I'm happy to do the build myself, engine rebuilds are nothing new to me and I quite like the process.
I'll get any specialist work done locally to me.
 
Just Rob. said:
I'm going with the rifled ones , I've factored in a rebore for pistons etc but as I've not sourced a lump yet I don't know what the crank condition will be like, I suppose I could make an allowance for any remedial crank work and go a size up.
As i'm ordering all the IE bit in one shipment I need to make allowance for these things.
Click to expand...

when i did mine in nov last year i ended with max shell at .75 under, i think i only had the option of king bearings. note however i had a spun shell that did thd damage along with bending crank a little so im told. generally options are .25, .5, .75 aftermarket on shells, youll need mains too if crank comes out, its just not worth not changing them too.

when i did mine i ordered rods asap but waited on the parts that needed dimensional checks
 
The problem is that I have a friend bringing the bits back with him so I really need to get them all in one hit if I can, I don't have the option of ordering them separately , well I do but it will cost me a lot more.
 
If the original BUL engine I bought from germany had arrived and not been written off i'd be in a better position to know exactly what parts were needed now, but that's life, just need to source another lump.
 
Just Rob. said:
The problem is that I have a friend bringing the bits back with him so I really need to get them all in one hit if I can, I don't have the option of ordering them separately , well I do but it will cost me a lot more.
Click to expand...

should of just got him to bring a CTS turbo, bolted it on in a weekend and be done with it......

but yeah, your all out plan looks good :icon thumright:
 
antwan64og said:
should of just got him to bring a CTS turbo, bolted it on in a weekend and be done with it......

but yeah, your all out plan looks good :icon thumright:
Click to expand...
Thats just a ko4 though, the tte420 is a hybrid ko4 so he will easily get that magical 400hp hes looking for :)
 
Yeah but that wouldn’t need the rods and rebuild too :whistle2:

he’s already weighed it all up I know, just when he mentioned a friend coming from the states the turbo is only a grand :blow:
 
To get a turbo back from the states would involve extra cost, the rods etc can be shipped over to me at a very manageable level and worth buying from the states compared to buying from a uk source.
 
@Just Rob. regarding your original plan to go hybrid ko3 im assuming you got a price for sending your ko3 turbo off to have the work done who did you contact and what was the quote?
 
I did indeed get a quote and i'm still having the bits I bought for the original plan modified to make up another k03 hybrid, not sure why but it seem's like a good idea, I could sell you it...:icon thumright:
 
Just Rob. said:
I did indeed get a quote and i'm still having the bits I bought for the original plan modified to make up another k03 hybrid, not sure why but it seem's like a good idea, I could sell you it...:icon thumright:
Click to expand...
As tempting as it is Rob ive just spent a whole lot of money on the two cars including a new engine and a holiday next month im not in the position to buy one just yet, im just curious to see how much a hybrid ko3 would cost for future plans :)
 
No probs Ricky,
I'm in no rush to sell it to be honest, it just seems mad to have the bits laying around doing zippo so i'd rather get a hybrid built up and then go from that point.
Hybrid K03 /4 prices seem to vary a fair bit depending on weather you go with an off the shelf setup ready to fit or you have a custom setup with a specific core fitted etc.

Rob
 
Turbo dynamic quoted me £70 to do the enlarging of the K03 housing and I was going to drop of the parts and get them to just assemble it all ready for a retro fit.
I am expecting the cost to be around the £150 ready to fit.
 
this is the core I have here fit to the k03/4 .
Upload 2020 3 13 19 56 46
Upload 2020 3 13 19 56 46
 
So you have to buy the ko4 core separate then have a company machine out your ko3 to fit? So about £150 for machining how much is the ko4 core? Just typed in and seems really cheap for a core i must be looking at the wrong ones..
 
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Good choice!

I have a spare mellett ko3 CHRA incase this billet one I had made implodes.

That will be a solid ko4/ko3 :icon thumright:

[I still think you should fit the HPFP and hybrid to the stock block just because its there while you build the other engine :whistle2: Rick can do tuning by remote tablet anyway]
 
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Ricky Burrows said:
So you have to buy the ko4 core separate then have a company machine out your ko3 to fit? So about £150 for machining how much is the ko4 core? Just typed in and seems really cheap for a core i must be looking at the wrong ones..
Click to expand...

