My K04 hybrid powered MK2 Cupra Sport track slag (it's now left the building) - SEAT Cupra.net

*roly* · 27-12-2007, 19:20

Some of you will know a bit about the car but i thought i would post up the details from the start (it'll take a while so bare with me

)

I purchase the car back in nov 2004 as a standard 2.0 16v cupra sport and decided it would be my sensible run about, i had all intentions of keeping it reletivly standard bar changing the exhaust and suspension but that wasn't to be.

After replacing complete exhaust system, panel filter, suspension, wheels and brakes i was happy with the look and drive of the car but wanted more power.

Decision time!! do i buy another mk3 cupra or convert this to 20vt power?? after trawling through ETKA and comparing parts etc i decided i'd have a go at the conversion (bearing in mind im not a mechanic by trade so would be learning as i went this was a kind of big task for me)

I found a doner car on good old flebay and after trailoring it back from Coventry set to work literally pulling the car to pieces. 2 weeks later the shell was sent to car heven and then the real fun began.

1 week on my mk2 rolled out of the workshop, housing a new 20vt engine and complete wiring loom (inside aswell) it took me another 4 weeks to get the car to a standard i was happy with but it looked almost factory when it was done.

Spec list as of 22/01/2012

Engine
• 1.8 20v engine bored to 1847cc
• Wossner forged pistons (82.5mm, 8:5.1 compression ratio)
• Scat forged conrods with 20mm wristpins
• Supertech black nitride intake and inconnel exhaust valves
• Backdraft motorsport baffled sump
• JBS05 hybrid turbo
• Forge K04 actuator
• K04 exhaust manifold
• Forge manual boost controller
• 4 bar fuel pump
• Devils own water methanol injection
• Braided fuel lines
• 386cc injectors
• Evoshield gasket
• Forge 200 series universal intercooler
• Custom intercooler pipe work
• Green cone filter
• Forge 007P recirculating dump valve
• Badger5 3” tip
• Vibratechnics race engine mounts
• Badger5 3” downpipe and decat
• 2.5" scorpion cat back system
• Wideband lambda sensor
• EGT sensor
• ABS pump relocated
• Relocated & bypassed N249 & N112 valves
• Carbon canister removed
• Secondary air pump and associated parts removed
• Setrab Proline SLM oil cooler with braided lines
• Oil catch tank
• Badger5 custom map

Transmission
• Neuspeed short shifter
• Lightened 2.0 16v flywheel
• Sachs racing clutch cover
• Sachs racing organic clutch plate
• Peloquin ATB differential with uprated bolt kit

Suspension
• KW Variant 3 Coilovers
• TT bushed front wishbones
• Omp front upper strut brace
• Neuspeed front 25mm anti roll bar
• Neuspeed rear 28mm anti roll bar

Brakes
• Brembo 4 Pots with ferodo DS2500 pads
• Standard rear discs and pads
• Dot 5.1 brake fluid

Wheels
• 7x17 Compomotive MO’s for road use
• 3mm front spacers
• 15mm rear spacers
• 7x16 OZ with Toyo R888’s for track use

Exterior
• Standard 16v front bumper with ghetto moddification for track use
• Standard 16v rear bumper
• Standard 16v side skirts
• Standard 16v boot spoiler
• Factory fitted carbon look B pillar trims
• Factory fitted carbon look rear number plate trim
• MK1 leon wing repeaters
• Osram indictor bulbs all round
• Rear wiper removed

Interior
• MK3 Ibiza dashboard and wiring conversion
• Custom Cages 6 point bolt in roll cage
• Sparco Circuit Bucket Seats with alloy side mounts
• LUKE 5 point harnesses
• VEMS digital wideband AFR & EGT gauge mounted in custom fascia
• Autometer boost, oil temp and pressure gauges mounted in custom fascia
• Manual window regulators
• All unnecessary wiring removed
• All sound deadening removed

*roly* · 27-12-2007, 19:27

There were a few teething problems to start with, airmass, N75 etc but with everything replaced the car ran sweet and even turned out to have a remaped ecu which was a bonus.

This is where the real probs started, i was happy with it for a while but then decided i needed more power (as you do) since the initial build almost 2 years ago the car as undergone various changes and i've thrown a small fortune at it.

