mk4 ibiza cupra project

Adjay

Active Member
Sep 5, 2011
393
1
Donegal,ireland
Hi guys
I just copied this from another forum in Ireland to show you what I have done already.
I introduced new car
2004 seat ibiza Cupra 1.8 turbo petrol bbu engine.
It has been mapped already to 210hp but I'll
Be changing the map to revo once I have the full exhaust system. It has at the moment a milteck back box so I'll be getting a larger downpipe and sports cat. I'm thinking of going back to Wales to get the exhaust system custom made like I did with the Leon Cupra I had, since I was really impressed with the system. At the moment it has big black 18 wheels that I will
Be changing since they don't suit the car. I'll be going down to a wide black 17 inch alloy and then lowering it on my favourite bilstein setup. And the engine will be getting the full forge Motorsport treatment like my old seat. At the moment there is a bit of tidying up to do like original dark grey side skirts and getting rid of the Cupra r lip and instead putting on the ibiza Cupra upgraded lip which was an optional extra when new, just like the side skirts. It's a little animal to accelerate a lot quicker than my mates Cupra r and will out pull most things since it's so
Light.


I'll also be putting the larger rear top spoiler on instead of the one that is on it.


1bar boost on acceleration he he he

Right I'm accumulating a to do list.
So today I went to get the rattling exhaust checked.
So good news and bad news. Bad news the reason the exhaust is touching is because the flex on the down pipe is nearly through so it will need a new down pipe. The good news is I have an excuse for my wife to let me get a stainless system quicker. So I'm now shopping for a exhaust system with a 3 inch down pipe and sports cat, but I have come to learn that you dont always have to pay big money for big name exhaust systems. Like I priced up milteck and magnex and they want €1000 which is redicious since I had a custom system from longlife exhaust system before and the quality was amazing with a lifetime guarantee and the full system was €650. So I'm getting prices from them to get it done ASAP but I'm open to other options.

Right I decided to go to souhans custom exhausts in trim to get a custom made system, they seam to have a good name from people on forums
Progress so far 3 inch downpipe and sports cat very very nice welds.





A small video I took of the exhaust from the back[video=youtube_share;XOtQBbgKL9g]http://youtu.be/XOtQBbgKL9g[/video]

A small bit of a update.. I went to get two slow punctures fixed to find out the reason Their leaking is because of two cracked alloys so even though I originally wanted to by new alloys,it wasent ment to be this soon. Well now I'm in the market for 17 inch alloys going away from 18 that where on it.

Well today I had a fun day. I fitted intercooler hard pipe kit and all forge turbo hoses.
Some pics.
The kit

First I had to take the bumper off and cut it.


This is the difference between the original and the new hard pipe which has been proven to give 7hp more

Next was putting the new silicone pipes onto the pipe back to the turbo.


The finished kit.


It now boost 1.1 then back to 1bar so a increase of .1 of a bar.
Post man just brought me something I had been waiting for
Gearbox mount.

As I was still luring in bed drinking coffee and my hands where full . I got my wife to open the box for me. Silly woman was very suprised when she opened the box, she thought they sent me a condom, I formed her they where not worried about our contraceptive but in fact they sent some lube for the bushing and not us. Du du du.
Alloys Update.
I went to go try on the alloy options, and it turned out most would not fit even with spacers. My brakes are way too big on the front.

The problem was the not the offset but the spoke design the x factor and also we could not go bigger than a 20 'll spacer or it would be too past the arch So feeling sad that I couldn't get alloys I was losing hope until they brought out another alloy to try with a spacer but wasent dark or gun Metal, so I was sceptical about.

So i bit the bullet and bought them, my plans still is the spray them anthracite.


 
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Adjay

Active Member
Sep 5, 2011
393
1
Donegal,ireland
As you can also see I took off that rotten black paint that was on the grills I have the two spot light covers off t
Too,they are seaming to be problem to get the paint off I might just be buying new onces.
 

Adjay

Active Member
Sep 5, 2011
393
1
Donegal,ireland
Na only just bought it recently in the last two month. Probably was the previous owner. Had to get rid of his wheels there where shocking.
 

Adjay

Active Member
Sep 5, 2011
393
1
Donegal,ireland
New alloys just fitted. Also just fitted end usr disks with yellow stuff pads.

Cold side relocation kit just finished but now repiping the boost pipe to a new more tidied place.
 
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Adjay

Active Member
Sep 5, 2011
393
1
Donegal,ireland
A small update them alloys I bought went back since I wasent happy with them. And I bought a set of original alloys from the UK and got them sprayed in a22 bmw platinum grey.



I also tidied up the boost gauge pipe and fitted a new one. Now looks a lot tidied.
 

Adjay

Active Member
Sep 5, 2011
393
1
Donegal,ireland
Also fitted new plastic grills for the spot lights and also a nice set of ebc usr disks on the front with yellow stuff pads.. I have just ordered new t.I.p from forge motorsports. So can't wait to fit it.
 
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Adjay

Active Member
Sep 5, 2011
393
1
Donegal,ireland
Update.


Lots of bits bought.
New Forge Motorsport t.I.p
The old pipe


The new




Also got a nice new coil pack cover


And once I fitted the tip it showed up how mad the previous owners map was. And I was getting faults everywhere and the car wouldn't run so I changed a load of bits to clear the errors. I fitted a new n75e valve a new maf sensor also a new map sensors and also the ecu errors was showing up misfire in cylinder 3 and 4 so I decided to buy some nice new coil packs from Awesome.



I also got a new pipercross viper kit.
 
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Adjay

Active Member
Sep 5, 2011
393
1
Donegal,ireland
Once all this was fitted it was still going into perminant limp mode when putting car under load from low revs. So it was time to get sorted with Joe Power in Dublin and get it remapped.

So was down there last Saturday and what an amazing mapper he is, I learned so much about my engine ecu he is a very clever guy and really knows his stuff coming from his military background in electrics.

On doing the first run the car straight away went back into limp mode turned out to be a toque error on ecu so a safety precal came on. But we could see how crap the map was. The chart was all over the place so its very apparent it was a generic map. The ecu through the rev range was having to recorrect the timing all the time. See in the next picture.
 
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