My revo/JBS/jabba IHI conversion

[Wilko]

I been after more power from my car for a while now, and after researching all the available kits out there, I kept coming back to the same conclusion. The only one that will fit a RHD car is a kit using the Jabba manifold.

I considered either a GT28rs or the IHI mated to the manifold, and concluded that the GT28rs was too big for the engine, and would push the power band too high in the rev range to be very useful, unless I could get the car to rev reliably to 8000rpm.

This left me with the IHI, and the thought of buying a bolt on kit rather than separate manifold, turbo, downpipe, tip, and oil/water lines had the prospect of being much simpler.

So off I trotted to Jabba to pick up a kit. Took the kit home and did a test assembly on my bench at home and discovered a few minor issues. Some of the banjos supplied in the kit either had the wrong threads on them, or bottomed out in the holes in the turbo.
Luckily I got one of the machinists at work to modify them for me. I told Jabba of the problems which they assure me they have now rectified.

I took the car and the kit up to JBS on the Monday morning, expecting to be without the car for 2-3 days. I spoke to JBS every day over the next week, and was kept up to date on how the fitting was (or should I say wasn’t) going.

It turns out that this is not a simple bolt on kit. The turbo and manifold went on and off the car 5 times to try and fathom a way of fitting the various oil and water lines. Eventually it was discovered that the only way to achieve it (unless you are Houdini) is to split the turbo in the middle, with it mounted on the manifold. It turned out that it was a good job JBS did split the turbo, as it had some nice big lumps of polystyrene packaging in the turbine blades.

Anyway, the kit eventually went on thanks to the determination of Kev and James. I went up to fetch the car the following Monday. I arrived mid afternoon, to see James fabricating the downpipe. Cast iron down pipe adapter welded to stainless steel down pipe. This is not the prettiest of solutions, but there wasn’t really a lot of choice given the parts supplied. JBS are currently having a full stainless steel down pipe made for me to replace the cast turbo outlet, which should be much neater.

For a tip, we had to modify the standard golf item, by sleeving it just before the turbo. I have been waiting for Jabba to finish there silicon TIP for a couple of months now, and it’s always 2 weeks away. If it ever gets finished, I will probably replace the one that JBS improvised for me.

For fueling, I was using a tt/s3 maf housing, and the injectors fitted during my E05 conversion.

Once the kit was on, it was down to Daventry to see Revo Kev. Mitchel had very kindly written a guesstimate program for the kit, and Kev uploaded it for me on the Tuesday morning. We then did an hour or so of road testing, and logging.

The car was smooth, and very tractable. If this was guess number one, then the finished program is going to be special. The cars now running V3 which is still a guess based on my vagcom logs from the car.

At the JBS rr day yesterday it made 331hp and 305lbft. You’ll see from the graph that it is extremely smooth, with no spikes. To say that I am impressed is an understatement, bearing in mind this is a guess for software. I have to conclude that Mitch really knows what he is doing.

I’ve done 4000 miles in the car since the turbo went on, and I’ve not had a single issue. It’s averaged 26mpg, and it’s nicer to drive than it ever was on a k03 or e05. It’s much more progressive, and is a lot less aggressive to drive. It will however upset anything this side of a 911 turbo. (non turbo 911’s are easy)

For anyone else who is considering doing this I’d say go for it. But be warned that the install is a major pain. It is anything but a simple bolt on. JBS are happy to fit the kit (for the right money), and if mine is anything to go by, it will be a very neat, professional install when it’s finished. If you’re sick of waiting for Jabba, then go for it. I would talk to James first though to see which bits to buy, as quite a few bits from the production kit are still in the box, and quite a few more will be replaced soon. If I did it again, I’d just buy the manifold, and source the other bits myself or have JBS source them.

I’ve been told that Revo will be offering maps for this kit, and also GT28rs kits in the near future through JBS.

I have to extend my thanks to JBS for how professionally they approached the whole thing, and to Revo for providing some cracking software. Jabba can take credit for a well engineered manifold, and picking a suitable Turbo for the engine.

Bit of a ramble I know, but I just wanted to share my experience to allow others to avoid some pitfalls.

