New Stainless Steel 1.8T Equal Length Manifold-Preview

[ibizacupra]

New Stainless Steel 1.8T Equal Length Manifold-Preview as to be running on my ibiza racecar shortly.

Genuine Equal length within 1/2" (18.5" runners)
High Quality TIG welded, back purged, jigged assembly, featuring narrow angle merge collector.

Lightweight construction, not made from heavy wall pipe fittings, built by a fabricator who makes WRC team systems, and Red Bull Racing development manifolds. Extremely high quality, British made manifold.

Pictures below of dummy setup on a spare cylinder head.
Shortly to be fitted to my ibiza during this week.

Enjoy
http://badger-5.com/bin/new-mani/new-mani-1.jpg
http://badger-5.com/bin/new-mani/new-mani-2.jpg
http://badger-5.com/bin/new-mani/new-mani-3.jpg
http://badger-5.com/bin/new-mani/new-mani-4.jpg
Top Mounted as you can see for ease of fitment, access to all fittings, improved flow for DP and inlet, (not stuck by gear selector cables)

more pics on next post

[ibizacupra]

http://badger-5.com/bin/new-mani/new-DP.jpg
Full Flow area DP in 3"


http://badger-5.com/bin/new-mani/new-turbo-mani-1.jpg
http://badger-5.com/bin/new-mani/new-turbo-mani-2.jpg
http://badger-5.com/bin/new-mani/new-turbo-mani-3.jpg
New Hybrid Turbo mounted onto manifold. Flanged in picture as IHI, but also T3 flange as req'd to suit GT30/35 units. This turbo going on mine is physically larger than GT30R.

This is a preview. There will be some updates on this for upper support brace.

Prices for production customer units will follow.
DP modification due on Mon/Tues on mine, production tooling jigs and fixtures have been made to replicate this.

Coming soon will also be an charge air pipework setup and intercooler also, from the same fabricator. WRC spec components & design.

[Saul]

n i c e

that looks quality :thumbup:

[m0rk]

I hope that fits, if so - it's the best looking I've seen bar none (let alone RHD fitment)

[ibizacupra]

I hope that fits, if so - it's the best looking I've seen bar none (let alone RHD fitment)

It fits m0rk.. its been on the ibiza already.
DP needs mod as its just sat on the steering rack slightly, the mod is due mon/tues next week as the jig needs to stay in step with the on-car fittings.

you can even see all the bolts and get spanners on them too! Woohoo :)

Details to be finalised on its pricing etc, but in this instance I have chosen a UK manufacturer to work with who knows their business extremely well. I am well pleased with the outcome so far.

Bolting mani on proper tonight as I forgot to take the exhaust gasket with me last night :doh:

Next to sort out water and oil lines, drain to sump etc.
intake pipework to be modded for bigger MAF tube again, and compressor outlet pipework to be modded to suit new location.

Still lots to do, but I am well pleased so far.
Pukka
:D

[Forbez]

That looks an awesome piece of kit!

Seriously, looking wicked.

If you need a tester or something to trial it on...........ahem!

[Ruddmeister]

Holy Moses that DP looks a piece of work too.......JBS last week with their Mani and Badger 5 this week......people wait 3 years for one then two come at once :cartman:

[max_torque]

Nice one Bill. that looks like a proper manifold!

few suggestions for you though.

1) add a pre turbine EGT boss, as you never really know how much work the turbine is taking out of the gas, so mapping to post turbine EGT is a bit of a guess, pre turb EGT means you just fuel to limit this temp (to say 950 to 975 if your feeling safe, or say 1000 if your feeling lucky! lol (steady state peak temps, you can have a few overshoots during transient manouvers etc))

2) get the manifold "normailised" after it's been welded, which depending on the material will probably be a couple of hrs in an oven at 650 to 700 degC

3) consider a "camcoat" finishing, i.e. ceramic coating to limit heat loss.

4) In the turbine exit cone / 90 deg elbow, try to seperate the wastegate and turbine exit flows for a few inches, we did this on scooby turbo DP's simply with a large chunk of steel welded in (needs to be thick or it'll distort and fail), and it added a few BHP, but more crucially, made the boost control much more linear. (which will be important in your fwd applicaton!)


