I posted some pictures up in the "mk4 single picture thread" on the mk4 Polo which belongs to one of my best mates, and some people said they'd like to see/read some more about it. Most of the info here is just copy-pasted from the thread I'm already working on E38 for me mate (his English isn't that fantastic plus he's more busy with his mk4 then with interwebz

So like I said, it sadly isn't mine :mellow: (if anyone is interested, this is my own mk4-project on CP) but fortunately it belongs to one of my best mates, who's been keeping up with the bloody thing for a couple of years, in which the project kind of got out of hand. But hey, that's the fun of it right?

Ok, so what's project "Double Dutch Dub", well, basically it's a mk4 Polo, with 500+ BHP and sortlike amounts of Nm's of torque (sorry, we don't do lbs/ft, but we do Nm's) on the crankshaft.

Yep, over fife-hundred bhp in a mk4 Polo. It is logically to do? No. Does it have a lot of grip? Well, it's still front wheel driven, so do the math Does it generate a lot of fun? Hell yeah B)

Some general specifications of the mk4 Polo:

-1,8 20v bi-turbo with 45mm throttle-bodies

-airride suspension (! yes, that DOES work out fine with over 500 BHP on the crank )

-Audi TT mk1 dashboard

-Audi TT mk2 seats

-16" 8 & 8,5 inch wide BBS RS'es (ball-polished)

-and many appearal-modifications

Some pictures of how it looked last year:

Some details on the engine of the mk4 Polo:

Engine (based on a 1,8 20vT):

-bi-turbo'd (2 Garreth turbo's)

-lightened & balanced crank+pulley+flywheel+pressure group

-titanium connection rod's in custom length and piston pin diameter

-JE forged pistons

-ported & polished head, with polished valves and combustion chambers etc.

-high-lift camshafts

-double fuel-line to inlet

-4x 1000cc injectors

-4 throttle-bodies

-ported inletmanifold to fit the ITB's

-custom inlet-plenum, with internal velocity stacks

-3" inlet piping

-huge-arse intercooler with 3" connections

-2 3" downpipes, connecting under the car, into 1 3" exhaust

-3" de-cat muffler & 3" backbox with a 3" exhaust all the way to the back

-KMS stand-alone motormanagement

-G60 gearbox, with TDI-internals

But a 1000 words can't beat a couple of pictures:

The "upper-turbo" (who needs airfilters?)

The "bottom-turbo"

Plenum + throttle-bodies

But he took it out last winter, in order to plug in some other fun-factors, and redo the entire mk4's appearance.

So the engine out of the car looks like this:

He just loves his engine

New plans for the engine:

-Schrick camshafts

-new turbo-internals

-modify the throttles

-Sachs uprated clutch+pressure group

-getting the head+valve-cover ball-polished (just for looks)

Turbo-internals:

Head + valve-cover alsmost ready to get ball-polished:

Throttle's + plenum:

Also the suspension is getting polybushed throughout:

Sachs clutch-kit:

Pistons still look freshly clean after over 5000 km's !

Some new braking + velocity stacks for on the inlet-side of the turbo's

Still working on the engine-bay:

Quick snap of the mk2 TT front seat:

Also the exterior is going for a re-do, new fresh (OEM-coloured) paint-job is to be done, together with a set of made to fit mk5 Polo front and rear bumpers:

The BBS RS'es

The mk1 TT dashboard a year ago:

The mk1 TT dashboard now during workings

Unfortunately I don't have a picture of the latest dyno-rund on my PC, only one from the "previous"set-up, with a single original 20vT-throttle and a small intercooler and 2"inlet-piping:

So, that's what the status on the mk4 was a couple of months ago, a lot has been done in the meantime, which is for the next posts

Looked around on my Photobucket-account, and found some more pictures, and more importantly, some video's of the bi-turbo'd mk4 Polo.

Working on our mk4's in Jeroen's shop:

Carlo Hulsen programming the KMS stand-alone motormanagement of the bi-turbo mk4 (Carlo Hulsen is the owner of the black mk2 Golf with a 2,0 20v bi-turbo on throttle-bodies, with 635 BHP on the crank using methanol-injection, if anybody wonders how that feels to be driven, ask Geoff or James from HAVOC-GTI-crew, they can fill in the details on that was absolute priceless to see their faces after a spin around the premises with Carlo in the mk2 )

"Onthe road", just to "test Carlo's programming skills"

After a couple of laps of the bi-turbo mk4 Carlo got out his owm Golf mk2 bi-turbo 2.0 20v

After the drive back to his shop, Jeroen found it necessary to "see whether the programming software survived the trip" :rolleyes:

Also he wanted to "pracktise" on taking of without wheelspin for the sprinting on sunday.

