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-   -   HYDE16 Build Thread - Project Jekyll & Hyde (http://www.golfmk6.com/forums/showthread.php?t=55924)

HYDE16 03-12-2013 01:41 PM

HYDE16 - Project Jekyll & Hyde Build Thread
 

Jekyll Is Dead! Long Live HYDE!
My previous HYDE16 - Project Jekyll & Hyde Build Thread theme led me to build a daily driver while striking a fine balance between a daycare shuttle during the week (JEKYLL) and aggressive performer during cruises, highway pulls or at track events (HYDE). I’ve focused on increasing stiffness, correcting or improving suspension geometry, adding traction, and realizing better overall response from driver input while limiting NVH, rattles and feeling beat up from long drives. After studying the effects of water methanol (thanks to Jamie@APR and tech@Aquamist), I was able to safely max out the ported & polished APR K04’s power potential with direct port water methanol and the APR V3.1 100 octane software file with 93 pump gas on a daily basis. To go a step further, I tested the limits of running E85 blends as direct port water methanol allowed for enough fueling headroom in the OEM fuel system to slowly increase E85 blends, ultimately allowing me to run E50 safely on a daily basis. Ever after all of this, the K04 still showed its limitations when I was decimated by an APR Stage 3+ MK6 Golf R, and after that, I decided it was time to move up to a big turbo build. Even though it was not required for this turbo kit, I decided to have the engine built to realize the full power potential of this big turbo choice. Now I can document what was needed to attain and effectively use this level of power. This thread is dedicated to building a big turbo GTI complete with engine and fuel build by Pag Parts Turbo, Pag Parts EFR 7163 Turbo Kit and supporting drivetrain build. As the build moves forward in its final stages, I will post updates with photos in this thread and the complete chronological, step by step build photos on a daily basis on Instagram (@becauseryanjacobs) for those who want to follow the progression. Also follow my HYDE16 - The Pag Parts EFR Turbo Kit Thread.


The Pag Parts EFR 7163 Turbo Kit:
After learning that PPT was developing a complete big turbo setup for the 2.0 TSI/TFSI market, I called Arnold to hear more about his upcoming turbo kit. He explained that he wanted to provide a fully bolt on, v-banded, singe scroll turbo kit with a choice of the EFR series 6758 .64AR or 7163 .85AR turbo (both internally gated) for stock engines or fully built engines with varying software options. In our conversation, Arnold explained that he wanted to provide a turbo kit which does not require upgraded engine internals or additional fueling (reduced output software file) but had the future power potential if a customer decided to have the engine built (higher output software file) and install additional fueling options (full output software file). When reading about the countless engine builds Arnold has completed for some of the highest HP Audi & VW owners, I decided to go all out and have PPT design a fully built long block engine to realize the full potential of his turbo kit. Needless to say, I am very proud to introduce the first PPT EFR 7163 Turbo Kit for the 2.0 TSI (EA888 Gen 1 & Gen 2) platform.

Big Turbo Goals:
Aside from wanting to build a higher power “street spec” engine for daily driving, listed below, I have a few specific goals or milestones I want to accomplish over the next year or two.
-Build and develop a GTI transmission to handle this power level (see Drivetrain explanation below)
-Develop water methanol / E85 files with the use of Eurodyne Maestro 7 Tuning Suite for highest HP/TQ stats
-Slipstream Racing Event – 1/2 mile dig or roll stats
-Island Dragway – 1/4 mile stats
-Updated article in European Car & Performance VW (European Car Sweating the Details, Perfecting the VW GTI One Component At A Time, March 2015 / Performance VW Built Not Bought, April 2014)

Audio:
Cadence Amplifier
Digital Design Subwoofer
Supreme Sound Custom Slim-line Subwoofer Box / Click Here for my HYDE16 review

Braking:
Audi TT RS Brake Scoops / Click Here for my HYDE16 review
Audi TTS Master Cylinder
Wilwood Forged Narrow Superlite 6R Big Brake Front Brake Kit & SS Brake Lines
Hawk Performance HB544B.628 HPS 5.0 pads
TyrolSport Master Cylinder Brace / Click Here for my HYDE16 review
VW MK5 R32 Rear Brake Conversion with StopTech 310mm Rear Rotors & SS Brake Lines

