May 27, 2008 - Stage 2?



A quote from the Feb. 1 update for this project:

We'll keep you updated on the GLI and how the kit is performing with even more miles on the clock. We'll mention here that our customer is currently saving up for VF RS/R version of this kit, with the larger GT2871R turbo and upgraded rods and pistons. I guess at some point we'll be determining if the DSG transmission can handle even more power - right around 400-hp worth.

Think back to the last update while considering the above quote and you'll probably easily see where this update is headed. The biggest twist so far is that since the VF RS/R kit is not yet available, we're going a different route altogether.

With the RS/S kit we already have an excellent compilation of quality parts, so it makes sense to use as much of them as possible. So while the turbo and GIAC programming will not be used from here on out, the turbo manifold, intercooler and plumbing, fuel injectors and fuel pump will al be reused. We're not exactly building our own version of the RS/R in that we'll be keeping the stock pistons and compression ratio and substituting a larger Garrett GT3071R turbo for the RS/R kit's GT2871R. Tests have shown that the difference in spool-up time between the two turbos is minimal when used in an FSI environment and since it's unlikely that our customer will ever be satisfied with any level of power for very long, the bigger turbo gives us more headroom for the future.

To work with the VF manifold we'll be using a (relatively) small T25 exhaust housing, but we don't expect to see a noticeable compromise in output or efficiency. Since we expect to go beyond 350-whp we've ordered up a set of Integrated Engineering forged connecting rods for some much needed bottom-end extra strength - for now and in the future.

Ultimately none of these high quality components means very much without some quality engine programming to make them all work together. As luck would have it, fifteen52 is a Revo Technik tuning partner and as such we have access to their yet-to-be-released 2.0TFSI GT3071R programming upgrade. Besides putting out quality programming options, Revo gives its dealers room to tweak for different fuel and timing scenarios.

By now some of you are wondering, "what about the completely stock DSG transmission - is it safe to put so much power through it?" The answer to that is that we do not know, but sure as hell aim to find out. You see, our customer understands there is an option should he require extra strength as far as his transmission his concerned, but he also understands that currently that option is priced in the $7k+ range. It's just a matter of time until other options become available and when this happens there's no doubt the cost will come down dramatically. We have good reason to believe he'll be just fine until then, and if something happens in the mean time we have a few tricks up our sleeve.

Below you see the pics of the disassembly process - nothing too interesting here - and tomorrow we'll begin by installing the new rods as well as removing the 28R turbo and installing the new 3071.
















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