Seat leon Fr 07' K04 Project

Hey I'm from south america and this is my build thread. Started december 2011 finished june 2012. Now taking some new pics of the car and get the reflash fro REVO tomorrow, so here is it enjoy it changes will come! comments and questions are welcomed.

here is the original thread from VW.vortex not many comens lots of views.
http://forums.vwvortex.com/showthrea...3#post74801643
starts

----------------------------------
Im moving my build thread up to here it will maybe have some more visits and questions.
original thread:

http://forums.vwvortex.com/showthread.php?5515147-Seat-leon-fr-k04-project

I haven’t find any good thread about a BWK04 but now its coming… im putting together in my Seat Leon FR mkII (K03 based car)… im trying to push all power hidden in this magnificent turbo out. Here are the actual mods of the car, and coming…
Photos coming later!

--ACTUALLY--
Engine
-FMIC Forge
-S3 up pipe
-Eurojet valve cover
-EVOMS 3” intake
-APR RSC 3” Turbo Back Exhaust
-Deleted PCV
-NGK Spark plugs
-R8 coils
-Custom catch can
-BSH engine mounts
-HPFP Autotech
-REVO stage 2+
-BSH boost tap
-Recent changed internals of gearbox (6spds manual 02Q)
-South-bench clutch stage 2 daily

Body
-Eibach Springs pro
-Upgraded sway bars
-Rear wheels spacers

In the car
-A/F AEM gauge
-Defi Boost Gauge

--COMING SOON--
-K04 turbo
-S3 injectors
-Neuspeed hi-flow discharge pipe
-BSH up pipe
-BSH 550Hp FMIC
-DevilSown Water meth stage 2+
-E-Boost 2 Turbosmart boost controller
-INA 1.8t Oil pump no balance shafts and Oil pan Baffled
-Fluidamper (not sure yet)
-IE 144x22 rods with riffle drilling and ARP 2000 bolts
-JE pistons 9.5:1 with tool steel wrist pins
-Main Stud Bolts ARP
-Ferrea valves kit OEM Diameter
-Peloquin’s LSD
-IMPORTANT ALL SEALS, GASKETS, SHIMS, ETC
-Big Brakes
-APR In tank fuel pump
-REVO STAGE ?? CUSTOM REPRO

Here i got some old photos of the car








my old forge intercooler


My actual engine bay !



im right now taking pictures of the pieces i got until now, post them later

Here are the pics of all i got until now


Old pod and Aem gauge

Old DV valve

Water-meth Kit


Head gasket, intake manifold gasket, Rod bearings and E-Boost2 with OSIR mount

Old fuel pump

New APR pump

Mounted

RODS PISTONS AND VALVES



BIG BRAKES


SOME MOTHNS AGO REBUILDING MY GEARBOX

PENDULUM MOUNT INSERT AND HEAD STUD BOLTS

INA BAFFLED OIL PAN, ADAPTATION FOR K04 OIL RETURN, MAIN CRANKSHAFT BEARINGS AND SEALS




I thought this never happened but here is my cam follower and piston shattered, and soon my camshaft scratched, but I have a new one from S3






Hey there people! I have been doing work! engine is out cams are off for valves, differential it's mounted and shots conning this or next week, here are some shot from my yesterday work




OEM wastegate Vs. Forge wastegate

A shot from Internet of how my downpipe started( forgot to pic )

After half an hour of work

Hole for AEM no wield sensor mount

Painted silicone coat
Ready with exhaust wrap

i did the pic i was very bored


HERE ARE SOME PICS (****TIE PHONE PICS) OF THE ENGINE OUT







here are other things I'm putting on the car
Eibach pro damper shocks and struts

neuspeed hi flow discharge, catch can ( getting some mod there), S3 injectors, new spark plugs, and sensor

K&N oil breather for catch can

coolant hoses, coolant, new water pump, turbo exhaust manifold gasket, red seal, assembly lub, oil cooler, new red vacuum hoses and red coil cables cover, cam follower, new south oil turbo feed adapter for oil press gauge pressure sender

4 oil filters (theres never too much oil filters such as cam followers), drive belt, timing belt rollers ad tensor

i cabin air filter and podia oil pressure gauge

new camshafts, sprocket bolt, adjuster bolt and cam cap screws, also gearbox oil seal.

BSH PIPING


and i have been waiting 2 months for these things
new front mount intercooler





and my new babes! Avant Garde M140 12x8.5 r18 ET35





i have been rally busy working, but i finally can concentrate myself in the car ! :laugh:

here i Have some updates, this are the pics of other LEON we finished 2 months ago, and still waiting for other mods, it runs a GTX3071R with 430WHp


love this car!!

there here are some updates of mine! i have been busy in exams so maybe next weekend car is on!opcorn: as i said cams ready, engine block being armed (had some problems with the oil crank gear waiting for new). here i have some pics of the differential, and what i made today afternoon!


i took the homework of polishing every bolt and they finished like this



Differential with ARP bolts




gearbox ready !! :laugh:




I THINK IT LOOKS SICK!

and on weekend i put together the rims with my old wheels




thanks hope likes!