Drivetrain:
034Motorsport Street Density Engine Mount / Click Here for my HYDE16 review
034Motorsport Street Density Transmission Mount / Click Here for my HYDE16 review
Advanti Racing Storm S1 17"x9" ET45 Wheels & Bridgestone Potenza RE-71R 245/40/17 Tires
APR Pendulum Mount with SuperPro Bushings
BMC Short Throw Clutch Stop
Clutchmasters FX400 with DMFW
DieselGeek Sigma 6-Speed Short Shift Kit
Dimple Magnetic Transmission Drain Plug / Click Here for my HYDE16 review
Driveshaft Shop 6-Speed Manual 500HP Level 2.9 Direct Bolt-In Axles
ECS Tuning MK6 GTI 6-Speed Clutch Bleeder Block / Click Here for my HYDE16 review
Fluidampr TSI Crank Pulley / Click Here for my HYDE16 review
GS Auto Solutions – Push Clutch to Start Bypass Harness
Peloquin’s Limited Slip Differential / Click Here for my HYDE16 review
Raceseng Circuit Series Shift Knob / Click Here for my HYDE16 review
Racingline (formerly VWR) Subframe Mount
TyrolSport Solid Shifter Bracket Bushing Kit (SSBB) / Click Here for my HYDE16 review
USP Motorsports 1st-2nd & 3rd-4th Steel Shift Forks / Click Here for my HYDE16 review
USP Motorsports Stainless Steel Clutch Line
VW “F” Version Throw Out Bearing & NLS 02Q Shims
VW MK4 GTI Metal Shifter Cable Bracket

Drivetrain - Pending:
Custom synchro or dog gearset
Darkside Developments 02M / 02Q 5th - 6th Selector Fork Reinforcement Kit
Tyrolsport x ARP 02Q Bolt Kit

Engine Bay:
Audi R8 Oil Cap
Custom Powder Coated Red Valve Cover
Custom Powder Coated Alien Silver ECS Tuning Catch Can
Custom Powder Coated Alien Silver Intake Manifold
Custom Powder Coated Alien Silver Neuspeed HI FLO Air Charge Pipe
Eurocars Billet Fender Bolt Kit / Click Here for the thread discussion
Forge Motorsport Washer Bottle Filler
Porsche 991 Coolant Cap
PTP Turbo Firewall Blanket / Click Here for my HYDE16 review
VW MK5 R32 Belly Pan
WhanAB Billet Aluminum Dipstick Handle

Engine Build:
ARP Head Studs
ARP Main Studs
Audi Allroad Intake Manifold
Audi Rod Bearings
Brute IX 144x21mm Connecting Rods (rifle drilled)
CP Carrillo 83mm Forged Pistons
INA Engineering Coolant Flange
INA Engineering Rear Main Seal
Supertech Inconel Exhaust Valve Set with Singe Groove Keepers
Supertech Inconel Intake Valve Set with Singe Groove Keepers
Supertech Exhaust Springs with Titanium Retainers
Supertech Intake Springs with Titanium Retainers
Tool Steel 21mm Wrist Pins
VW Main Bearings

Engine Fueling:
Aquamist 10L (2.6 Gallon) Baffled Tank / Click Here for my HYDE16 review
Aquamist Check Valve Jets & Manifold
Audi 8V S3 Direct Injection Fuel Injectors (4)
Audi Allroad Fuel Rail
Bosch EV14 Twin Spray Port Fuel Injectors (2)
PPT Custom Fuel Basket with Walbro 450 LPFP
PPT Port Fuel Injector Holders (2)
ProMeth Pulse Series Solenoid
Torqbyte BM1 Bluetooth Unit
Torqbyte CM5-LT Controller
Torqbyte 4-bar MAP Sensor
Torqbyte PM3 - Pump Amplifier
Torqbyte VAG Plug-n-Play Adapter

