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Ibiza Cupra Tdi

Discussion in 'Readers Rides (SEAT)' started by alexjbass, Nov 16, 2014.

  1. alexjbass

    alexjbass Active Member

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    So - thought I'd keep track of the progress on my new car, with mods etc all in one place rather than littering up the forums with all sorts of posts!

    I have owned quiet a few cars, and they are always a compromise between economy (I have, and have had pretty silly commutes at various times) and fun as I really like my cars. My Renaultsport Megane DCi 175 was awesome but the 10k service intervals and its appetite for tyres and expensive oil (£70 on oil every service) was a killer. Loved my Abarth 500 but mpg wasnt amazing... We also have a fairly trick VW T25 so I decided on my last car to be sensible and buy something that would be cheap to run - lets just say I got bored, and thats why I'm now the proud owner of a 2004 Seat Ibiza Cupra.

    It seems mechanically very good, and unlike a lot of them doesn't have mega miles. Exterior wise it is a bit tatty - wheels need a refurb, and has some rust on a wing - just needs a good clean really. Also has the advantage of some Weitech coil overs, and amazing history and receipts.

    So, one very long train journey later, this is how I picked it up. It performed faultlessly on the 5-6 hour drive home, so I'm pretty happy;

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    This is the rust - will sort with a new wing;

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    Have quite a few plans - will keep this thread updated as I go.
     
  2. alexjbass

    alexjbass Active Member

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    So - first couple of upgrades. First thing (within 1 week of ownership) was to get rid of the EGR valve - went the Allard route which I now realise may not have been the most cost effective... but hey, its done a job!

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    Why get rid of the EGR valve? Check this out - a properly looked after Ibiza, full Seat service history and this is what the egr valce looks like;

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    You can spend all the cash you want on intercooler hoses and bigger turbos, but, that is seriously cutting down air flow and efficiency! I bought a bluetooth ODB reader off ebay and cleared the engine management light with the Torque app.

    Finally for now, I replaced the dated head unit wit something a little more modern;

    [​IMG]

    This Parrot Asteroid runs Android and is solid state (no CD drive) so fits nicely in the dash... and looks and sounds a hell of a lot better than the original!
     
  3. alexjbass

    alexjbass Active Member

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    So, a bit more progress this weekend. On Saturday, I did a fairly long drive to pick up a stainless exhaust system, with a Miltek De-Cat 3" downpipe, a green cotton filter, and a 2 new front wings (minus the rust of my current ones!)... Really looking forward to getting the 'zorst on (next weekend...)

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    Then today, I got my recently purchased spacers on... Decided to do it properly with H&R Black edition spacers;

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    Really chuffed with the result, here are some before and after pics (but before it had settled) to give an idea;

    Before;

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    After

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    How it should have left the factory?!

    I did 20mm all round... on a test drive I did get the occasional rub from the front (when pushing on, going into a compression, and turning... on one of our local country roads) so may raise the coil-overs at the front a couple of clicks to hopefully avoid this.
     
  4. alexjbass

    alexjbass Active Member

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    So - not quite as much done as I wanted as I burnt my hand during the week!

    I did get some rather nice pressed steel plates on (forgot to get pics), and also replaced the standard air filter with a lovely green cotton one;

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    I also replaced the rotten front wing with a 2nd hand replacement - its not a keeper, but will definitely keep the weather out - something that the original one couldn't manage;

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    I didnt get a chance to get a finished pic, but did get a pic of a wingless ibiza (after a bit of a clean) where you can see the lovely calipers/discs and swanky coil-overs!

    [​IMG]

    So - hopefully, exhaust and a couple of winds on the coilovers next weekend!
     
  5. smithysmoo

    smithysmoo Newbie

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    Can't believe how clogged that egr is...crazy.
     
  6. mitja155

    mitja155 Active Member

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    Most problems with clogged EGR is in cars with low millage per year. btw.. it nice black ibiza ;)
     
  7. alexjbass

    alexjbass Active Member

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    Hey mitja155 - the mileage is about 10k a year, but, wear on parts suggests its not been ragged... hey ho - its off now.

    So, this weekend got the Miltek De-Cat and Stainless system on. As ever (with used parts) its never as easy as first intended, but we got there! Most of the day was spent undoing Powerflow's shoddy workmanship - take the way they had fitted the de-cat to the rest of their custom system for example;

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    Luckily we were working in my mates garage, so had plenty of space and a shelter from the arctic conditions!

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    After a lot more fiddling, and accounting for Power-flow's tolerances, and general sorting, we got there (including a mad dash to tool station for some welding gas at 5 mins to 7!).

    Only have pics of the tailpipe, but, it revs a lot free-er, and pulls really nicely... there is also a nice rumble (not droney at all) and a nice bit of turbo noise!

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    Needs a clean, and me to fit the pressed steel plates properly!
     
  8. mjstokes85

    mjstokes85 Diesel Power

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    Will be keeping my eye on this for ideas for mine! Good work so far :D
     
  9. alexjbass

    alexjbass Active Member

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    So - couple more little bits and pieces; not much interesting tho!