5) get out there and thrash / enjoy it! lol

[RobDon]

Looks amazing Bill, love the Cobra snakehead DP and big-a55 turbo! :D

[Ant FR]

Does it now have that raspy sound like a new shape M3.

[David_smith_909]

that looks the business, im not jelous tho, honest :clap:

[guy fawkes]

so bill what you expecting power wise with the big turbo and new mani and what benefits, compared to cast iron mani, besides weight saving. looks also to be first class construction, I'm impressed.

[Addo]

impressive peice of kit bill

[ibizacupra]

Nice one Bill. that looks like a proper manifold!

few suggestions for you though.

1) add a pre turbine EGT boss, as you never really know how much work the turbine is taking out of the gas, so mapping to post turbine EGT is a bit of a guess, pre turb EGT means you just fuel to limit this temp (to say 950 to 975 if your feeling safe, or say 1000 if your feeling lucky! lol (steady state peak temps, you can have a few overshoots during transient manouvers etc))

2) get the manifold "normailised" after it's been welded, which depending on the material will probably be a couple of hrs in an oven at 650 to 700 degC

3) consider a "camcoat" finishing, i.e. ceramic coating to limit heat loss.

4) In the turbine exit cone / 90 deg elbow, try to seperate the wastegate and turbine exit flows for a few inches, we did this on scooby turbo DP's simply with a large chunk of steel welded in (needs to be thick or it'll distort and fail), and it added a few BHP, but more crucially, made the boost control much more linear. (which will be important in your fwd applicaton!)


5) get out there and thrash / enjoy it! lol

Cheers Paul.
this is version #1, stamped 01.

Ceramic coated is next on list.

I like your suggestion of pre-turbine EGT boss.. We'll add that, thanks.

I'll ask about normalising, as I did suggest this from the beginning as fully annealed is what I preferred.

Wastegate seperation is in place within the DP for a few inches. Just did'nt post pictures of it. (forgot to download em off the camera late last night)


I hope it will work as well as it looks.. We have to make the top support for it yet to brace the turbo.

Cant wait to get it running to let rip. Been a long while coming.

[ibizacupra]

so bill what you expecting power wise with the big turbo and new mani and what benefits, compared to cast iron mani, besides weight saving. looks also to be first class construction, I'm impressed.

I am expecting >450bhp from the new spec turbo/mani as step #1

To come also is a larger intake manifold, single plenum this time, combine with R32 throttle body (75mm vs 59mm of stock) as step #2
Also got a pair of special grind CatCams to drop in too as step #3

All 3 step changes should gain power. We will have to see about delivery, but I hope it all works out.

Certainly have more power than traction on road tryes - lol

[ibizacupra]

Holy Moses that DP looks a piece of work too.......JBS last week with their Mani and Badger 5 this week......people wait 3 years for one then two come at once :cartman:

typical eh! :p

just like buses.

[chrisbond69]

now im jelous bill grrr didnt think i would be, i think i might have to look into, big turbo when i get my promotion, maybe on a newer car mmmm love it, bit beyond my realms of knowledge and metal skills though

[ANDY BLUNT]

Thats a lovely piece of work mate,cracking finish etc,i hope it all goes well.What kind of clearance to the bonnet when the pipes are connected and would people have to lose their s3 strut braces to clear?:cheers: Andy

[ibizacupra]

Thats a lovely piece of work mate,cracking finish etc,i hope it all goes well.What kind of clearance to the bonnet when the pipes are connected and would people have to lose their s3 strut braces to clear?:cheers: Andy

I have removed my strut brace for now for ease of access in and out.
Not sure on clearance until I have the modded new pipework.
looks like it will be close... but not sure if mine will fit back on as is or not...

Bonnet clearance is no problem. Pipework run is same as before just detail end connection is in slightly different position so mod req'd to join em up again.

