K03 hybrid

[JonnyX]

Quite right Grizz... the amount of time actually saves wont be worth while. Someone like MRC who may charge book time on an engine pull - they probably have this to an art now and can do it far quicker (I would have thought?). Doing something like this they would have to learn all over again and it would end up taking them longer in man hours (at least on the first few) - so not necessarily cost effective for them.

Good call laying the ground rules S4TAN... nothing worse than your engine being half out the engine bay as they the tuner would have you over a barrel and you would have no choice but to agree to whatever terms they provide - justified or not.

My concern (voiced a couple of pages back ) was that most tuners who
do this regularly still seem to quote a ~20 hour book time when in reality
they can probably do it quicker. As has been stated, the consensus for an
engine pull and refit is 10-12 hours (from DIY'ers and AW) - if all goes
according to plan (i.e. no seized or sheared/rounded bolts etc.). There
is no real incentive for a tuner to even attempt to do this in-situ when
the reality is the time delta will not be significant(it's very kind of
Doug to even consider it). I think the right way to do this job is to pull the
engine but perhaps offer it at a fixed price (parts extra of course)?

It's a shame the job is such a PITA! I think we would all be running round
with K04's if the fitting was easier (cheaper ). I am looking at doing the
following in the next few months:

Turbo and E manifold swap
IM swap + gaskets
RS4 Y-pipe, Air box and Injectors.
New inlets for K04's
Fit RS4 clutch and flywheel
Possibly fit lower CR head gaskets (I have the gaskets just need to decide
if it's worth it)
Replace cam tensioner gaskets
timing belt, water pump, thermostat etc.

I have all the parts except for mounting hardware, inlets and cam belt
stuff but I bet I am looking at a quote of ~25 hours labour for that lot!!!

(btw, anything else I should do?)

[jeffw]

Fuel pump & exhaust ?

[s4woody]

he has a milltek..

[S4TAN]

Ok chaps - just been to see Doug; after a lengthy chat we concluded (as has everyone else in this thread) that it really is an 'engine-out' job - so the 'in-situ' is a no-go ...

Ah well ... back to the drawing board ... I will have to wait until my 'blowers' go POP (in which case I am forced to bite the bullet) or until I get the time to hire myself out as a jigolo to rich middle-aged ladies and do 6 nights at £500 a time ...

[MCB]

or until I get the time to hire myself out as a jigolo to rich middle-aged ladies and do 6 nights at £500 a time ...

I have made a request to Admin for a dreamer icon so until then this will have to do!

[S4TAN]

HEY! I'm selling myself cheap at that rate ...

[shineydave]

HEY! I'm selling myself cheap at that rate

.....Eagerly awaiting the inclusion of a "Tart" emoticon

[ChipHazzard]

HEY! I'm selling myself cheap at that rate ...

What happens when they ask for a refund ???

[ZeroK66]

Turbo and E manifold swap
IM swap + gaskets
RS4 Y-pipe, Air box and Injectors.
New inlets for K04's
Fit RS4 clutch and flywheel
Possibly fit lower CR head gaskets (I have the gaskets just need to decide
if it's worth it)
Replace cam tensioner gaskets
timing belt, water pump, thermostat etc.

I have all the parts except for mounting hardware, inlets and cam belt
stuff but I bet I am looking at a quote of ~25 hours labour for that lot!!!

(btw, anything else I should do?)

Deffo lower the CR - you can run more boost/better timing. For the same level of boost the engine can take in more air & result in the same CR at compression (IE: not too high so you run poor timing). More timing = more power. MRC quote 8 hours to do this... if you are doing the IM already, well your labour is already half covered.

I had this discussion at length and I did the following:

- By IM I assume you are going for the larger 2001.5 IM that has the F-Hose removed & allows for better power? If not I suggest you do this. Unfortunately there was a little confusion at the time of doing my car and this was never done. - ~300ish? Get folic spacers for this too... save on heat soak when you are lining up at the pod lol
- RS4 engine mounts - ~300ish
- Snub Mount ~50ish
- FMIC - At 800ish you get great performance, similar cost to RS4 intercoolers unless you grab a bargain.
- If you take the FMIC get large custom intake plumbing - costs only about £50 more than what you would need to buy anyway.
- New Alternator - over kill, but maybe get a new set of bearings put in, bushes & volt regulator fitted, peace of mind.
- New Power Steering Pump - again over kill, but I thought hell why not

That is everything I think... if I think of anything else I will let you know.