Pics below show various states of play over the last couple of years and a few of the build process

*roly* · 27-12-2007, 19:40

*roly* · 27-12-2007, 19:44

As it stands today

Next mods will hopefully be custom made oil cooler and a baffled sump, eventually i'll go BT conversion aswell

*DaNnY_LaD* · 27-12-2007, 19:57

Have you got any bits of that yellow cupra as i need a new foglight

*roly* · 27-12-2007, 20:01

none at all it was scrapped almost 2 years ago

*jenk* · 27-12-2007, 20:10

Top work bud, this has to be the most complete mk2 on here.

*driveforward* · 27-12-2007, 20:36

Hats off to you sir!

A classic example of:

"I'm not modding this car!"

"It's staying standard"

*crezz* · 27-12-2007, 21:10

you should be really proud mate, i would love mine to look half as good as yours. it is so sweet

*tris* · 27-12-2007, 21:24

All I can say is what a car and to think that you did it all your self mate

TOP JOB!!

*redcupraboy* · 28-12-2007, 10:06

Wow what an absolutely lovely mk2, well done with the mk3 cupra engine conversion, its a right stealthy bit of kit, really liking the white compomotives for the rally look, used to have those on my old 106 series2 rallye, well done!!

*Ibiza125* · 28-12-2007, 10:11

Looks great mate! That will be a little flyer!!

*roly* · 28-12-2007, 12:23

Thanks for the comments, i'll try and update this thread with pics and details as it progresses throughout 2008

*Cupra_Jay* · 28-12-2007, 12:56

car looks good mate, seen it a few times already, and is really smart!! good work fella!

*Czechboy* · 28-12-2007, 15:48

Top car Ben, I remember following the progression thread of this. Can't believe its been 2 years already.

Mig

*jamie paton* · 28-12-2007, 16:36

makes me almost want a mk2 again. very smart mate. how much power is it putting out at the moment.

*roly* · 28-12-2007, 16:48

Mig

I've still got all the pics and details saved somewhere but it would take me days to sift through it all

jamie

It was custom mapped at jabba back in july where it pulled 227 bhp & 240 lbft on k03s

*jamie paton* · 28-12-2007, 16:51

christ that'll be entertaining mate, i bet you absolutely hump some really unsuspecting motors. i take it its got the mk3 dash as well.

*roly* · 28-12-2007, 17:09

it is good fun

suprises a few people who arn't expecting it to still be with them at xxx mph, still needs more power tho!!

full mk3 interior and all wiring loom up intill i fitted the cage and recaros

*__B3NNY__* · 28-12-2007, 18:01

Superb mate. Looks like you have done one hell of a good job on the conversion. Is that the laguna dci intercooler?