    Spent a good day, properly deep cleaning the arches/coilovers/callipers etc so that I have a small hope of adjusting the coilovers (going to raise the front a click or 2, and drop the back a similar amount);

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    Also replaced the 'bodge' juilee clip on the exhaust with a nice stainless t-Bolt Clamp;

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    Planning on spending a good couple of days on it over Christmas - have a long list of jobs, and will update as I go...
     
  10. adamb87

    adamb87 cupra gone :(

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    Looks a nice motor you have there. Keep up the good work.:)
     
  11. Ickx

    Ickx Active Member

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    Nice look with spacers! Can you show me how looks front wheels after installing spacers?
     
  12. alexjbass

    alexjbass Active Member

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    Bit of an update - decided to get my wheels refurbished. I had spent quite a bit of time looking at possible wheel change options, but after some horror stories about AP Caliper clearance, aswell as the fact that I was happy with the stance of the original wheels, not to mention the way they looked, went with the refurb route.

    Got them done by a new company called Auto Body Solutions (www.autobodysolutions.net) who are based in Newton Abbot. They were excellent throughout the process - great comms, loads of pics and updates throughout the process, very helpful and accommodating, and most importantly a great job.

    So - before they looked like this;

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    Color wise, we went with the color that features on the Cupra grill sections - but with more flake so the wheels really pop when the sun hits them. They completed a full refurb - tyre off, strip to metal, blasted, lots of remedial action etc.

    Here are the pics;

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    And some full car pics;

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    Like I say - am mega happy with the service, and the result... really works on the car I think.
     
  13. alexjbass

    alexjbass Active Member

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    Got hold of some genuine Bosch Aero wipers to smarten up the front end a bit - its brilliant that Bosch have finally started making an Aero wiper that you can fit to older style arms;

    [​IMG]
     
  14. Seat_Lass

    Seat_Lass Active Member

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    Looks good
     
  15. Josephine

    Josephine Active Member

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    Good car, its looks makes me go crazy.
     
  16. alexjbass

    alexjbass Active Member

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    So - some updates...

    Have purchased a new turbo for the car. Includes various upgrades, and tweaks, and should be god for 250bhp with a remap... here is the item in question;

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    So - spent a day with my mate and it turned into a preparation day for the turbo fitting. FOund a boost leak (on the lower turbo hose), did an oil/filter change, removed the egr canister to ease access to the turbo, and various other bits and pieces (getting rid of any unnecessary engine bay bits!). Also sorted the supporting mods we will do (exhaust to add to the Miltek Cat-Back system and a new clutch) as well as some swanky bits of silicon!

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    So - we are looking at doing the turbo on our next meet - and fixing the lower boost pipe leak (bit of mig welding to the stainless joiner on the hose) at the same time.

    In other news, changed the head unit for a cheap JVC unit as I wasnt getting on with the old one. The illumination perfectly matches the Ibiza interior, and it works flawlessly.

    [​IMG]

    Big power on the way!
     
  17. alexjbass

    alexjbass Active Member

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    Just another couple of quick pics of the progress... Working on it last weekend;

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    And some of the unnecessary rubbish removed from the engine bay to improve efficiency/packaging/running/everything!

    [​IMG]
     
  18. alexjbass

    alexjbass Active Member

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    So - new turbo specs are;

    Its a hybrid, with T1749 housings and CHRA shaft with custom designed turbine wheel, compressor wheel and bearings.

    Seen plenty of 250bhp+ graphs using them!
     
  19. alexjbass

    alexjbass Active Member

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    So - nice and early yesterday morning, I setoff to my mates with this boot full of goodies;

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    In there I have, a new Milltek Cat Back system (2.5" bore), Darkside Developments Intercooler pipework, a tecniclutch clutch and SMF kit (rated to more than 600lb foot of toque as well as my new turbo. I bought the pipework kit as I kept experiencing boost pipes popping off and the comedy amounts of smoke were getting a bit tiresome! Anyway, plan was turbo and pipework, with clutch and exhaust at our next visit.

    So - the dismantling began! Car up, and bumper off;

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    Showing just how minging the intercooler was! Intercooler and most associated pipework out;

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    Here are the offending items;

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    Inlet manifold etc out;

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    And a whacking whole where the turbo used to sit;

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    So - here are the old and new turbos sat next to each other;

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    They are the same housing, but totally reworked inside... the most exciting bit being this diffrerence in size :drool:

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    So, new turbo on with a new manifold, and I got to business on cleaning out the inlet manifold, and got this lot out of it;

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    But, after a bit of elbow grease it did clean up nicely;

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    Blanked off the crankcase breather inlet into the intake, and will be fitting a catch can on our next day;

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    Now - the Darkside kit... what a nightmare! I know they say bits of bumper have to be cut, but, it was a hell of a job! Eventually, got the top pipe in place;

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    And the bottom one was a hell of a lot easier;

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    (Also - note the shiny intercooler :p).

    And thats where we eventually got to.... still working at 11pm! It was freezing! So, exhaust, catch can and clutch on our next session hopefully.... then mapping!
     
  20. Badger

    Badger Active Member

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    Great work! Look forward to an update :)

    I did my turbo change around this time last year and it was freezing! At least you have a unit to work in ;)
     

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