[max_torque]

cracking finish

lets hope not! lol! :p

[Chris Eyre]

Looks very well put together - professionals on the case 110%

[ibizacupra]

Aiiiii :D :D :D

[F2 Stu]

Bravo, that looks top notch.

the one shown is the prototype you've made yourself, not a production one?

[xJib]

Looks very nice :thumbup:

Out of interest, how much do you think it'll cost?

[ibizacupra]

Bravo, that looks top notch.

the one shown is the prototype you've made yourself, not a production one?

Its the first/prototype, but tooling/jigging has been made to replicate it. Manifold has been fitted tonight peace of cake.. :)

Normal spanners and sockets Woohoo :D

The company making this make WRC manifolds. Red Bull Racing exhausts/manifolds as well as other top notch motorsport companies. Its pukka stuff.

The design has been between us. They are very good at what they do.

:clap:

Price is TBC for a wee while longer.

regards
bill

[Feel]

Effing good prototype. Looks very nice Bill, interesting flange - not cut all the way through, and those "v" between the bolts at the top of the flange - not seen those before?

Collector not that narrow an angle, but I guess it's a compromise.

Looks really well thought out - clever/interesting that the branches come into the colector on opposite sides (1-3-4-2) whereas most of the others come in clock-wise fashion.

Are you going to brace that monster of a turbo?

Flexi looks a bit of a distance from the outlet?

[ibizacupra]

Effing good prototype. Looks very nice Bill, interesting flange - not cut all the way through, and those "v" between the bolts at the top of the flange - not seen those before?

Collector not that narrow an angle, but I guess it's a compromise.

Looks really well thought out - clever/interesting that the branches come into the colector on opposite sides (1-3-4-2) whereas most of the others come in clock-wise fashion.

Are you going to brace that monster of a turbo?

Flexi looks a bit of a distance from the outlet?

The collector is one they had on another manifold they used..., not as shallow as the one I made but when you look down it, its nice and open. compared to the cast manifolds its a lovely blend.

There is a top support brace drawn up that they have sent me to have made, which is to do. I can see what you mean re the DP flexi. I think I will add a support for the DP to the block, so its not flexing as a lever under acceleration/decelleration (with 450bhp hopefully behind it) - Its running race engine mounts but I think there will be some residual movement.. Nice feature of it being light tho, is it wont weigh the whole assembly down.

[Rick-24]

Jesus bill....sure that turbo is big enough....hope u havent got induction at ur front bumper u'll be suckin cats , dogs and little kids up lol.... looks very spankinly nice tho:p

[ibizacupra]

Jesus bill....sure that turbo is big enough....hope u havent got induction at ur front bumper u'll be suckin cats , dogs and little kids up lol.... looks very spankinly nice tho:p

Hehe... its fairly big.
fits nice tho.
making inlet pipework to it now in full 3" in stainless pipe too.

Hoping to get it running by the end of this weekend.

[t18con]

bill, off topic, but the downpipe, wat i.d. are you reckoning on for circa 450bhp?

[ibizacupra]

bill, off topic, but the downpipe, wat i.d. are you reckoning on for circa 450bhp?
3" od pipe.
http://badger-5.com/bin/new-mani/new-DP.jpg

[t18con]

i had considered going bigger, in fact my k04 was bigger tbh.

[ibizacupra]

K04 does'nt need 3" for its flow ability -

3" is the max I can get over the beam as I personally would'nt go from a bigger DP bore into a smaller exhaust bore to choke it again.

will have to see what it does.

[t18con]

get your thinking bill. ps do you never sleep?