Hey after hard word the car is ready but some details left to correct, i leave you here pics
this is the damage to the old clutch

old brakes



THINHS LEFT TO DO
Oil Catch Can (wield something and plug)
Programming


HOPE YOU LIKE MORE VIDS COMING!

Long time...

I know it has passed long time since my last posted. My car finally produced 315WHP at 22Psi
here it how he sits know, black matte plastidipped



But some week ago this happened

[/IMG]

[/URL][/IMG]



The damage goes on and on, but right now i dont have more pics, but as it happened work started right away



Took all the interior and paint it metallic black

[/URL][/IMG]

[/URL][/IMG]

[/URL][/IMG]

[/URL][/IMG]

[/URL][/IMG]

After clear coat and buff this is the final result, i still need to do some cleaning

[/URL][/IMG]

[/URL][/IMG]

Also made custom fiberglass base for my two intak LPFP's

[/URL][/IMG]

All mucked up

[/URL][/IMG]

Cleaned engine bay...

BEFORE

[/URL][/IMG]

AFTER

[/URL][/IMG]

[/URL][/IMG]

After that i made i second pass... later on cleaned Gearbox

[/URL][/IMG]

And took pistons and rods out, they were perfect!

[/URL][/IMG]

Now the next part comes, maybe im gonna throw in some BT, or other things keep it touch!

Daniel M said:

Looks awesome in matte black.

Very nice projeect!! Thinking about having my centre console done black too.

Click to expand...

Looks very nice black, hope to have the car ready within a month so post more things! keep in touch thanks!

I agree, the badge would break up the black nicely. Look forward to seeing it all done.

very nice job

where did you get your intercooler from as i am after one but having trouble finding one

Roganjosh said:

Very nice build thread and its always good to see this much hard work going into a motor

with it all being matte black and the wheels silver i think the seat badge would have looked better silver too

Click to expand...

Thanks! It was once silver, but the had to repaint the complete grill and left it like that! more is coming keep in touch!

sb_33 said:

I agree, the badge would break up the black nicely. Look forward to seeing it all done.

Click to expand...

I'm on it you will see this car refreshed some weeks from know!

ginger monster said:

very nice job

where did you get your intercooler from as i am after one but having trouble finding one

Click to expand...

The intercooler its from BSH Speedshop from a gti, I adapted it welding some tabs to it, cut the security bar, and srew it there! tight fit but works great! and the piping is all the same. You could also try a garrett.

This is Garret last week install on my brothers Leon

Benzy said:

Looks great!

Where did you get the gauge pods from?

Thanks

Click to expand...

Pods are from Podi.ca From GTI Mk5, just made little cuts some nice screws and perfect fit! the only thins is that they are located in California Usa... But throw them an email! expensive but the gauges are really beautiful! it is worth!



Thanks for comments! keep in touch and help me with this new advise Thread!

Rollcage and +++ updates!

Hey guys, I know its been quite a very time since my last post, but I haven been lazy! Been working on lots of stuff so here we go BOMB of pictures for you!! Enjoy!

BTW BOUGH A WELDER AND OTHER TOOLS FOR ALL THIS PART OF THE BUILD







STARTED WORKING ON NEW STAINLESS STEEL INTAKE





EVERYTHING TOGETHER BEFORE GETTING WELDED





JUST REALIZED I DIDNT TAKE ANY PICTURES OF THE FINISHED PRODUCT WITH THE NEW MAF HOUSING I MADE BY MYSELF NEXT TIME

I WAS BORED ONE NIGHT SO TOOK SOME FIBERGLASS BONDO AND CABLE AND DID THIS









ITS READY FOR PRIMER AND PAINT ALLL SANDED SMOOTH. AFTER THIS IT COMES THE BATTERY RELOCATION, AND NEW METH TANK

<-- CABLES TUCKED UP ALL THE WAY TO THE BACK OF THE CAR

<---- AND TANK PROTOTYPE AND MADE SOME ALUMINUM BRACKETS



<----AND TANK FINALLY WELDED AND GOT BIT RUSTED BECAUSE OF THE SEVERAL LEAK TESTS



<---TANK CAP ADAPTED FROM OLD PLASTIC TANK



ALSO MODIFIED THE PUPM ITSELF AND BASE, BUT AGAIN NO PICTURES YET



AFTER THIS GOT MYSELF INTO WORKING IN THE CABLES OF THE ENGINE BAY, GOT SOME NICE PRODUCT FROM WIRECARE.COM FOR PROTECTING MY WIRES







