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Building a highly successful and competitive race car from a standard road going Audi TT was never going to be easy. The road car, although beautiful in design and superbly engineered, doesn't lend itself naturally to the race track. It's worse trait is its weight. You can strip all the unwanted parts out including airbags and trim. Ultimately the only way to overcome weight is with raw power.
A remap brought the original standard engine up to a reasonable 270 BHP with a race exhaust. It didnt last long and melted no 4 cylinder whilst being tested by Track and Race Car magazine.
We looked around for a complete big turbo kit that would Fit, be complete, well developed with gauranteed power and reliability. Nothing on the market fitted our requirements, in fact what was available was so far from what we needed, I was seriously worried this would be the end of our project. To make things worse, some serious tuning companies had tried to develop Big turbo kits and failed misserably.
The rescue call came from the UK's main importer of Garrett turbos. They had been looking for someone with our credentials to develop and produce a big turbo kit for the 1.8T engine for some time. They offered us full support and access to the complete range of Garrett ball bearing high performance turbos.
With a target power of 350 BHP, we selected the Garrett Gt2860RS. We needed to balance top end power with fast spool up time. The 'Disco Potato' as it is known fitted the bill perfectly.
The next step was to manufacture a reliable and strong exhaust manifold. We looked into equal length Stainless Steel fabricated manifolds. However, to win a race you must first finish, regardless of power. The tubular manifolds are notorious for cracking and when they are positioned down the back of an engine, thats really not a good idea. Cast manifolds had a better reputation, to be doubly sure we opted for a high nickel content material which can withstand extreme temperatures in motorsport. The exhaust manifold we now produce has been the backbone of our kit, it flows beautifully and we still haven't had one fail!
The connecting pipework had to flow smoothly and fit perfectly. Negotiating the 4 wheel drive transfer box is tricky. The pipework we now produce in house has been tweeked throughout the development of the kit. It looks beautiful in 316 stainless steel, Tig welded and polished.
The small details of the kit are where some serious time was required. The flow and return of the oil and coolant is critical to the reliability of the turbo. Extra brackets and clamps are also fabrictaed to complete the finer details.
The first race car kit was mapped by AMD Technik in Bicester. The car ran 360 BHP without fail over 2 long seasons. The engine was standard internally and the fuel system was standard too.
With all this knowledge and experience it made great sense to share the kit with others. Since its first appearence we have sold over 30 big turbo kits for 1.8T engines. We have succeeded where other have failed miserably. We are proud and passionate about our product.
At the end of 2007 we decided to push the development further. More power for the race car! Over the years we have rebuilt and tuned many 1.8T engines. We have put this knowledge into a new race engine which uses Forged 82.5mm 8.5:1 low compression pistons and our own forged pistons. The new kit uses the bigger still Garrett GT2871R. Fuelling is taken cars of by Genesis injectors and an in line fuel pump. Our tuning partners at Revo have developed a custom map and the car is now producing 400 BHP!
In 2008 we will be developing the 400 BHP kit further on the TT. We will also be introducing the new Seat Leon 2.0TFSI race car to the curcuits using our new turbo kit producing 340 BHP with intentions to build a 450 BHP 2.0TFSI kit over the season.
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