APR Stage 3+ one year on.

[Ianb]

Just a quick update on this kit now that I've been running it for a year or more.

All's been very well with the car except for my first real track experience at Combe where due to high EGT's from retaining too much heat on the manifold as it was wrapped on top of the ceramic coating it caused a small blow on the manifold to turbo connnection.It was also highlighted that my Neuspeed FMIC was woefully inadequate hence the Forge item was fitted.
The manifold was duly replaced last September and it's been fine ever since.

I was pretty happy the car done well at GTI International winning the 1/4 sprint in the MKIV class which ordinarily doesn't float my boat with harsh sprinting putting extra strain on the transmission. Certainly James from CC wondered what was under the hood after pipping his high powered Octavia but all in all it was a fun day.

I decided this year at 109k that it was probably a good idea to refresh the engine before running into a catastrophy that would have been expensive to repair. Running these power levels on a stock engine with this mileage I felt I was on borrowed time if a rod let go even though APR are happy to run this kit on stock internals.

The engine was pulled out with my ex TSR friends who stripped and rebuilt the head and block using parts I had ordered from the US.
I decided to keep stock compression and bore size as they were still in perfect shape.

We repalced all bearings and oil pump and I used Mahl pistons with the 20mm pins together with Scat rods and ARP fastners.

The head was rebuilt using Supertech Inconnel valves and I decided to fit a baffled sump for peace of mind.

Car is all back together and run in and so far hasn't missed a beat.


All I can say is how nice the APR kit has been smooth progressive and mighty quick when required. I'm glad I opted for the complete kit for peace of mind.


I only hope that now it's rebuilt it will be good for another 100k.

Ian

 

[ryan_s3]

remind us ian what is the stage 3+ kit?

 

[virdi]

Sounds good.

What power are you making?

 

[David_smith_909]

remind us ian what is the stage 3+ kit?

http://www.goapr.co.uk/k04kits.html

 

[Ianb]

remind us ian what is the stage 3+ kit?

Ryan car is as follows:

APR Stage 3+ Engine Conversion completed April 2007.

Engine fully Rebuilt March 2008:

Stock Bore Re-honed, stock compression.
Mahl Motorsport Pistons (Stronger 20mm Gungeon pins)
Scat Forged H section Con Rods.
Supertech Inconnel Race valves.
Head fully rebuilt.
New VAG Oil Pump.
Jabbasport Baffled Sump
New Big end bearings and shells.
New Gaskets including crank mainshaft.
NewSouth inlet gasket.

APR Stage 3+ kit to include:

APR Modified Garrett GT28RS Ball-bearing turbo
Twin Wall Tubular Exhaust Manifold with life time warranty.
APR Uprated injectors
APR Uprated Secondary Fuel Pump
APR Larger Cast MAF Housing
APR 3" Large Stainless Steel Down Pipe with Sports CAT.
Milltek Stainless Steel Exhaust.
Uprated Spark Plugs
APR EMCS Interchangeable Programming Via Cruise Control.
VW OE Cruise Control.
Forge Motorsport Twin Pass Intercooler (New Sept07)
Forge Motorsport Oil Catch Tank and Breather System.
Vibtratechnics Uprated Engines Mounts.
Neuspeed Uprated Dog Mount.

Transmission :
Sachs Sporting Uprated Clutch lightened and balanced Flywheel.
Fully rebuilt Gearbox Utilising Quaiffe ATB differential.
Neuspeed Short shift.

Brakes: Tarox 2 Piece Bells and Rotors utilising Tarox 330mm Brake Discs 6 POT Callipers.
Tarox Race Carbon Pads Front and rear.
Motul RB 600F Fully Synthetic Brake Fluid.
Full ducted Brake kit.

Suspension:

Koni SSK Adjustable Suspension (Height and Rebound)
Neuspeed Fully adjustable Rose jointed Anti Roll Bars.
Powerflex Uprated Bushes all round (Wishbones and Rear Beam.)

BBS CH Motorsport Alloys.
Goodyear F1 rubber.

Oettinger Body Styling.

Ian

 

[Ianb]

Sounds good.

What power are you making?

345bhp and 330lbs on 98RON fuel

Haven't dyno'd the race fuel programme yet!!

 

[Willie]

Feck aye min

That should keep you smiling for a while

 

[Ianb]

It certainly does and the beauty of this kit is that it's been 'reliable'.... that's worth alot in my book and my car was the first one fitted at Awesome.

You can also DIY these kit's if you've got yhe knowledge and tools.

