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Thread: Sams TFSI turbo conversion (maybe!?)

  1. #31
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    Exhaust went in today. The down pipe section of the K03s/K04-001 dump was cut off and in its place a dump off the TFSI turbo was made up. From what I can gather the flange is the same between the earlier BorgWarner Mk5 K03 version of this turbo, so if I have to change to that iteration then it'll fit too. The K04-064 from the Mk5 Pirelli and Mk6 'R' has the same flange but I'm not certain its in the exact same spot. Either way I'm pretty sure 3 turbos will work on this dump/flange. So the conversion is complete.....no going back!

    Sams TFSI turbo conversion (maybe!?)-img_3258-jpgSams TFSI turbo conversion (maybe!?)-img_3254-jpgSams TFSI turbo conversion (maybe!?)-img_3255-jpgSams TFSI turbo conversion (maybe!?)-img_3253-jpg
    Attachment 54148Attachment 54149Attachment 54150
    The orientation on these pics is a bit whack but you get the gist. So it turned out that the 90 straight off the flange did work. Its mouth had already been opened up. It just had to be cut closer to the bend to make it eliptical in the vertical plane and then the sides stretched wider. Its ever so slightly angled towards the drivers foot and then all it needed was a small little 45 degree to turn it under the car. I got it flanged too. It might be fine on a hoist to twist and turn 2 meters of one piece dump pipe out of the car but not when you are lying on your back on stands in your garage or at the track. The flanges allow me to drop the centre section straight out the bottom and then removing the down pipe is just some very accessible nuts.
    I;ll probably drive it tomorrow on the stock MAF and old turbo tune just on the spring and the next mission will be upgrading the TIP for the bigger MAF and getting the juicier base map into it.
    Last edited by sambb; 09-06-2022 at 11:38 AM.

  2. #32
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    Awesome stuff Sam!

    Glad you finally decided to go ahead with the swap!

    Hopefully fulfils your expectations for a while.


    Sent from my iPhone using Tapatalk

  3. #33
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    well my hand was forced. managed to damage a blade on the K04-001 at Luddenham. I thought I'd just cooked the bearing but it turned out the whining noise was a shaft not liking its new 'balance'. Lucky I didnt do the last session. This was all meant to go in with the new engine once that was finished but its getting a guinea pig run on this engine now. At least when the new engine goes in this tune will allow it to be turn key ready to run and close enough if the small port to large port conversion won't be too big a difference.

  4. #34
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    INLET SIDE:

    Sams TFSI turbo conversion (maybe!?)-img_3260-jpg

    You just need to cut the Forge or whatever brand turbo inlet hose (TIP) 2/3rds of the way down for a pipe off the compressor. Catch 22 is that if you cut the TIP off lower, the PRV pancake for the PCV system will be able to go in where I've plugged BUT the hose diameter will be too narrow to fit over the turbos pipe. Cut it where it'll fit and this happens. Not a biggy - I'm running as vent to atmo catch can at the moment and i'll just have to throw in a silicon tee pipe down the track to be legal on the PCV side of things. A normal 2.5in to 3in 90 degree pipe fits too but then you need take offs somewhere else for the N75 valve, PRV, diverter valve and brake booster amplifyer thingy. This was the most convenient.

    Sams TFSI turbo conversion (maybe!?)-img_3262-jpg

    If you are upgrading from the stock 2.5in MAF to a 2.75 inch I.D MAF off an S3, then you need to graduate the forge TIP's 2.75in silicon pipe opening up to 3inch so that you can fit it. I did that with some bits I had on hand and managed to get the MAF into a spot where the original cable would reach. It'll have a heat shield under it all once I'm set with where everything will go.

    Sams TFSI turbo conversion (maybe!?)-img_3264-jpgSams TFSI turbo conversion (maybe!?)-img_3265-jpg

    I could have run with the pieburg TFSI boost solenoid which is situated on the turbo itself. Access to it turned out to be easy provided you have the car in the air but what I really wanted was easy access to everything. So I ran the plumbing up from the turbo so that I could use the original N75 in the OEM mounting position. I'll need to extend the cable a bit but thats not an issue.

    Sams TFSI turbo conversion (maybe!?)-img_3268-jpgSams TFSI turbo conversion (maybe!?)-img_3267-jpg

    The diverter valve turned out sweet. I had always been running a pre-throttle body position for the diverter valve. With this setup I was able to re purpose the factory diverter valve pipe to give me a pretty straight shot at the T-pipe that I have ahead of the throttle body. Turbosmart do make a fully pneumatic replacement for the factory electric DV that comes with this IHI turbo. Its the neatest solution but again I like having everything where I can see/get to it and the pre throttle position for the DV has some boost response advantages and is how the diverters are run on the Golf 6 'R's with the bigger K04-064s.

    Sams TFSI turbo conversion (maybe!?)-img_3271-jpg

    starting to take shape. Just need to sort an airfilter/box, find some big P-clamps to hold all the inlet in place, wire up the N75 solenoid. Longer term I'll integrate the catch can into the intake when some more bits arrive.
    Last edited by sambb; 10-06-2022 at 01:22 PM.

  5. #35
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    Thumbs up

    If the forum back end here had likes you would be drowning in them.

  6. #36
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    Thanks mate. appreciate it.


    Just putting the Dave base tune in now. Spent the day getting things a bit more finalised.

    confirmed the upgraded MAF housing internal diameter. The MAF is off a 6.0L W12 Phaeton.
    Sams TFSI turbo conversion (maybe!?)-img_3281[1]-jpg
    Sams TFSI turbo conversion (maybe!?)-img_3286[1]-jpgN75 wired up. Needed a a 6 inch extension soldered in to reach.
    Sams TFSI turbo conversion (maybe!?)-img_3287[1]-jpgFilter on. Ready to tune!

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