[ibizacupra]

get your thinking bill. ps do you never sleep?

sleep? not much lately..
long long days currently.

getting there tho.
mani & turbo bolted on proper now. DP on it, oil drain is 1/2 done.
intake pipe fab'd and ready to go on.
getting plenty of TIG practise in... :D
outlet pipe modded now, hoses (thanks for Forge) being used to couple it all together.

was hoping to fluid it up but just ran out of time. Amazing how long making silly little things ends up taking. Burned hours on the oil drain pipe fabrication & still not completed.

got my 16th Race deadline... and its tight again to achieve it.

going back to 3" DP vs bigger.... noise is something I need to manage also for regs/track days.
I have a DP killer for the rear box which reduces 3db(A), with me being marginal on static sound test for 95db(A) on warm exhaust now, but too loud on drive by on boost. (track days not race day sound checks)



:help:

[ibizacupra]

well it lives :D
fired it up for 1st time for what seems like months (well it is I guess :hide: )
Brum Brum

no leaks :)

some more heat shielding and the likes to do, tidying of some pipework to N75 to do, but the motor runs.

going to pop some V-Power in it and run it about and see what happens.

top support bracket is taking shape, now we think we have sussed a neat way of rose jointing the support bracket to take the turbo's weight.

Will keep a beedy eye on EGT's and A/F whilst having a quick blast.
then ready for mapping.
next race in only just over a week now. got to be a driver there as our trailer had a woopsie and now needs a new axle which is 2-3 weeks away - dammit.

these things are sent to try us I spose.

getting there

[minimivic]

Bill,
You got any ideas of price yet I'm looking for a t3 flanged manifold, and yours looks ideal.

[ibizacupra]

I need to confirm still... (yea I know I said that last time - LOL)

[Scotty_b]

Bill i remeber a while ago you said you were doing IHI conversions??? Would you be offering this in kit form? Just looking at JBS, Jabba and still the garrets to see how viable they are for me and so far you are one of the few to offer an equal length mani which is high on my list of wants for my conversion.

Any ideas on whats needed for this conversion as your the only source of info fella

[ibizacupra]

Bill i remeber a while ago you said you were doing IHI conversions??? Would you be offering this in kit form? Just looking at JBS, Jabba and still the garrets to see how viable they are for me and so far you are one of the few to offer an equal length mani which is high on my list of wants for my conversion.

Any ideas on whats needed for this conversion as your the only source of info fella


I am doing IHI conversions yes (or others). The mani for mine can also be T3 flanged for Garrett application as req'd. DP is turbo specific.
the usual larger MAF, injectors goes without saying, also cat size is a factor (or decat).
My mani is'nt going to be cheap tho...

All down to what sort of spec you're after power wise vs budget.

A few options out there for spec to be tailored.

[Mitchy]

Bill is your price going to be competitive with JBS/Jabba?

Jabba costs £845 for their manifiold and downpipe.
JBS costs £1100 for their manifold and downpipe.

Was told jabba manifold is only good for 350-360bhp? James's design at JBS will allow a lot more. With JBS, they do a custom downpipe for each individual car, jabba i just think is 1.8t generic.

Will you be offering downpipe also and will the price be competitive with those above?

Deciding on which route to go :shrug:

[ibizacupra]

Bill is your price going to be competitive with JBS/Jabba?

Jabba costs £845 for their manifiold and downpipe.
JBS costs £1100 for their manifold and downpipe.

Was told jabba manifold is only good for 350-360bhp? James's design at JBS will allow a lot more. With JBS, they do a custom downpipe for each individual car, jabba i just think is 1.8t generic.

Will you be offering downpipe also and will the price be competitive with those above?

Deciding on which route to go :shrug:
Trying to get hold of the mani man (on business) to confirm the prices.

You cant compare the JS cast manifold with this one however. apples & pears.
JBS one is different construction to this one also, which the published pictures show.

Its a case of you get what you pay for. It wont likely be as cheap as a cast manifold, but has significant advantages over the cast one, eg:- ease of fitment, higher airflow potential from top mounted location etc etc.

JS DP's vary from application with or without cast elbow outlet, and ibiza fitment is 2.5" DP due to rear engine mount proximity.

I dont know about the power limitation said to be from the JS mani, as I have not experienced it personally. I think we will see some >400+bhp motors running on this mani which will confirm something.. Compared to an equal length tubular mani however, I doubt it has as much flow potential, but this is only a factor if you have high enough flow (power) anyhows, which is turbo spec & choice.

As soon as I nail down the pricing I will.

