mk3 cupra ko3 hibrid progress relisted

[Adam180]

hey, this is my second attempt at a progress thread,.

this all began in november 2008

100% standard appart from a blue flame exhaust system.
80k miles and mechanically sound as a pound
so, i started off be sending my wheels off to get refurbished in black and new tyres,

my first modification was my FMIC

i got the universal unit and found it fantastic, no real power increase but looks fantastic and fits, well, ok so the intercooler pipes to run under the car not around the engine and im sure i COULD reroute them but no issues have arrisen yet.

i then had a common fault where my pedal box snapped. got it welded back up the following day so no problems since. recomended fix for anyone this happens to.

next i bought a forge 007 recerculation have and a K@N replacement filter,
no increase in power or noise.

i then got my car remapped by my cousin who has a tuning company here in northern ireland( obd-autotune)

got 194hp and 220ft/ibs of torque.

with all this new power it wasnt long b4 something give in, or my who clutch system,
required a new clutch pedal, slave cylinder, master cylinder, flywheel, clutch plate, cover plate and release bearing, thankfully i wa still working in seat so got the lot cheap and fitted it one evening after work, instead of replacing it with an oem one i got an aftermarket VR6 unit. straight swap, HAPPY DAYS!!

i then got my cupra wheels back from the refurbishment company and went about getting them strapped on ASAP

the following day i get a lcr splitter

http://i364.photobucket.com/albums/oo89/adam180/Photo-0015.jpg

progress grown to a hult for a few months while i saved to get my turbo hibrided.
just so i could push the 200+hp barrier

i also contacted forge and asked for a sticker since they were so kind to sell me a BOV
and even more kindly of them they send me a keyring. 2stickers and something else but i cant remember what it was.

got my turbo removed, treated, refitted in the space of a week and noticed an increase in torque immediatly but with more boost comes the need for more fuel so im now started splassing cash on fuel parts, the 1.8t specialist who will be doing the new mapwork lives in cyprus so he will be sending the files forward and back through my cousin with dyno testing for each modification. hoping to have this finished by mid september, i will have the option of to maps switchable they a 2 way toggle switch in the **** pit, one for economy running low boost and one completely off the hook since it will only be active for short periods of time.

a friend of a friend has a 1.8t A3 and offered me a splitter R valve for cheep so bumped mine onto ebay, got the splitter R fitted and have really enjoyed the Hiss! and its nice that if i ever do get tired of it i can just adjust it closed.

sadly my ecu packet it last month but thankfully a local breakers yard had one in stock so just swapped the chips of, IMO and CAN and all was well again for a tenner, BEAT THAT!!

also, had the melted fusebox fault happen too,

 

[Adam180]

so while i was waiting for a replacement unit to come, it did a bit of chavving up

while in the engine bay area i fitted a 4.0bar FPR and some vacumm pipes were swapped for BLUE ones

and then yesterday i fitted my coilovers, for ebay shop, hottuning, i cant fault them perfect fit,
while i was doing the suspension i fitted all new mounts, bushings and bearings, PROPPER JOB!

all the way down baby!!!
got possitive camber at the front and negitive at the rear so its going in for 4 wheel kpi aligment done next friday,

and then finally, while washing it this evening i discovered i had a side light out so went to by local motor sports shop, and bought a side light bulb and wind deflectors, LOOK FANTASTIC and a great fit, one touch still works,
will put pictures up tomorrow of it dropped with the wind deflectors,

the last remaining mods are

seat sport front strut brace, (in transit)
CRN 40grove disks and ebc pads, (hoping to order this week coming)
and colour code my bump strips,

leaving me with the complete style and running gear to support the final remap going in

hopefully with the health to drive and enjoy it for a year or two,

thanks for reading and feel free to comment,
heres a few before coilover pictures taken last saturday, i will list the after fitting ones tomorrow, cheers

COMPLETE

 

[daves ibiza]

hey nice car mate did you get your fueling sorted im doing my hybrid now was it a big increase

 

[turbo009]

Nice and tidy cupra mate

 

[Ibiza125]

Nice car buddy! Do you not find the hottuning coilovers are a very crap ride? What sort of power are you getting from it so far?

