Tom.'s Darkside Developments big turbo'd Ibiza TDI

[Tom.]

Lots of good updates, time for one with a slightly depressive feel to it.

Bascially, did a trackday at Cadwell the end of last month, and managed to crack a piston.

The plan now is to rebuild the engine with a new set of pistons, which will hopefully go for cryo treatment, a set of Rosten forged rods, uprated main bolts, and all new bearings. Whilst the head is off, it will be going for CNC porting and flowing, then once the engines all back together, I'll be fitting a set of big bore PD injectors, and a 2265 turbo. Plan is to be at 300+bhp by GTI International. It's very much an achievable target, so long as i can get the head sorted quickly.

Some new bits have turned up in the post already.

Pistons:

Forged rods:

 

[Scott-o]

Seen that on your fb, glad to see your getting stuck straight back into it!

If you need the head doing on a deadline the place I work at on Saturday's does head modifications to any extent

 

[jonjay]

Perfect things to do tom. Good luck with it.

 

[1.9...stefan]

Looking forward to seeing the results

 

[Tom.]

More updates. Finally got my cylinder head ported and flowed!!!

Looks good, and has been done by possibly the best in this country? Work was done by Ric Wood of CNCheads.

Just need to finish rebuilding the head gear on it. Also had the inlet manifold matched to the inlet ports. All looks much better than before

Also, I figured whilst it was in bits, I'd fit a paddle friction plate to my clutch setup, to cope with the power im going to be running.

The bottom end is out, and hopefully will be rebuilt back end of this week/start of next week.

Only issue at the moment is that I've not been able to find a cam I'm happy with, so sticking with standard for now until I do.

 

[MarkWales]

Fairplay looks good work - but they are not cheap

 

[Gooner_Mike]

Liking these 2 pics. Sounds like you have some serious plans!

 

[jonjay]

Awesome Tom.

My ported and flowed head is just sitting there gathering dust

 

[Tom.]

Thanks for the replies lads.

Bottom end is stripped and in the process of being rebuilt. There is NO wear on anything! To say the engine has done 90k miles, its like brand new. Goes to show that looking after it pays off!

Also decided to go for the Newman cam, which should be with me by the end of the week. Going to be a last minute push to get this car running by Inters!

 

[jonjay]

Thanks for the replies lads.

Bottom end is stripped and in the process of being rebuilt. There is NO wear on anything! To say the engine has done 90k miles, its like brand new. Goes to show that looking after it pays off!

Also decided to go for the Newman cam, which should be with me by the end of the week. Going to be a last minute push to get this car running by Inters!

Newman cam - interesting. Has it been properly tested Tom? Guessing decision came from recommendation?

 

[rashcupra]

Oohhhh il be watching this space buddy!!! Honestly 300bhp in an ibiza is soooo good they weigh nothing and handle great! Gonna be good whrn done mate, il be keeping an eye on progress.

 

[Tom.]

Update time. As some will know, the engine is back in the car, and running. Took it to GTI International last weekend, and it got a lot of attention.

The car is now back in the workshop, and the gearbox is coming back out, as the company who rebuilt the bottom end, havent fitted the crankshaft oil seal right, and its pissing out into the bell housing. Hopefully only be off the road for a couple of days though.

Also got my new Forge intercooler fitted. Bumper has been well and truly butchered!

Made myself a catch can too. Fancied something a bit different, and knocked this together Friday morning before setting off to Inters.

 

[Gooner_Mike]

What bumper? Looking good as always pal. Much difference with the Forge cooler on?

 

[Tom.]

New engine build now has 1500 miles on it, and I've been starting to open it up a bit. Feels good.

Few new bits.

First, new cone filter. Decided to go with a Jetex one, as not only is it blue to match the rest of the bay a bit better, but it's also less restrictive, yet filters just as well as the Green cotton that was on there. I replaced the filter, as it had unbeknown to me, been rubbing on a jubilee clip, and worm through slightly.

Also treated myself to a new headunit, as i knicked the one I had in the Ibiza for my Corsa.

And a few general pictures.

 

[Scott-o]

Looks min mate, last two pics it's looking great!

Have you logged the airflow between the green an the jr filter?

When are you hoping to gather some power figures?

 

[Tom.]

Cheers Scott. I don't personally have any flow data for the 2 filters, but in the latest redline they did a test on them, and out of the cotton filters, the Jetex was the best. Was also cheaper than the Green filter!

Power figures won't be coming until I have the new turbo and injectors on, so couple of months I reckon.

 

[Tom.]

Off work all week so been tinkering with a few little bits.

First update is that a week or two ago, I finally got round to fitting my drivers side harness. Thanks to Adam Kelly for giving me a helping hand with it.

Yesterday, I decided I'd make use of the redundant rear windscreen wash, and set about bodging up a pikey intercooler spray.
Bit of spare vac pipe and some copper pipe later, and I now have an intercooler spray

As i can monitor intake temperatures on my VI monitor, I thought id put it to the test. I knew the effects would be minimal, but it is dropping the temperatures a couple of degrees, when at cruising. Have to wait and see what its like when under hard load. If nothing else, its making use of the washer now at least.

 

[Phil_JJ]

Every little helps!

 

[Tom.]

Pressed plates which will be going on this afternoon:

Mounted my boost gauge better, as before it was only stuck to the dash with double sided tape. Bolted it to the pillar now.

Quick picture without the front plate on.

One of Daz's super duper stickers.

New tyres on the rear:

And a picture of my boost gauge and VI monitor:

 

[Phil_JJ]

Looks a moody bugger in the front end shot!