27-12-2007, 19:20	#1
roly midnightmotors.net Join Date: Jan 2002 Location: Midnight Motors Workshop Posts: 1,896	My K04 hybrid powered MK2 Cupra Sport track slag (it's now left the building) Some of you will know a bit about the car but i thought i would post up the details from the start (it'll take a while so bare with me ) I purchase the car back in nov 2004 as a standard 2.0 16v cupra sport and decided it would be my sensible run about, i had all intentions of keeping it reletivly standard bar changing the exhaust and suspension but that wasn't to be. After replacing complete exhaust system, panel filter, suspension, wheels and brakes i was happy with the look and drive of the car but wanted more power. Decision time!! do i buy another mk3 cupra or convert this to 20vt power?? after trawling through ETKA and comparing parts etc i decided i'd have a go at the conversion (bearing in mind im not a mechanic by trade so would be learning as i went this was a kind of big task for me) I found a doner car on good old flebay and after trailoring it back from Coventry set to work literally pulling the car to pieces. 2 weeks later the shell was sent to car heven and then the real fun began. 1 week on my mk2 rolled out of the workshop, housing a new 20vt engine and complete wiring loom (inside aswell) it took me another 4 weeks to get the car to a standard i was happy with but it looked almost factory when it was done. Spec list as of 22/01/2012 Engine • 1.8 20v engine bored to 1847cc • Wossner forged pistons (82.5mm, 8:5.1 compression ratio) • Scat forged conrods with 20mm wristpins • Supertech black nitride intake and inconnel exhaust valves • Backdraft motorsport baffled sump • JBS05 hybrid turbo • Forge K04 actuator • K04 exhaust manifold • Forge manual boost controller • 4 bar fuel pump • Devils own water methanol injection • Braided fuel lines • 386cc injectors • Evoshield gasket • Forge 200 series universal intercooler • Custom intercooler pipe work • Green cone filter • Forge 007P recirculating dump valve • Badger5 3” tip • Vibratechnics race engine mounts • Badger5 3” downpipe and decat • 2.5" scorpion cat back system • Wideband lambda sensor • EGT sensor • ABS pump relocated • Relocated & bypassed N249 & N112 valves • Carbon canister removed • Secondary air pump and associated parts removed • Setrab Proline SLM oil cooler with braided lines • Oil catch tank • Badger5 custom map Transmission • Neuspeed short shifter • Lightened 2.0 16v flywheel • Sachs racing clutch cover • Sachs racing organic clutch plate • Peloquin ATB differential with uprated bolt kit Suspension • KW Variant 3 Coilovers • TT bushed front wishbones • Omp front upper strut brace • Neuspeed front 25mm anti roll bar • Neuspeed rear 28mm anti roll bar Brakes • Brembo 4 Pots with ferodo DS2500 pads • Standard rear discs and pads • Dot 5.1 brake fluid Wheels • 7x17 Compomotive MO’s for road use • 3mm front spacers • 15mm rear spacers • 7x16 OZ with Toyo R888’s for track use Exterior • Standard 16v front bumper with ghetto moddification for track use • Standard 16v rear bumper • Standard 16v side skirts • Standard 16v boot spoiler • Factory fitted carbon look B pillar trims • Factory fitted carbon look rear number plate trim • MK1 leon wing repeaters • Osram indictor bulbs all round • Rear wiper removed Interior • MK3 Ibiza dashboard and wiring conversion • Custom Cages 6 point bolt in roll cage • Sparco Circuit Bucket Seats with alloy side mounts • LUKE 5 point harnesses • VEMS digital wideband AFR & EGT gauge mounted in custom fascia • Autometer boost, oil temp and pressure gauges mounted in custom fascia • Manual window regulators • All unnecessary wiring removed • All sound deadening removed __________________ K04 Hybrid Track Toy Last edited by roly; 02-09-2012 at 20:19.

27-12-2007, 19:27	#2
roly midnightmotors.net Join Date: Jan 2002 Location: Midnight Motors Workshop Posts: 1,896	There were a few teething problems to start with, airmass, N75 etc but with everything replaced the car ran sweet and even turned out to have a remaped ecu which was a bonus. This is where the real probs started, i was happy with it for a while but then decided i needed more power (as you do) since the initial build almost 2 years ago the car as undergone various changes and i've thrown a small fortune at it. Pics below show various states of play over the last couple of years and a few of the build process __________________ K04 Hybrid Track Toy Last edited by roly; 27-12-2007 at 19:33.

27-12-2007, 19:40	#3
roly midnightmotors.net Join Date: Jan 2002 Location: Midnight Motors Workshop Posts: 1,896	__________________ K04 Hybrid Track Toy

27-12-2007, 19:44	#4
roly midnightmotors.net Join Date: Jan 2002 Location: Midnight Motors Workshop Posts: 1,896	As it stands today Next mods will hopefully be custom made oil cooler and a baffled sump, eventually i'll go BT conversion aswell __________________ K04 Hybrid Track Toy

27-12-2007, 19:57	#5
DaNnY_LaD Big Turbo Leon Cupra R Join Date: Jun 2007 Location: Manchester,Walkden Posts: 5,315	Have you got any bits of that yellow cupra as i need a new foglight __________________ HTA-GT2868R Leon Cupra R Built By INA Engineering & AKS Tuning

27-12-2007, 20:01	#6
roly midnightmotors.net Join Date: Jan 2002 Location: Midnight Motors Workshop Posts: 1,896	none at all it was scrapped almost 2 years ago __________________ K04 Hybrid Track Toy

27-12-2007, 20:10	#7
jenk Senior Member Join Date: Feb 2005 Location: Telford ay it... Posts: 3,605	Top work bud, this has to be the most complete mk2 on here. __________________ I wish it looked this good...... http://www.jenk.me.uk All my mixes are here!!!!