Engine Miscellaneous:
Audi R8 Coil Packs
Braille GU1R Green Lite Lithium Battery Combo / Click Here for my HYDE16 review
Dimple Magnetic Engine Drain Plug / Click Here for my HYDE16 review
ECS Tuning Catch Can
FourSeasonTuning Battery Bracket
GruvenParts 2.0T Billet Intake Manifold Linkage Arm / Click Here for my HYDE16 review
Motul Sport Ester 5w50 100 Synthetic Engine Oil
Neuspeed HI FLO Air Charge Pipe
Neuspeed HI FLO Turbo Discharge Pipe
NGK BKR8EIX Iridium (2668) Spark Plugs
Pag Parts Turbo Front Mount Aluminum Intercooler
TyrolSport UG Aluminum Radiator / Click Here for my HYDE16 review

Engine Software:
Eurodyne EFR 7163 Software File (Pag Parts Turbo tuned with Eurodyne Maestro 7 Tuning Suite)

Engine Turbo - Pag Parts Turbo (PPT) EFR 7163 Turbo Kit:
Borg Warner EFR 7163 .85AR (internally gated)
PPT 3” Stainless Steel Flexpipe
PPT 3.5” MAF Housing
PPT 3.5” Silicone Intake
PPT Coolant line kit
PPT Oil feed line kit / flange adapter
PPT Oil return line kit / flange adapter
PPT Single Scroll V-Banded Cast Stainless Alloy Exhaust Manifold
PTP Turbo EFR Turbo Blanket
PTP Turbo Lava Downpipe Wrap
SPM 3” Custom Turbo-back Track Exhaust
Tial Sport MVI-2.5 Internal Wastegate Actuator
Treadstone Performance HoneyComb MAF Mass Air Meter Airflow Straightener
TurboSmart Kompact VAG II Plumb Back Diverter Valve
VW 2.5 Bar MAP Sensor

Exterior:
deAutoLED de360 Fog Light Kit
deAutoLED License Plate Kit / Click Here for my HYDE16 review
deAutoLED Parking “City” Lights
deAutoLED Reverse Lights
deAutoLED Turn Signals
DeutscheAutoParts Exhaust Alignment Bushings / Click Here for my HYDE16 review
Glasstopfen Rear Hatch Wiper Delete
Go2Customs Headlights
Maxton rear diffusers
Painted Carbon Steel Grey Rear Hatch Assembly
Painted Carbon Steel Grey Side Markers
Painted Silver Exhaust Valance
Painted Silver Front Lip Spoiler
Painted Silver Mirror Caps
Powder Coated Black Rear Brake Calipers
Splitter’s P.R. Front Splitter
SRS-Tec Rear Spoiler Addon
Tinted Rear Reflectors
USP Motorsports RFB LED Puddle Light Kit (4-Door) / Click Here for my HYDE16 review
VW Golf R LED Tail Lights
VW Highline Front Grille

Interior:
Corbeau RRB Seats
deAutoLED Interior Cabin Lights
deAutoLED Interior Trunk Light
deAutoLED Rear Footwell LED Lights
deAutoLED Stainless Steel Seat Inserts
Double Apex Volkswagen USB Charger / Click Here for my HYDE16 review
Ecliptech Shift-P2+
German Automobile Technic E-Brake Handle
German Automobile Technik Steering Wheel
Innovate Motorsports ECB-1
Polar FIS+ Advanced (F03) MFD Display / Click Here for my HYDE16 review
ProClip USA Car Mount & Phone Holder
Redline Goods Perforated Leather Shift Boot
Stinger RKXTK Roadkill Trunk Kit
VW Auto-Dimming Mirror with Homelink
VW Dash Cubby
VW Euro Switch / Click Here for the thread discussion
WeatherTech Digital Floor & Cargo Liners

Suspension:
H&R Front 26mm & Rear 24mm Sway Bars
ST Suspensions XTA Coilover Kit / Click Here for my HYDE16 review
Stern Rear Subframe Brace
SuperPro Control Arm Kit / Click Here for my HYDE16 review
SuperPro End Links
SuperPro Roll Centre Adjusting Ball Joint
Swift Rear 400lb Progressive Springs
TyrolSport DeadSet Rigid Front Subframe Collar Kit / Click Here for my HYDE16 review
TyrolSport DeadSet Rigid Rear Subframe Collar Kit / Click Here for my HYDE16 review
TyrolSport Hatch Brace / Click Here for my HYDE16 review
Unibrace UB
Whiteline Rear Trailing Arm Front Bushings / Click Here for my HYDE16 review

