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NEW Highflow K04 exhaust manifold and hybrid 372bhp on lupo

Discussion in 'Badger5' started by ibizacupra, Jan 5, 2014.

  1. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    OKies.. some of you will know of what we've been busy on recently on k04 exhaust manifold solution.. Facebook is the most up to date place to see our updates btw
    https://www.facebook.com/Badger5Ltd

    Anyhows.. We have commenced testing of the K04 hybrid AND High Flow K04 Exhaust manifold combo.

    372bhp plot
    [​IMG]


    K03 hybrid on Lupo compared to the BBT K04 hybrid on my new test K04 high flow exhaust manifold...

    Looks promising power/temp wise.
    [​IMG]

    [​IMG]

    EGTs max on the plotted run 825'c measuring in normal k04-023 position factory stylee.

    I need a stiffer actuator.. This run was on 9psi actuator cranked to give 10psi actuator only boost.. Swapped to a forge one I had on shelf with white spring, and it ran less boost.. doh! 15psi BBT actuator to get asap and then continue with this and find the actual limit as I am not sure I'm there yet. EGTs being my guide, there's some left in it if I can hold more boost up top.

    Very pleased with the result so far.
    More mods to come to see what we get.

    Manifold works fine :)

    :)


    More to follow shortly... we're not done yet.
    15psi Actuator being fitted now, add some fresh vpower (not the fuel which has been sat in there since July) and we will see what it can do.


    FITTING GUIDE FOR HIGH FLOW K04 EXHAUST MANIFOLD IS HERE>> http://badger-5.com/bin/k04-manifolds/chinafold/K04 Fitment Guide.pdf

    Fitted Manifold: Note easy access for supplied stainless bolts and nordlock washers
    [​IMG]

    Badger5 High Flow K04 hybrid hotside
    [​IMG]

    Badger5 V3 80mm TIP complementing hybrid K04 manifold/turbo combination
    [​IMG]

    The NEW High Flow K04 exhaust manifolds - Ready to Order now
    [​IMG]
     
    #1 ibizacupra, Jan 5, 2014
    Last edited: Jan 29, 2014
  2. toosmiles

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    Excellent results m8
    is this KO4 high flow manifold an upgrade over the standard manifold on my cupra?
     
  3. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    there's more..
    max it can mustre in current hardware spec is below

    [​IMG]
     
  4. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    yes.
    in two versions.. std bore exit to turbo size and "upsized" to suit hybrid K04's of my spec, built by BBT for me to my spec...

    The std bore version we tested before xmas.. 315bhp on mini hybrid.. all was well.
    This one is the upsize one on my hybrid

    testing outright flow and temps etc etc etc

    Smallport AUM engine on lupo.. bog stock, just IE rods in it.

    372bhp max.... K04-023 based turbo

    Happy and satisfied @ same time.
     
  5. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    these are the respective two versions I have been testing
    [​IMG]

    [​IMG]

    The setup in action: Note minimal glow especially compared to thin wall tubular k04 manifolds
    http://youtu.be/2A-K_tRy_IE
     
    #5 ibizacupra, Jan 5, 2014
    Last edited: Jan 5, 2014
  6. Pommeh

    Pommeh Active Member

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    Do you have a ball park figure on the costs of each?
     
  7. wild willy

    wild willy Full Member

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    :worship:
    Well done Bill, the results from your recent testing on your manifolds has redefined what a
    K04 hybrid can achieve. A lot of work has gone into this and your willingness to try out new theory's not for the first time is what keeps the Badger5 team ahead of the competition.
    300 badger ft/lb @ 6500 rpm is awesome and I feel a customer has the best of both worlds....small turbo spool with Big turbo top end (entry BT at least);).
    All the component parts have complemented one another but the combination of the following has made for a killer spec:-
    WMI
    Badger5 high flow manifold
    Highly ported hot side
    Beach buggy Turbo
    K16 turbine
    3.5 inch down pipe
    63mm charge pipe
    Badger5 map.
    umpteen other tricks I've missed.

    What I wonder would a SEM and largeport head bring.:D
    Rather you than me road testing the Lupo, you'll need your experience of the Ibiza.

    The manifold I think you can safely say has earned its stripes and I look forward to having a decent manifold back in my bay.
     
  8. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    thanks carl.

    :thumbup:
     
  9. BoostHard

    BoostHard Complete Plonker

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    Those manifolds have had some serious working done.

    Remember seeing them on your bench last time I was there.

    How long does it take you to port each manifold? Looks seriously time consuming.
     
  10. JDUB 20V

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  11. toosmiles

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    nice,so is it a straight bolt on,straight swap over for the 'upsized' manifold for mine?
     
  12. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    Upsize needs upsize turbo hotside. Std size version for std size hotsides.

    Sent from my HTC One using Tapatalk
     
  13. alias

    alias Active Member

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    Wow, top work! If ever there was a reason to not bother with BT...

    Who casts the manifolds Bill? Any idea what kind of cost they might retail for?
     
  14. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    manifolds are £292.67+vat, and include stainless steel turbo bolts, Nordlock washers, OE gasket to head + turbo to mani gasket for std sized outlet version. Upsize version will run gasketless.

    Machining and special hotsides for the hybrid are available from me/BBT...
    The upsize unit would work with a modified turbo hotside to bore match and allow me to "tickle" it to assist its flow performance.

    I am finialising costings on the machining of hotsides currently.

    thx
     
    #14 ibizacupra, Jan 6, 2014
    Last edited: Jan 6, 2014
  15. JDUB 20V

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    Look forward to seeing you in few weeks :)
     
  16. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    Mostly the Machine shop now on the version I have evolved to...
    I finish deburr and hand blend after the CNC machines done the major work on opening out stuff.
     
  17. RDS

    RDS OEM+

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    Bill, if I sent you the BBT hybrid I've got sitting in the house will you port the hot side? If so let me know the price and I'll sort out sending it down

    Cheers
     
  18. Hobbiniho

    Hobbiniho Active Member

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    wow that is some seriously impressive numbers i take it there will be lots of testing done? (has been done?) on these manifolds to ensure crack free? or is than not a problem with this design?
     
  19. JDUB 20V

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    Bill is the 3.5 downpipe deffo needed or can i use a Miltek downpipe & decat bud? Not sure on bore size off top of my head.
     
  20. BoostHard

    BoostHard Complete Plonker

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    Miltek is usually 2.75

    Sent from my GT-I9300 using Tapatalk
     

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