 

[ibizacupra]

aside from the manifold face seal to turbo warp/blow

 

[Ianb]

aside from the manifold face seal to turbo warp/blow

Minor complications Bill compared to some

Awesome were excellent and were quick to replace the manifold and put inconnel studs in.
The original studs together with heat wrapping put the EGT's up which didn't help.

 

[ibizacupra]

compared to some eh ian?
2 race seasons of lurvely operation I can be very happy with mine.
do some more track days first and see if it continues to be ok. (which I hope it does)

 

[Wilko]

Bill
How many races have you missed over the last 2 seasons because the car wasn't running?
What is you hours on the spanners: hours on the track ratio for the last 2 seasons?

Only teasing

 

[Ruddmeister]

Bill
How many races have you missed over the last 2 seasons because the car wasn't running?
What is you hours on the spanners: hours on the track ratio for the last 2 seasons?

Only teasing

Perhaps we should just get you 2 guys padded up and you can thrash your issues out in a controlled environment

I'll even referee for free

 

[ibizacupra]

Bill
How many races have you missed over the last 2 seasons because the car wasn't running?
What is you hours on the spanners: hours on the track ratio for the last 2 seasons?

Only teasing

oh my god here we go again

LOL @ the fish called wilko

DNF's yep been a few. missed none at all until this seasons slow rebuild and evolution.
causes:
oil pipe pulled off when front engine mount lost its securing nut (after a g'box swap earlier that week)
several gear failures, 3rd twice , 5th once
CV's x 3
gear selector cable shearing x2
gear box top bearing shearing (not dnf but breakage none the less) x 3 - quaife g'box caused, hence retired it

Changed turbo's trying different units to see what I preferred power vs delivery. None have failed. PE1820, FPgreen, FP Red, 8cm housing also tried.

Failures of engine? one broken exhaust valve spring caused when engine buzzed when gear selector broke.

turbo manifold failures or anything else engine? none at all despite full race season(s), test days, track days etc.

Engine remains the one built by elton in Oct2005. Its done very well, as has tubular manifold and sundries.

Drive your car on a single track day and I doubt yours would last at all - lol

 

[jamiebennett81]

great write up Ian, very interesting to read and seeing that it is still going strong

currently gt2x going on, but not ruling out going GT30 and a rebuild at some point a while down the line

 

[pj1985]

Off topic but you cant really compare any of Bills failures to say ians apr stage 3 or wilkos tdo5 golf etc even with track use as Bill runs quite alot more power.

 

[Wilko]

oh my god here we go again

Drive your car on a single track day and I doubt yours would last at all - lol

Did a few laps of the ring in anger this year bill, got there and back, plus a few Sunday morning sessions at donning ton, and a bit of time at the pod. Plus hit the limiter in 6th a few times whilst mapping.
The car survived it all. I've even managed to stop cooking the brakes. Needs a driver upgrade mind!

I've got it to a point where it's reliable now (famous last words) so I'm leaving it be.

If the only problem ians had in a year of bt is a blowing mani-turbo seal, that aint bad. Find me a jabba manifold that doesn't blow, or hasn't warped the turbo flange. I'm sure there are some, but I haven't seen one.

 

[Ianb]

Did a few laps of the ring in anger this year bill, got there and back, plus a few Sunday morning sessions at donning ton, and a bit of time at the pod. Plus hit the limiter in 6th a few times whilst mapping.
The car survived it all. I've even managed to stop cooking the brakes. Needs a driver upgrade mind!

I've got it to a point where it's reliable now (famous last words) so I'm leaving it be.

If the only problem ians had in a year of bt is a blowing mani-turbo seal, that aint bad. Find me a jabba manifold that doesn't blow, or hasn't warped the turbo flange. I'm sure there are some, but I haven't seen one.

Thanks Wilko I agree but why does Mr B have to be so pessamistic about other people's car's??

I've done plenty of track work previously and having spent the dosh on this conversion knowing how hard track is on these big turbo converted car's I thought I would be 'wise' to rebuild with at least stronger rods a baffled sump and some better valves.....advice Bill has given for some time!

The APR kit is a pleasure to drive and own and as a drive in drive out conversion it will surely make sense for some of us non DIY buffs.

As for track I have made it as robust as possible but in the end it is still my everyday road car and it is certainly not built solely as a competition track weapon.



Ian

 

[Wilko]

Thanks Wilko I agree but why does Mr B have to be so pessamistic about other people's car's??



Ian

I don't know Ian. You're not the only one who finds it tiring. He's got a reputation to defend/destroy, whatever.

Are you going to do the sprint at inters again? Got a few tricks to beat you this year.

 

[h17och]

we all get it. i think it just comes free when you go BT....

"Big turbos now include a free 'pessamistic bill' with every purchase, get yours while still in stock"

HoocH