Now for the pictures


Downpipe close to steering rack


Turbo inlet


Downpipe close to steering rack and driveshaft.


Looks pretty standard up here doesn't it.


One for the skoda boys


The gratuitous money shot

[Saul]

good stuff john, will have a mooch at rr day

[kiq12]

I was just wondering into total, what would be a good estimate of how much you have spent on tuning to get the amount of BHP youve greatly achieved? If you dont want to answer thats okay, as quite a blunt question. Do you reckon it was well worth the cash?

Either way, great work!!

[ryan_s3]

looks good mate,congrats on a job well done.i'm going the gt28rs route ,hopefully everthing will go ok!!

[vern]

i enjoyed reading that john cheers

vern

[Wilko]

Originally Posted by kiq12

I was just wondering into total, what would be a good estimate of how much you have spent on tuning to get the amount of BHP youve greatly achieved? If you dont want to answer thats okay, as quite a blunt question. Do you reckon it was well worth the cash?

Either way, great work!!

The mods I've done to my car should have cost the thick end of 8 grand. Not all of these are power mods, as handling and stopping become kind of important. But I'm a good blagger, so it's cost me a lot less.

[Madmile]

U had chance to compare it to other performance cars on the road?. If u know what i mean.

[Wilko]

well I mentioned that 911's (996) are easy to upset. Not turbos of course. Boxter S was easy, evo 8 fq340 was similar to a 911. And thats in a lardy arse MkIV, so in a beeza there ain't much that'll be faster

[Madmile]

What happened with the Evo, what gears and what speeds do u start do go away from it?. On a private rd of course.

[ibizacupra]

Originally Posted by Madmile

What happened with the Evo, what gears and what speeds do u start do go away from it?. On a private rd of course.

Any... but up to 50-60 traction will put you a bit behind.... then 2nd grips.... and bye bye other car.

[Madmile]

So basically coming off a r-about at say 40mph, your going to go straight past. Thats what i am looking for. Totally owned. I cant remember how fast Jabba's car was now.

[BenS1]

That was a good read.
Glad its all worked out for you, and hopefully Jabba will have mine done soon too.

Only 8k you've spent on mods? I've spent over £15k on mods to my Ibiza.... more than the price of the car!

Looking at the dyno plot, it appears that the torque drops rapidly from 6250rpm. I thought the torque stays high right upto the (adjusted) limiter at 7500rpm? Or haven't you had the rev limit moved?

Ben

fantastic reading, wow what a project! glad to hear you are happy with it, i kno i sure would be!

[m0rk]

Originally Posted by BenS1

Only 8k you've spent on mods? I've spent over £15k on mods to my Ibiza.... more than the price of the car!

I doubt he counts getting ripped off for labour as much

[Ruddmeister]

Wilko


Nice to see a write up, having been in this car I can confirm it is quick, seriously quick, the Poloquin LSD and suspension mod's are a must too.

The most noticable thing is the way the car revs, smooth, progressive and all the way to 7,000rpm plus (and more rpm to come I undrestand). The way the car puts the power down is coming from a less powerful front wheel drive car the traction is fantatic - hooks up and goes.

To say I and Vennuth were impressed with the car is an understatement.

I say well done for having the b@lls to do this conversion

Looking forward to the RR day at JBS next month


Steve

thats the sort of power id like.. but lack of funds mean i have to stick wiv wot i got for the time being

one day tho! i will get the IHI conversion....

oh yeah,,, last time i spoke to the bloke who owned jabba's old blue IHI Ibiza it was running 363bhp....nice...
come to think of it, that was for sale when i had mine jabba'd! y didnt i buy it??

[Saul]

Originally Posted by Ruddmeister

the Poloquin LSD

Steve

that must be one mint diff

[edc]

The Peloquin is a copy of Quaife's ATB not LSD too IIRC

[Ruddmeister]

Originally Posted by Saul

that must be one mint diff

LOL at my typing

POLOquin

Mint Indeed, chubby fingers and small keys

[Revo Kev]

Hey guys I just have to emphasise that this is an experimental code, we would like to offer big turbo software in the future although as you can appreciate these things take time and we have to decide on exact specifications that we would like to provide software for. We are looking to offer big turbo software, but it is going to be in the long rather than short term.