Building a 1.8T Stage III+ Conversion

[Beetsport]

We have produced many 1.8T engine conversions and seem to be getting more and more interest lately thanks to Thesamba community and other forums as well as customer spreading the word. All along we have been working with a very popular company for helping us delete VW’s immobilizer that keeps the engine from starting without the original ignition key (from the donor vehicle). Their name is APR which stands for Audi Performance Racing. APR also installs our performance enhancement chip which brings the 1.8T stock horsepower from the 180 to 209 and torque from 174 (stock) to 242 ft. lbs. of torque.

We are now working with APR to produce a monster dream Syncro. The Stage III+ Turbo kit is capable of 340 horsepower and 320 foot-pounds of torque at the flywheel on 93 octane gas, while retaining stock-like drivability. Well not Vanagon stock that is . Slightly lower performance is experienced with 91 octane gas.

Several of you have seen the 1.8T Stage III+ engine going into the Syncro Dream machine at the Van-O-Rama slid out of the Synfalia on a clever engine/seat rail system.

Being installed with this engine conversion ( and are probably needed..) are Porsche 930 Axles, Decoupler with Solid Shaft, Big Brake Kit front and Thicker Rear Drums (good thing huh… ), Complete rebuild Transmission with Oil Deflectors, Air over Water Intercooler System. Must be forgetting something here. Oh, complete paint job, all window rubber replaced etc. etc.

Truly a very nice Syncro Westfalia!!!

Pictures shows are the engine from this Monster Syncro Dream at the Van-O-Rama. More pictures to come if the interest is there.

Enjoy

Strange seeing an engine hanging out of a Syncro. The center that is..

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'90 Syncro Westy 1.8T with 180hp 174 torque, CA safe!
http://H2oVanagon.com
http://www.thesamba.com/vw/forum/viewtopic.php?t=217285

[Alaric.H]

They might want to ditch the soild shaft a vc will do much more.
and a LLSD will make it stronger.

[insyncro]

Interesting.
I have been commenting on another thread about Subie vs. Bostig.
This setup you are building will most surely be powerful enough to be ranked with the WRX turbo and one of my worked EG33 Syncros.
I like how clean you keep the engine bay with all the workings.
I'll keep watching your build.
Keep up the good work.


As far as "hook up" and traction, nothing will match the solid shaft.
If you are in need of all wheel drive on pavement, it will not be a good choice. As was previously stated.


dylan

[Christopher Schimke]

Very cool! I am seriously considering doing a 1.8T swap myself and I have connections to APR, so I will definitely be watching this one as it comes together. Should be a fun one!
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"Sometimes you have to build a box to think outside of." - Bruce (not Springsteen)

*Custom wheel hardware for Audi/VW, Porsche and Mercedes wheels - Urethane Suspension Bushings*
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[wildenbeast]

Are you still developing the 2.0T as well? I would be interested to try out either the 1.8T or 2.0T at altitude.
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- Bill, '93 Eurovan Syncro Weekender (2.5 manual ACU)

[Alaric.H]

[1621]

Stefan,

Looks exciting. I'm interested in seeing how this one turns out. My 1.8T (your first paying customer) is still running strong with 40K+ miles on the conversion. Too bad really, I'd be interested in another 100 hp/lbs of torque. Keep up the good work, and please post some pictures of your current build.

Erik
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'85 Westy

[jacob.]

Man, I wish I had 10K to have you install the 1.8t. Talk about my dream vanagon!

Is anybody on the East side of the U.S.A. doing these conversions?
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[mtnwater]

[Dingchowping]

I've been turning wrenches for an APR dealer for several years and have built several Stage II, III, and III+ 1.8t motors. I can vouch for Beetsport's claims that their turbo kits are the most thoroughly sorted, best engineered, and most factory like drivability of any turbo kit out there. That said, I don't think the Stage III+ is the best idea for a vanagon. The huge Garrett turbo is pretty laggy and makes the 1.8t more of a high strung race motor. Awesome at the track (assuming you can put all that power to the pavement), but on the street its actually SLOWER than the K04 based Stage II. The K04 runs out of puff at higher RPMs so peak horsepower is down compared to the Stage III, but its just as responsive as the stock K03, so it produces massive torque through low to mid rage RPM's.

Want your cake AND eat it too? The 2.0 TFSI motor with the factory KO4 turbo/manifold (S3 and TTRS) and APR software makes the same power as a Stage III+ 1.8t but with the responsiveness and massive midrange torque of the Stage II. We've found that across the board the 2.0t is MUCH more responsive to performance tuning than the 1.8t. It also does away with the leak and failure prone cam chain tensioner, and oil feed issues to the turbo are also resolved.

The 2.0t isn't without its faults though. Certain models experience excessive wear on the cam follower for the high pressure fuel pump, and the stock integrated diverter valve fails often (this is resolved with the S3/TTRS's external vacuum actuated valve), and its HYPER sensitive to vacuum leaks, ala the old MC 10v turbo 5 cylinders.

I don't mean to rain on your parade, I actually think a Stage III+ in a Vanagon would be very cool...the noise that big Garrett turbo makes at full song is EPIC! I just wanted to throw out some different data points from a different point of view. Best of luck on the project.

TTFN,
Adam

[VWhead]

Hey Stephan, stageIII WOW! That syncro is going to Haul A#$.
Are you making a monster offroad synco for SdM,or a daily driver?
Can't wait to see more pics!
Keep up the good work!

Paul

[dredward]

[240Gordy]

[nealcapener]

I guess, that makes it the first mid engine Syncro.
Sure makes changing the oil and other maintenance easy.

[Beetsport]

[syncrodoka]

I have seen several american and import trucks in the junk yard that were Line-X/Rhino liner coated. It is a great way to hide rust to the point that it is unrepairable
Might want to rethink it before you have yours sprayed.

[Beetsport]

It sure looks great though... Not much of a rust problem here in the valley.
_________________
'90 Syncro Westy 1.8T with 180hp 174 torque, CA safe!
http://H2oVanagon.com
http://www.thesamba.com/vw/forum/viewtopic.php?t=217285

[syncrodoka]

I kicked a hole through the side of a rhino lined truck. Cancer was bubbling up but you couldn't tell how bad the metal was underneath.
My '86 syncro came from the valley and it is a really dry car. It must be nice to not worry about the rust monster.

[Beetsport]

Well the Mid-mounted engine found it's way into this Beautiful Syncro Westy. The Syncro Dream...

Creating a lot of horsepower is pretty cool. Trying to keep those 300 or so horses cooled down is another trick. This Syncro Westy is specially fitted with a couple ways to help out.

After Run coolant pump that circulates coolant after the engine is turned off until a pre-determined temp. Most ALL newer turbo-ed cars have an after run coolant pump. ...

Also an after run cooling fan that comes on when the engine bay area is above a pre-determined temp too. This also happens when the engine is turned off.

Water over Air Inter-Cooler with it's radiator mounted up front where the old spare tire went with a variable speed cooling fan. Cooler itself is on the right side of the engine compartment.

This Syncro Dream is a Dream to drive. Lets just say there is no hill out there that can slow this Syncro down. Feels like every bit of 300 horsepower and a very cool sound when the turbo spools up.. Puts a very large on my face! and probably the owner even more..

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'90 Syncro Westy 1.8T with 180hp 174 torque, CA safe!
http://H2oVanagon.com
http://www.thesamba.com/vw/forum/viewtopic.php?t=217285

[syncrodoka]

300 horsies