:thumbup:

[ibizacupra]

*update*

Drove the ickle yellow beastie last night for 1st time. Was going to do this saturday, but a woops with a front wing, softer front springs than before and too low a ride height ( lower by nature of 200lb softer front springs).
Pushed car out of workshop, car on slight steering lock and the nsf wing got pulled under by tyre and eat itself. :doh:

PlanB fit the wide wings I have been making ASAP. - bugger!

So its now on wide wings so no clearance issues at all :D +70mm per side wider. (but not as pretty as I would like due to time running out ( Race on Saturday)

Drove it last night, just briefly as its making a trip up to Custom Code for mapping tonight, collecting Friday for Saturdays next race. (why is it always so close to race days??? boo hooo, stressed!)

Aside from being incredibly bumpy on its new muchos stiff rear springs (my backs going to get pounded) it drove ok. Tentative prod at loud pedal and boost spooled in at 3K with some meaningfull urge, ~10psi from memory. 1st/2nd gears forget it.. as soon as boost climbed, traction dissapeared. Tried again with 3rd gear roll in..... 3K pulling ok, 4K MADNESS ensued. Span up big time. Tried it again this time trying to watched gauges as well as road. (you know on the starwars things when the millenium falcon goes into hyperdrive? - same thing when the boost comes in - the world goes blurry) This time just as the madness came in, span up instantly, looked like just over 4K rpm and the guage was pegged. (30psi) - time to back out of it and go back to workshop.

Fingers crossed it all holds together.
Makes all the right snarly, noises... got some wastegate chatter so I need to check the DV is working well enough, or is in fact big enough to cope. (larger feed pipe req'd maybe) - A visit to Forge to fix that no doubt.

No trailer currently (axle busted) so driving to CC tonight and back again friday, and to Combe saturday (all being well) - best book a few sessions with a chiro me thinks.

[Ruddmeister]

Bill

Sounds like even more of a monster than before, what turbo did you go for in the end or i that a secret???

Steve

[ibizacupra]

Bill

Sounds like even more of a monster than before, what turbo did you go for in the end or i that a secret???

Steve

bigun

:)

[Ruddmeister]

bigun

:)

blimey THAT big :cartman:

[ibizacupra]

lol, nearly.

its along the lines of TD06-20g but a hybrid of sorts

[andy_dea]

so have you moddified standard wings bill?

how have you done it cut a slit out of the arch across and added a filler strip of metal in to bring them further out?

or are the along the lines of f2 style?

something im interested in doing, fs can use the same sort of parts to widen the track like rob t has, just not sure if can use the equavalent 20vt passat shafts? with an ibiza box

[ibizacupra]

so have you moddified standard wings bill?

how have you done it cut a slit out of the arch across and added a filler strip of metal in to bring them further out?

or are the along the lines of f2 style?

something im interested in doing, fs can use the same sort of parts to widen the track like rob t has, just not sure if can use the equavalent 20vt passat shafts? with an ibiza box


I'll take pics when I get time. they're painted (and finished in a hurry) - not the quality finish I want so will have to revisit them when I get time...

Steel and made from originals yes, with inserted piece, with helpfull advise from max-torque on how to.

+70mm per side

[ibizacupra]

mapping has been done today...by James and Custom Code

reminder of where it was as same spec previously when first PE'd.
http://badger-5.com/bin/Dyno/bill-ibiza-1900PE-small.jpg


current setup is on plot I was sent. (ran slightly more since at 489bhp & 355lbft):-
http://badger-5.com/bin/Dyno/Badger%205%20RR%20Run-small.jpg

To come is R32 throttle body and large single plenum intake manifold in step2, followed by Special Grind CatCams in step3.

Looks like its getting there.
:)
:thumbup:

[m0rk]

Sorry what! you've got a nigh on 500bhp ibiza?

I have to dig out the 200bhp is enough post

[ibizacupra]

Sorry what! you've got a nigh on 500bhp ibiza?

I have to dig out the 200bhp is enough post

well its seems its working slightly better (well on the higher side of my optimism) than I thought.