NOW TO THE FUN PART!!---AFTER A PVC BLUEPRINT AND SOME TUBE BENDING HAD THIS DONE



SO STARTED DISASSEMBLY OF ALL THE INTERIOR









<---ALL THIS IS GETTING POWDER COATING, ALREDY SAND BLASTED, WAITING FOR HAVE ALL PARTS SO I CAN HEAT UP THE OVEN AND HAVE SOME FUN

MOVED PART OF MY WORKING STATION NER THE CAR



SO IT BEGINS





<---SOME OF MY TUBE WELDING







<---EMPTY ENGINE BAY

AFTER PRIMARY STRUCTURE WAS IN GOT DASHBOARD AND SEATS IN FOR SOME CLEARANCE TESTS, ALL GOOD























ALL THIS IS AROUND 2 MONTHS OF WORK, TODAY STARTED RUNNING SOME HORIZONTAL TUBES AND REINFORCEMENTS















<--- I KNOW ITS NOT STRAIGHT GOTTA WORK ON THAT TOMORROW

THIS IS THE MAIN IDEA FOR THE BACK, SOMETHING LIKE A "V"





FINALLY THIS IS THE COLOR I THINK I AM GOING TO PAINT IT, BUT I WANT A BRIGHTER COLOR SO I AM STILL ON THE SEARCH



I HOPE YOU ILKE MY BUILD, KEEP WORKING ON OT AND THEN THE WORK ON THE ENGINE STARTS I HAVE GOT SOME BIG PLANS!!. NEED SOME HELP HERE HOW DO I CHANGE THE NAME OF THE THREAD?? HELP ME OUT HERE!


THANKS GUYS,
ANDRES

tonto said:

This is amazing!

I like this ALOT!

Click to expand...

Thanks man! km going to upload pictures next week! hope at least someone likes it ! keep in touch!

Matthew FR said:

Dont like the plasti-dip looked better before imo, Like everything else though

Click to expand...

Hey thanks for the comment! Right know i am removing it because i want my bright black back so be pleased!BTW your car color is amazing! keep it touch!

Andres Nunez

reece1591 said:

this thing is insane lol
wish i had the money to do it and the time lol

but defo want a front mount as looks so good through the bumper added to the list lol

Click to expand...

Hey thanks for the feedback, yes this takes tons of time, you start doing a small thing and end doing something completely different! keep in touch!

Small Update

Hey guys here is a little teaser of what is coming for this baby!







If you want to know more start researching on those par numbers and few boxes that picked up from DIPYOURCAR!

Update time!

Hey, i have forgotten about this i have tons of pics

As for the parts i bought they are most of it replace parts, but one is special...

First the packing is perfect, they make sure is perfect made to protect it, because believe, its not cheap.







Sorry about the low light in the pics, my flash got damaged, and lighting in my room sucks.

The moment you unwrap the head, you just get astonished by the clean and perfect it is
























I hope you like pictures because i have a lot of them!!

this is the touch i most like
























This product is really what you pay for, i will post later pics of the head already assembled.

Hope you enjoy it!

So talking about parts here is all i have got

This box contains all the parts



I wont show each part because is all fitting, screws, gaskets and stuff like that



But i want to make some emphasis on this, Eurodyne Maestro 7

It comes in this tiny simply box





All contents



And the module itself



Hope this makes the difference when tuning this baby up

So as soon i arrived from my trip two weeks ago work started as i star classes back again in some weeks.

started by cleaning and getting all my tools organized



my new torch set up







Then i disassembled the old head and this came out







Now head comparison



The difference is astonishing
Now back to the cage, fished the back reinforcements





and started on the rear X

first one



second one



AAAANND DONE







The hole Rear Parts looks a bit lower on the passenger side but my level says not, so IDK whats happening there



Then did some work on the battery box







The two small holes are for the main cables going to the front of the car, and the Big one in the middle is for the ones going to the Amps.

...............Work still goes on and on

I pulled out my oven i got last year in a sale (BTW Really nice by the price i got it)

And started on the Powdered Coating





This will be painted the same color

Valve cover before and after two coats





It had some high sports so i sand it back down





polished the oil cap









and did bunch of stuff

UPDATE TIME! continued...

continued..







This are my new Sparco seats they are awesome!! Pm me if you want one of them



Then the rust proof started im using this two products

























And i still miss the top coat.


it looks like its not too much, fur believe, doing all this stuff by yourself is really time consuming, and also trying to make all perfect.


Hope you like this more updates coming, such as paint, rims paint, dipping tho whole car, and of course, the engine! thanks

Andres Nunez