£170 with VAT for a decent core or you can go anti surge billet wheel for an extra £100
 
Ricky Burrows said:
So you have to buy the ko4 core separate then have a company machine out your ko3 to fit? So about £150 for machining how much is the ko4 core? Just typed in and seems really cheap for a core i must be looking at the wrong ones..
Click to expand...

not the easy Ricky.
You need a K04 manifold and modify the exhaust mount to work on a b7 as the stud fixing positions are different, you need a suitable k04 core and then get the compessor housing enlarged, and possibly sort out the wastegate acctuator , other than that good to go.
 
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I had a head start with beardy matts kit as the K04 manifold had allready been modified ready for b7 fitment, there was the new K04 core , all that was needed was the compressor housing enlarging and the wastegate acctuator changed , job done.
If i wasnt going bonkers i'd have just carried on and fitted it.
 
That's why i decided to finish of the K03/4 project , i doesn't need a great deal more doing to get a working setup for a lot less than a new off the shelf kit, well based around s3 power output that is.
£150 spent on completeing the kit will give me a K03/4 s3 based hybrid ready to fit any tfsi B7 .
 
Modified K04 manifold ready to accept b7 HFC or whatever one is using .
Aturbo4
 
just need to enlarge the K03 compressor housing, and adjust the wastegate actuator rod / mount bracket.
Aturbo3
 
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Not the best comparison between the two but here goes.
K04 manifold has a larger hot side to start with , and the different wastegate position can be seen between the 03 and 04, only a small difference but one that need to be factored in .

K034hyb 2
 
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Still ongoing with this project chaps and just awaiting some parts to be shipped , some bits from the states are delayed but that is to be expected .
I'm making progress with what I can for now.:icon thumright:
 
Last edited:
i3oricua said:
I have SMF and I'm quiet fond of it. It's a clutch masters fx350. It's stuff but very street drivable.

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

I’ve got a Southbend Stage 3 daily clutch with SMF from the US and the peddle feels like OEM. ****** good bit of kit.

If memory serves me right it can handle up to 470 ft-lbs. Makes me want to stick a BT on her!
 
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Ok then chaps, I bit of better news on this project and hopefully another key part of the project .
I've managed to secure a full "BUL " engine as the basis of the project build, only snag is that I can't get up to to collect it just yet , so will have to wait for a week or so, anyway at least I've got that part organised now.
 
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Just Rob. said:
Ok then chaps, I bit of better news on this project and hopefully another key part of the project .
I've managed to secure a full "BUL " engine as the basis of the project build, only snag is that I can't get up to to collect it just yet , so will have to wait for a week or so, anyway at least I've got that part organised now.
Click to expand...
Thats good then mate, have you got the tte yet?
 
No , still awaiting that along with other goodies, delays with shipping have been blamed , but expecting the bits very soon hopefully based on emails I've received .
Upwards and onwards chap.:icon thumright:
 
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I Need to rehome all these other bits still inc the plan A parts, will get that list up double quick now.
 
Just Rob. said:
I Need to rehome all these other bits still inc the plan A parts, will get that list up double quick now.
Click to expand...
A different time of year and I would of had the brakes and ko3 hybrid from you, but given the situation most of us are in and I'm due to get some flipping oil heating I have to be a bit savvy with the redys, its hard to justify buying new brakes to the mrs when I don't even drive it lately lol.
 
Fully understand Ricky, i'm still working 6 days a week and the shut down doesn't really stop my line of work.
I free'd up a pot of cash a while ago from selling off some very collectable ducati racing parts otherwise I would not have been doing all this project to be honest, just wanted to get something of more benefit to me than a box full of parts I never use, this way I get the most out of things.:yes:
 
A carbon racing fuel tank of a 916 racing clawed back £2k alone so worth selling it really.
 
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That's why I tell the mrs I should keep everything, she would end up binning the lot as its "clutter" in her eyes lol
 
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That's so true Ricky, my better half nearly threw out this very sought after racing dash backplate a few years back , It was in my desk draw and she thought it was junk, luckily I managed to retrieve it , but a close call.:scared2:

Timer1
 
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yep, read that a few times and still haven't taken it all in .:haha:
 
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