R32 throttle body with larger single plenum inlet mani to come too, which I am convinced will increase flow. (APR's similar mani claims 37whp over on vortex-which I am not expecting, but 1/2 of that would still be nice and break into the 500's) - Caviat being of course "Dyno Lottery" (TM) before anyone else claims it :D

[RobT]

pmsl - looks like an atmo curve - well done that man

I'm going off to buy shares in gearboxes, clutches and driveshafts LOL

[RickC]

(i am in no way having a go but)

is this driveable, i saw the vid of your car with a mate in the passenger seat filming it , and it looked unbelivably hard to control once the turbo spools up, when at a rr day i had a chat with madmile and he said 320 was an animal,

however i think its f kin awesome, and would be sweet with four wheel drive.

[ibizacupra]

lol, I am stockpiling them too..

going to be an interesting ride home tomorrow nigh from Chesterfield.

i iz finkin itz goin to be a well 'ard ride ome tomoraz

:rock:

[Feel]

Sorry what! you've got a nigh on 500bhp ibiza?

I have to dig out the 200bhp is enough post

Yeah, I quite like the "getting there" comment as well. 490bhp and only "getting there".

Planet Badger - wierd place.

[ibizacupra]

(i am in no way having a go but)

is this driveable, i saw the vid of your car with a mate in the passenger seat filming it , and it looked unbelivably hard to control once the turbo spools up, when at a rr day i had a chat with madmile and he said 320 was an animal,

however i think its f kin awesome, and would be sweet with four wheel drive.

remembering its a race car (but road legal :D ) firstly and foremost..

dunno is my answer tho. will let folks know.

obviously traction is going to be very optional, and with a dose of the wet stuff who knows.. It used to spin in all 6 gears with the PE in the wet so thats a clue. (if provoked)

the power plot looks like it could be quite drivable, but lets face it, its only fwd.

will be fun seeing what it can do tho.
:clap:

[ibizacupra]

Yeah, I quite like the "getting there" comment as well. 490bhp and only "getting there".

Planet Badger - wierd place.


getting there.. yep. as in seems like 100's of hours have gone into it to get it to here.. (oh wait, it was 100's of hours-lol)

had the turbo since GTi International, hence the comment about getting there.
new mani has been on order for weeks too, but looks to be coming next week hopefully. R32, 75mm throttle body awaits it now, then the catcams, which again I have had for a couple of months also.
Want to dyno between the steps to see what bits help or hinder the power and or its delivery.

[caney]

that is ridiculous bhp bill:wtf: is the jbs rr running now then? as that dyno sheet reads the wrong date etc? also 480 odd bhp@ only 1.6bar! wtf size turbo have you got on there:-o remind me not to line up against you at gti next year;)

[RobT]

roll out the racelogic time, will be well quick if you can get grip

[J@mes]

good luck to you bill... your a brave man! :yes:

close to 500bhp in an ical beeza!... simply amazing! :dance: lol

[ibizacupra]

that is ridiculous bhp bill:wtf: is the jbs rr running now then? as that dyno sheet reads the wrong date etc? also 480 odd bhp@ only 1.6bar! wtf size turbo have you got on there:-o remind me not to line up against you at gti next year;)

yea its just being "tested", so i guess stuff like date etc is pc clock based? (been sat off for a very long time as we know) Dunno really, was'nt there today. Ignore the boost on the label, its more than that.

As for 1/4 mile... if its like before I should be even slower now if like before, so you should have no problem nuking me. :) {again! :hide: }

[ibizacupra]

roll out the racelogic time, will be well quick if you can get grip

its on my list after clutch/plate diff

[caney]

its on my list after clutch/plate diffwhat clutch set up are you going for bill? you have the spec stage3+ at the moment?

[ibizacupra]

what clutch set up are you going for bill? you have the spec stage3+ at the moment?

thats the same as before. not touched that. (was talking clutch diff/plate diff not clutch...)
spec stage 3+ jobbie in there as clutch)

[James G60]

Wow! Looking good Bill, see you Saturday at Combe :)

[ibizacupra]

aye. aiming to be there.
looks phatter now too.