PM'd you about a high flow manifold to add to the list

 

[daves ibiza]

hi mate did you get your hybrid done without mapping it and did it drive ok

 

[Adam180]

hey, hibrid is done and mapped to 243.6hbp
cant remember the torque,
yeah im running standard injectors at 4bar with a LCR fuel pump. seams to be plenty, i was expecting to have to run BAM injectors but the company that wrote the programming were able to get the power from standard ones, and its also now fulling on the over run. BEST BIT
so i get alot of bangs as it runs down

Guy turbo rabbit from greece did it.

hottuning coilovers are shite!

 

[DaNnY_LaD]

243bhp from a k03 hybrid ?

That way down on power

 

[turbo009]

243bhp from a k03 hybrid ?

That way down on power

Agree should be in the 270ish

 

[cupramillo]

Thats what i was thinking, the standard cupra injectors will be proper maxed out, id get a set of BAM ones and get the map tweaked to suit.

Nice car by the way!

 

[tarzan]

not good with injectors maxed out 243 bhp is like a ko3s almost.do like cupramillio says get a set of bam injectors and get more power

 

[Adam180]

lol, thank u all very much for your interesting comments,
i have always planned to put bam injectors in, but iv to drive 50 miles to and from work a day and im not even running 1.0bar of boost on a turbo built to take 1.4 so safety is the main thing until i get a run around diesel,

gonna put some more pictures up 2moro, car is really clean at the minute so ill snap up a few in the morning after a quick wash.

wore threw an ABS wire also, will get up a few pictures of that aswell
just added in 6 inchs of extra wire and heat shrinked the whole think and rerouted it, i have almost a degree of camber at the front so there is quite alot of lean on the suspension at full lock,

thinking about selling the car in a year so the rush is on to have EVERYTHING done to it b4 its next MOT in febuary

i was in touch with badger5 yesterday to buy there full braided hose kit, also going to purchase the 40groove discs i seen on ebay and my pads are like new so just keep the standard ones in for another month then get a set of ebc ones(any advice on compounds would be much appreciated) and racing fluid(the blue stuff) and that will be it all finished and minted up,

the only other exterior things i have planned it just to paint the callipers silver when im doing the brakes and colour code the bumper strips and maybe a set of aero wipers when my current ones are wore out.

interior wise, would love a set of buckets, thought about buying fixed back ones and having the cupra material put into them for an OEM look but dunno if i have the heart to butcher cupra seats, or else just a set of raceland leatherette recliners,(oppinions Very welcome as its a tuff decision, other than that, my wee car is finished

think im gonna try get a stardard R next or another cupra and keep it standard. buy a really good set of coilovers. next one will have to be red tho, love any car in silver, but the red R's and cupras look MINT!

 

[Adam180]

update!

just a few from the weekend

planning on buying some sound deadening material at the weekend and stuffing the doorcards and other interior trim, gonna take a note of speaker size and fitment too and look into replacing the standard speakers, im not want for sound systems but wouldnt mind a bit of good sound clarity every now and then

also on the down side, finding it hard to start on cold mornings

so far ive only tried new bosch super 4 plugs which made no difference,
compression test, made 170psi accross all 4 cylinders
did notice that spark plug number 4 was alot cleaner than the others so i swapped it with no.1 so ill cheak again in a few days time to see if the sooted one place in cylinder no4 is clean and the one fitted to no.1 is sooty, if u know what i mean(the old switcharoo) failing that gonna swap the injectors over and fit a fuel pressure gauge to see whats going on there, i have a 4bar regulator but no way of knowing what its really making.

one step at a time so i know whats helping and whats causing

worse case

new head gasket, so going to carry out a leakage test after the above and if worst come to worst ill buy a new head, put all new

valve springs
valves
cotters
oil seals
lifters
tappets
and maybe even a set of cams
prices a set with Cat today( may aswell prepare for the worst)

anyone have any issues like this
85k miles on it so sorting getting within the lose of compression area anyway

 

[Adam180]

More news

got my secondary air injection blanking plate on saturday and fitted it yesterday, quite simple come of the allen key bolts where hard to get at but got it all ripped out no problemo!

not having the SAI anymore left the power steering pump loom a bit.....floppy so cable tired it up out of the way. nice tidy job,
just wonder what resistance of resistor to use for the multi plug so i can shorten all the wires.

also spray painted my subframe, wishbones, and rear axel gloss black, just to keep them clean and protect from rust.

Any one Re-undersealed there cupras yet?