Special Thanks To:
apa11393, Erball, eurocars, GTR Killer, James9120, Jamie@APR, Jeff43, Jettaglis, jettaglx91, kern417, Mdhollis, RGTI13, Simmsled, tech@Aquamist, the bruce, U-20T, *****2.0t, wndwsdwngti860 and many others from the GolfMK6 Big Turbo Discussion Thread

Work Done By:
Caste Systems Performance - Norwood, NJ
Detailer’s Domain - Norwood, NJ
KMD Tuning - Saddle Brook, NJ
Linden VW - Linden, NJ
Pag Parts Turbo - Deer Park, NY
Redline Speed Worx - Washington, NJ
TyrolSport - Ridgewood, NY

Media Coverage with Photo Credit to M.Spad Photography and Mike Hyatt Photography:
Automobile Blog, How One Owner Built a 375-HP 2011 Volkswagen GTI, July 2015
CarBuzz Reader's Ride, December 2013
CarBuzz Facebook Page Discussion
Reddit, How One Owner Built a 375-HP 2011 Volkswagen GTI, July 2015
European Car Sweating the Details, Perfecting the VW GTI One Component At A Time, March 2015


PASMAG Waterfest 23, July 2017


Performance VW Built Not Bought, April 2014


Special Thanks To:
Allset, Arin@APR, Bender, bostonaudi, bRett32, Bronson@APR, crew219, dasVW.com, DRedman45, GlfSprtCT1, grambles423, GunKata, GunMetalGTI, HalvieCuw, hockeystar17mnj, Jamie@APR, Jason3d, Jeff43, Jmnj, John@Unitronic, Junker, KanDyWyte, Malaki, mdhollis, Modshack, Mustache Rash, neonphase, panda_man22, Paul@DeutscheAutoParts, prospal, Quoddy, RioGrandeValley, Simmsled, Simple_John, smrtypants44, Steelcurtain, Tecni, the bruce, U-20T, Veedoubleme, Wastegate13, xola3que

Desert MVIGTI 03-12-2013 01:55 PM

That is one well sorted GTI.

Love the Hartmanns. Which offset? How much ride degradation from your 18's? Any rub?

HYDE16 03-12-2013 01:57 PM

Quote:

Originally Posted by Desert MVIGTI (Post 1094226)
That is one well sorted GTI.

Love the Hartmanns. Which offset? How much ride degradation from your 18's? Any rub?

Thank you sir.

Hartmann's are ET47, fronts used 3mm spacers to clear Forge BBK so ET44. 0 rubbing at all with 225/35/19 tires and Driver Gear springs. Wheels and tires were only on for a photo shoot and will go back on next week for good.

HYDE16 03-12-2013 02:27 PM

HA!

HYDE16 03-12-2013 02:30 PM

Thank you! I have yet to find a MK6 GTI with these RS5/Audi TT-RS wheels in bright silver. I painted the side mirror caps to match.

I am unsure if I should paint the front VW lip and the rear exhaust valance to mimic the Audi TT-RS look.

boostedmk6 03-12-2013 02:35 PM

Wow... I absolutely love the stealth look you got going. Very well done.

A_Bowers 03-12-2013 02:37 PM

Very nice!!! Another CSG Brother!

Im slowly building things up to get to where you are at on the suspension setup.

HYDE16 03-12-2013 02:40 PM

Thank you, I guess I'll leave the front and rear lip unpainted.

Desert MVIGTI 03-12-2013 02:41 PM

I almost hate to bring this up in the warm glow of your performance parts resume, but where did you end up sourcing that metal water pump?

HYDE16 03-12-2013 02:43 PM

PM sent.

corrado917 03-12-2013 02:49 PM

Great build,Sub'd :clap:


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