[Harry's cupra]

I am going to have to take a trip up to Combe on Saturday now as I am going to have to see this, that simply is amzing power for the little Ibiza.

[David_smith_909]

i cant even believe what i have just read, nearly 500bhp in a ibiza??? WTF!! if you get grip, then happy days, wish you all the best mate, keep us updated on how your getting on :clap:

[Don]

Insane. Nice one! Photos and video please, people who are attending Coombe...

[octy-piv]

Bill say HI to "Pat" for me:)

He made my downpipe for my Octy vrs....nudge nudge wink wink

Phil

[ibizacupra]

Bill say HI to "Pat" for me:)

He made my downpipe for my Octy vrs....nudge nudge wink wink

Phil


lol

[B)]

[ibizacupra]

Pricing for the manifold as follows:-

Manifold in stainless steel:£1100
3" Downpipe for IHI configuration (with 1/8" NPT EGT port) & x2 lambda bosses: £373

Options:
Ceramic coating: £250
Inconel: POA
External gated: POA

Prices are subject to vat & carriage.

Combined as a full package of turbo upgrade with spec of turbo to suit application.

This is a high end setup for those seeking >400bhp of extremely high quality manufacture.

Looking for first 5 orders to proceed for economies of scale for manufacture.


regards
Bill

[ibizacupra]

Pictures below of updated manifold & Hybrid turbo before the manifold goes off for Ceramic coating.
Some prevantative additional bracing for road car application added (buttracing etc) and 2-piece DP to facilitate easier fitment and different vehicle installation (ibiza to mk4 golf platform cars for example)

http://badger-5.com/bin/new-mani/badger-mani-V2-1-small.jpg

This is a 450bhp+ conversion potential with proven manifold flow capacity on my own ibiza which now produces 517bhp from the same setup.

This manifold has been developed in conjunction with Primary Designs (Pat Barrett), who makes systems for the likes of Red Bull Racing Formula One. Top quality as you would expect, with many years of competition experience of materials and fabrication methods to ensure reliable function. (this is not a cast pipe fittings fabricated affair) - http://www.racecar.co.uk/primarydesigns/frameset.htm

This is a high end system, and extremely high quality for which you do get what you pay for in this world.

[GOLF GTTi]

Bill would this fit a 225Q TT???
Would the turbo sit too high to allow the original strutbrace to stay in place?

[ibizacupra]

my own ibiza strut brace still fits withou touching anything.
not sure if this piccy helps you.
http://badger-5.com/bin/new007mani/phat-turbo.jpg
DP would be different bottom end I expect

[GOLF GTTi]

Looking at the height of the exhaust housing in comparison to the rocker cover, I think it might fit into the TT's engine bay with the original strut brace fitted.
As you say Bill, the downpipe would need modded to fit the Milltek cats (Twin).
How much more lag do you get compared to the VF34-p20?? Does it feel flat low down the rev range?

Thank you! :happy:

[ibizacupra]

not flat no. but dont expect anything much to happen until 3K pull wise, and 3.5K you have 1bar boost on board and from then its a rush of power & 2bar or more if you want it sustained to whatever limiter you're prepared to run. 8200rpm at the moment on mine. maybe 8500rpm when the cams go in if power keeps rising like it has to the imposed 8200rpm rpm limiter.
The acceleration is immense. With 4wd ability to put this to the ground it would be stunning acceleration i think.
The DP would be start again more than likely, certainly the lower section.

[Mitchy]

With 4wd ability to put this to the ground it would be stunning acceleration i think.

Nah you would have them pesky 4wd tranny losses slowing you down ;)

On a serious note, is it possible to convert your FWD to 4wd? Have you thought about it? It would cost a few bob, but it would be worth it in the end as with 4wd you may actually manage traction below 120mph:D ;)

How much does your car weigh Bill, 1050-1150kg?