And a look around the mk4:

And more is going to be done on the engine itself too, for instance a set of new Cat Cams camshafts

-plus he did some welding work under the bonnet during "quit times" on the job (works in the family-car-garage), doesn't look nice and smooth yet, but it's a start:

The engine bay is getting smoother by the day

Also some more chrome arrived:

And the new brakelines:

It's so empty on the inside nowadays :(

(that's a Dutch anti-car-theft card hanging there, saying "this car is already emptied out")

And we're coming up nice on the engine bay too:

Since the original oilsump got banged a lot while driving low on the airride, a less low pan has been sourced, with a steel bottom plate for extra strength:

Plus the inlet-sides of both turbo's have been modified to fit bellhouses/velocity stacks, for improved airflow, to spool up the turbo's faster then before:

Front brake set-up assembled, using S2-calipers (dual-pots), braided hoses, etc.

And the new motor-mounts are in from the USA, VF Engineering ones all around:

Test-fitting the engine/gearbox on the new VF Engineering motorsupports:

Smoothing out the bay:

One side almost done, little sneak-peak-shot with one of the VF supports in place:

And two new Forge Motorsport 2-way adjustable actuators for both turbo's:

2 blanking plates from Forge for the original recirculation valve-openings on the turbo's are also on their way over, plus a lightweight aluminum pulleykit and some more bits and bobs.

Also 2 more up-dates for his project, got the pipe-work from the forced induction back, plus alternator-housing, valve-cover etc. from polishing:

And started on the clutch conversion, instead of cable clutching it is all going to be converted to a hydraulic clutch using OEM VW parts! Here's the modded paddle-set, with the hydraulic clutch paddle in place, with a manual throttle paddle/cable, one of a kind made by combining OEM VW-parts B)

Working with air-tools, infra-red lamps, and a lift on "working-height" should be made obligatory for some "hang-loose style Dub-moddin"

Overview of the bay, with the VF Engineering supports put in place, the mounts will get fully polished in the end, so far just partly polished due to time lacking.

And the inlet-piping which was ballpolished also in place:

Working:

And plugging in the new firewall to the chassis:

Now it's time for some basecoat!

We had some parts chemically treated, some minor bits, bobs and bolts and stuff from our engine's, here's an overview of some of our stuff after treatment:

The plenum and the last piece of boostpipe came back from the ball-polisher:

And with the plenum and modded fuel-rail on the engine:

Also a new carpet was ordered at the VW dealership:

And that's it so far, hope you all appreciate reading on this Dutch mk4. I'll try to keep this thread posted as much as possible, and since I hang around the shop several days a week, I'll take enough pictures along the way of the project for you lads/lasses

Hey m8. This 's got to be the sickest polo out there . Keep us informed about this pocket monster :).

Damn this is sweet...weve got a few 20v mk4s popping up over here in the uk but this is just too another level...what are his plans for the bodywork now? much preferring the mk5 bumpers!! =D

This is Evil love it!!!!

Nice one

Looks awesome! Bodywork is coming along nicely, what colour is it being changed too?

wow!

Anyone have tissue's am all out. :p

Anyone have tissue's am all out. :p

Dear lord...

I am too!

Also a new carpet was ordered at the VW dealership:

Carpet straight from VW? That must have cost a fortune...

Mate like you said i dont think words can describe it...

FUCKIN AMAZING!

I have to ask how much in total?

Dimz

Edited 2 March, 201016 yr by don_stavrou

Umm.. Wow!

Great work Keep us updated with both your projects!

Deze draad is ontzagwekkend!

Sorry, my dutch isnt great LOL

Deze draad is ontzagwekkend!

Sorry, my dutch isnt great LOL

Haha, you just totally used an online translator, those tend to translate "thread" into "draad" which is the kind of thread which you use to sow buttons on a shirt

Na, I just never knew that there was a diiferent type of "thread", sorry :)

Holy Shit! Best Mk4 ever??????

Major Respect!

Very impressive

Just wondered if you considered a twin charger setup with turbo and supercharger? And if so, why did you decide to go down to bi-turbo route?

Amazing project, look forward to seeing it all done and in paint

Ash

awesome mk4 like most folk have said prob the best ever a dont think you can beat this.

Amazing project, look forward to seeing it all done and in paint

Ash

M.I.V.W.

david.

-bi-turbo'd (2 Garreth turbo's)

right my mate pointed this out on the E38 thread....garreth turbos? is that a supermarket brand like asda price turbo?

also read on E38 it were over 500bhp is this true?! hope so!! that would be fucking mental.....bet u need arni arms to control the torque steer

but looks sweet (the engine) not to keen on the smooth bay etc though, but hey with this engine i jus wudnt give a toss!!

-bi-turbo'd (2 Garreth turbo's)

right my mate pointed this out on the E38 thread....garreth turbos? is that a supermarket brand like asda price turbo?

also read on E38 it were over 500bhp is this true?! hope so!! that would be fucking mental.....bet u need arni arms to control the torque steer

but looks sweet (the engine) not to keen on the smooth bay etc though, but hey with this engine i jus wudnt give a toss!!

hows your dutch?? gotta give jarno the odd spelling mishap! it "is" not it "were" and yes it is! :p

and whos this arni with the arms?????

david.

OMG that is chuffin Fantabulous!!!