27-12-2007, 20:36	#8
driveforward Is at the Nürburgring Join Date: Nov 2002 Posts: 3,317	Hats off to you sir! A classic example of: "I'm not modding this car!" "It's staying standard" __________________ BMW Z4M Coupe

27-12-2007, 21:10	#9
crezz pedro motorsports Join Date: Jun 2007 Location: Woolacombe Posts: 4,446	you should be really proud mate, i would love mine to look half as good as yours. it is so sweet

27-12-2007, 21:24	#10
tris The Daddy Join Date: Feb 2005 Location: Kent & Track Days Posts: 3,685	All I can say is what a car and to think that you did it all your self mate TOP JOB!! __________________ LeonCupra.Net Tris's Readers Ride Thread

28-12-2007, 10:06	#11
redcupraboy Senior Member Join Date: Oct 2006 Posts: 533	Wow what an absolutely lovely mk2, well done with the mk3 cupra engine conversion, its a right stealthy bit of kit, really liking the white compomotives for the rally look, used to have those on my old 106 series2 rallye, well done!!

28-12-2007, 10:11	#12
Ibiza125 Motocross nut Join Date: Feb 2007 Location: Aberdeenshire/Glasgow, Sunny Scotland Posts: 2,749	Looks great mate! That will be a little flyer!! __________________ Stage 3 Mk3 Ibiza Cupra - 205 1.9 GTi - 205 1.8 STDT - 205 track car

28-12-2007, 12:23	#13
roly midnightmotors.net Join Date: Jan 2002 Location: Midnight Motors Workshop Posts: 1,896	Thanks for the comments, i'll try and update this thread with pics and details as it progresses throughout 2008 __________________ K04 Hybrid Track Toy

28-12-2007, 12:56	#14
Cupra_Jay Orange Wheels FTW!! Join Date: Oct 2006 Location: Pub!! Posts: 962	car looks good mate, seen it a few times already, and is really smart!! good work fella! __________________ Black 2006 Mk4 Ibiza Cupra - 219bhp & 244ft/lb - April 2013 AmD Stage 1: Milltek exhaust, SFS TIP, Pipercross Induction Kit, Forge Strut Brace, JOM Coilovers, Whiteline RARB, EBC Discs, DS2500 Pads, FK Grille, 6K HIDs and Orange wheels!!

28-12-2007, 15:48	#15
Czechboy Tarmac terrorist Join Date: Apr 2005 Location: Hampshire Posts: 1,608	Top car Ben, I remember following the progression thread of this. Can't believe its been 2 years already. Mig __________________ NOW: GSX-R 600 + 328 Sport

28-12-2007, 16:36	#16
jamie paton Senior Member Join Date: Jan 2006 Location: fife, scotland Posts: 1,059	makes me almost want a mk2 again. very smart mate. how much power is it putting out at the moment. __________________ black leon cupra r, performance torque tweaked, recaros front and rear, touran rear wiper and aero fronts,bailey dv30, BMC cda, blueflame exhaust, grooved brake discs all round, private"L30N" plate, 6000k HID's,ultraleds, led sidelights,

28-12-2007, 16:48	#17
roly midnightmotors.net Join Date: Jan 2002 Location: Midnight Motors Workshop Posts: 1,896	Mig I've still got all the pics and details saved somewhere but it would take me days to sift through it all jamie It was custom mapped at jabba back in july where it pulled 227 bhp & 240 lbft on k03s __________________ K04 Hybrid Track Toy

28-12-2007, 16:51	#18
jamie paton Senior Member Join Date: Jan 2006 Location: fife, scotland Posts: 1,059	christ that'll be entertaining mate, i bet you absolutely hump some really unsuspecting motors. i take it its got the mk3 dash as well. __________________ black leon cupra r, performance torque tweaked, recaros front and rear, touran rear wiper and aero fronts,bailey dv30, BMC cda, blueflame exhaust, grooved brake discs all round, private"L30N" plate, 6000k HID's,ultraleds, led sidelights, Last edited by jamie paton; 28-12-2007 at 16:56.

28-12-2007, 17:09	#19
roly midnightmotors.net Join Date: Jan 2002 Location: Midnight Motors Workshop Posts: 1,896	it is good fun suprises a few people who arn't expecting it to still be with them at xxx mph, still needs more power tho!! full mk3 interior and all wiring loom up intill i fitted the cage and recaros __________________ K04 Hybrid Track Toy

28-12-2007, 18:01	#20
__B3NNY__ OEM with a 'Twist' Join Date: May 2005 Location: Oxford Posts: 3,649	Superb mate. Looks like you have done one hell of a good job on the conversion. Is that the laguna dci intercooler?

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