You need a vmax run to see what it will do:) 180mph no probs i would think with appropriate gearing

[GOLF GTTi]

Bill how would you think this set-up would be in and around town using a 1900 bottom-end and a ported largeport? :confused:

[ibizacupra]

its a shopping car to drive. no funny habits, just an ibiza..
nail the throttle however and it all happens rather rapidly... but its just as easy to toodle around thru town (ignoring my crappy g'box in there @ the moment)

[GOLF GTTi]

Mmmm, very interesting! I'll be very interested to hear how your customers Golf turns out. Am I correct in thinking this is a TD06 / Garrett hybrid? Is it rebuildable?

Thanks Bill!

[ibizacupra]

its rebuildable yes.. as are mitsi turbo's

[ibizacupra]

New Badger5 Equal LengthExhaust Manifold

Ceramic coated and now with 2-piece DP
Hybrid TD06-20G unit shown fitted (IHI flanged)

450bhp capable

Enjoy. :)

http://badger-5.com/bin/new-mani/badger5-ceram-mani-1.jpg
http://badger-5.com/bin/new-mani/badger5-ceram-mani-2.jpg
http://badger-5.com/bin/new-mani/badger5-ceram-mani-3.jpg
http://badger-5.com/bin/new-mani/badger5-ceram-mani-4.jpg

[minimivic]

Will you please stop teasing me.......lol

[RobDon]

Looks freakin' awesome, and that turbo looks huge ... WOW!

[ibizacupra]

on a mk4 golf right now.
still running it in.
going to be a nice bit of kit 400+bhp easy. (@ wheels)

[Ibizaκιας]

hello.. i just saw the pictures in the first page. could you tell me where i can find a monifold for the gt3076 turbo? my engine code is AYP. the only problem is that my car is in greece.. but i beleive that if he made this one he can make an other one without the car there..

[ibizacupra]

i can supply the one I developed for my ibiza, but my ibiza is rhd so needed to he made for rhd.
yours will be lhd car?

www.full-race.com would work for you.

I have one of these 'squeazed' onto my racecar currently with gt35 sat on top. *tight* fit

[Ibizaκιας]

thank you very much for your info. but what is the rhd?????

[Feel]

rhd is Right Hand Drive (steering wheel on the right hand side of the car)

lhd is Left Hand Drive (steering wheel on the left hand side of the car)

[Ibizaκιας]

i beleive it has nothing to do with the monifold..

[ibizacupra]

i beleive it has nothing to do with the monifold..


It has everything to do with the manifold

clearance to steering rack and brake servo being the reasons why rhd vs lhd is an important factor. Yours is lhd so you will have a wider choice of options I think

regards
bill

[Ibizaκιας]

so its not easy to get the right monifold for my car??? can you suply me one??

[ibizacupra]

so its not easy to get the right monifold for my car??? can you suply me one??

I have posted you a link to www.full-race.com for one - it is "easier" for you to find the right manifold as yours is left hand drive (lhd) as is the USA, where most manifolds are made for (huge market relative to UK, with our different handed drivers position)

T3 or T25? external gated or not?

what turbo do you plan putting on top of this and what power spec are you hoping for?

[ibizacupra]

http://www.full-race.com/catalog/images/1.8t%20transverse%201.jpg

this is what sits on my race ibiza currently

http://www.full-race.com/catalog/product_info.php?cPath=841_874_876&products_id=304

enjoy
:thumbup:

[Ibizaκιας]

i want to use it with external wastegate with the gt3076 turbo from garret. i think its T25 but im not sure. im looking at around 400+ whp with the unitronic big turbo file. is it possible to find the right monifold from the site you gave me and show it to me because i dont want to buy something useless??

edit.. will this fit to me?

[ibizacupra]

full-race is T3 flanged. the one pictured in the link I posted above

you sure your 3076 is T25???

[Ibizaκιας]

someone told me about the T25. i dont know. i have to find out before i choose a monifold. if it is T25 i think i can make something to make it T3 dont i???

[ibizacupra]

flange adaptor for T25 to T3 could be done yes.. but I would be surprised if your 3076 was T25 flanged tho, and you also want external gate? (unusual for smaller T25 flanged housing to also want external gate)

[Ibizaκιας]

i will try find out as much info as i can. thank you very much for your help.. i really need it..

[ibizacupra]

no problem