You have the right idea though... collect all the bits over time so when it does go bang you have a nice pot of parts ready to rock and roll, no sudden huge cost like I had to face

[MarkB]

Slightly off topic Jonny and Leon

I've had a reply from Jacob http://buehnengineering.com/forums/view ... highlight=

I'm now thinking much as before. If my turbo's go bang I'll get some K03/K04's and also have them ported and polished. I would also clean up the casting on the exhaust manifolds myself. Not sure if i'd go for the clipped turbine wheel as I like the car as lag free as possible.

Ceramic coating I wouldn't bother with, though I might try some thermal exhaust wrap. I would like to know just how good ceramic coating is, can't see a thin layer make a vast difference. Any have any data regarding this?

On the fuel side I would get a 5bar regulator, uprated fuel pump and treat the car to a custom remap.

Costs...

Turbo's $695 ea + $125 ea for Port & Polish = ~£1000

5bar reg $120 = ~£75

uprated fuel pump $210 = ~ £135

Sundries ~£200

Remap ~£500

Total cost <£2K

This is of course me doing all the spanner work...

Thoughts please?

[JonnyX]

Deffo lower the CR - you can run more boost/better timing. For the same level of boost the engine can take in more air & result in the same CR at compression (IE: not too high so you run poor timing). More timing = more power. MRC quote 8 hours to do this... if you are doing the IM already, well your labour is already half covered.

OK. Sounds good. I already have the 034motorsport gaskets.

I had this discussion at length and I did the following:

- By IM I assume you are going for the larger 2001.5 IM that has the F-Hose removed & allows for better power? If not I suggest you do this. Unfortunately there was a little confusion at the time of doing my car and this was never done. - ~300ish? Get folic spacers for this too... save on heat soak when you are lining up at the pod lol

Yep. vagaprts list the BC part at ~190+VAT. From AW it suggests getting the
AC part number (from a tip Allroad). Anybody know the difference?

- RS4 engine mounts - ~300ish

Already have these.

- Snub Mount ~50ish

Already have this.

- FMIC - At 800ish you get great performance, similar cost to RS4 intercoolers unless you grab a bargain.
- If you take the FMIC get large custom intake plumbing - costs only about £50 more than what you would need to buy anyway.

I already have RS4 IC's which I am going to stick with for the time being.

You have the right idea though... collect all the bits over time so when it does go bang you have a nice pot of parts ready to rock and roll, no sudden huge cost like I had to face

Well, I hope so. It's still fecking expensive though! . Any suggestions on
fuel pump? I think a Walbro insert would be good enough. The Bosch 044
looks good but it's ~$450. Too rich for me.

I also plan to fit an RS4 oil pump if this is possible.

Thanks for the info - it's good to hear from someone who has done it.

[JonnyX]

@MarkB - sounds good. My K04's are with Jacob at the moment. I am getting CC, P&P and P&P wastegates. I too
don't want to lose low end spool so decided not to go with a clipped turbine wheel. I am going to get P&P and CC
manifolds from vast as soon as I can get my arse in gear . I thought about porting the manifolds myself. There's
not really much you can do. The only thing that looks doable is smoothing out the welds at the exhaust port end.
These seem quite messy and occlude the port quite a lot. The Turbo end actually looks OK and would probably
just need lapping a little to clean it up. There is a company in Didcot called Zircotec which can do the coating for
~250gbp. So, if you did the porting work yourself CC manifolds would probably cost < 300GBP all in. I think tubis
are better but I just can't justify the price. I am only really looking for a reliable 400hp. These manis are good
enough on the RS4 for that power level. Anybody want to port my manifolds? (I have 5 - not including those on
the car )

For your other items - you are looking at Vast I would say from the prices. I would also check out 034motorsport.
Your fuel pump price is exchange which means you need to factor in shipping (and VAT and duty on the return of all
these items) - what about getting the insert here for about 85GBP and fitting it yourself? There are some instructions
on AW I think which seem quite straightforward(this is what I am considering). Seems like a damn good plan
though

Oh, if you need someone to hold your beer for you whilst doing the spanner work I can do that. I think we are pretty
close geographically. Perhaps you can persuade Woody to help?

[MarkB]

Thanks, your welcome to hold the beer but I do hope I won't be doing the work. Just if the need arises I'd like to gain a little from the work put in.

I was only very quickly looking at prices and would probably do the pump myself UK sourced and also the regulator.

My main worry about this plan is Jacob coming up with the goods in time if I needed them...

[S4TAN]

What happens when they ask for a refund ???

Never happen ... they'll be asking for encores, not refunds ...

[Alps]

What happens when they ask for a refund ???

Never happen ... they'll be asking for encores, not refunds ...

... and when you're unable to deliver that encore... well then you'll have no choice but to refund