K04/Hybrid & Big Turbo Support Group

[Traptalk]

Creating this thread to continue the discussion and progression brought about from the EBay k04 thread now that is locked... if anyone wants to continue the discussion that is

A place to discuss tunes, logs, hardware, dragy/track times for all of us beyond stock turbo


Expanding the title to be more open to all the other turbo options out there


Edited*
__________________________________________________ __________________________________________________

Background :

I built this turbo to be a budget replacement for the $1900 loba k04 hybrid I had to send back for repairs from a manufacturers defect, using data acquired from the eBay turbo thread.

I took a slightly different approach. I used a housing that no body had used with a chra people have only talked about wanting to use.

The set up:

Housing - TBO K04-064z
CHRA - Enhanced Turbos 9 blade turbine / 7/7 billet anti surge compressor wheel / upgraded bearings
SoCal Porting - port & polish + ceramic coatings
Forge Motorsport Wastegate - FMACVAG06 w/ yellow spring set to 10-11psi (mounting bracket swap required)
OEM DV + n75
PTP turbo blanket

Not counting the cost of the blanket which I already had laying around and shipping/taxes this cost roughly around $1200 said and done

I decided to use the “TBO K04-064z” because it looked identical to my loba turbo with the turbo muffler deleted and it even showed Borg Warner logos on the housing in the pics - it’s clearly fake but it’s a good fake

At the time this turbo was available on eBay for $780 or AliExpress for $520 so naturally I picked the cheaper option. Ali seller is quick to ship and packages well









After the PnP and coatings











Some measurements for the nerds :







Once assembled :





Next to it’s more expensive counterpart - could be twins



Fitting the blanket :







And finally installed :






Turbo now has about 1500 miles on it.

After attempting to get a very high boost (28psi) custom tune with hp tuners with mixed results I’ve settled with APR K04 software.

I have map switching, and direct port methanol, so I’m running the 100 octane file for now. I’m still using hp tuners for zf8 tuning but for now the ecu is staying on apr.

Decided on APR because of the common issues seen with IE’s k04 software not meeting requested boost that many have reported and been burdened with

Some data logs

93 octane map (no meth)

https://datazap.me/u/traptalk/apr-k0...e?log=0&data=1

100 octane map (93octane + 625cc of 80% meth)

https://datazap.me/u/traptalk/apr-k0...e?log=0&data=1

[schwiz23]

I got everything installed this weekend and am heading to a local dealer for an APR K04 tune this afternoon. Being as through Trap had instant results with APR and we are on the same turbo (mine doesn’t have all the fancy p&p), and a bunch of guys are having issues with IE, I decided to completely ditch IE. I should have went with APR for my stage 2 tune before they were discontinued. Money down the drain. Oh well, live and learn.

I’m excited to get to drive the car with the new turbo and tune! I don’t think I’ll be posting logs tonight as the CHRA requires a 100 mile break in period before changing the oil.

Big thanks to Trap for all his knowledge and support. He’s been super nice about all of this.







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[Traptalk]

I got everything installed this weekend and am heading to a local dealer for an APR K04 tune this afternoon. Being as through Trap had instant results with APR and we are on the same turbo (mine doesn’t have all the fancy p&p), and a bunch of guys are having issues with IE, I decided to completely ditch IE. I should have went with APR for my stage 2 tune before they were discontinued. Money down the drain. Oh well, live and learn.

I’m excited to get to drive the car with the new turbo and tune! I don’t think I’ll be posting logs tonight as the CHRA requires a 100 mile break in period before changing the oil.

Big thanks to Trap for all his knowledge and support. He’s been super nice about all of this.







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Looking forward to seeing those logs bud

Glad you got it all buttoned up and running!

[Iceman502]

Remind me, which wastegate did you go with?

Are you using the N75 and diverter valve that came with the eBay turbo, the old ones off your OE IHI turbo (winking at you Mars), or did you buy new ones?

And the most sacred question of them all: which spring did you go with and what's the crack pressure set to?

[schwiz23]

Remind me, which wastegate did you go with?

Are you using the N75 and diverter valve that came with the eBay turbo, the old ones off your OE IHI turbo (winking at you Mars), or did you buy new ones?

And the most sacred question of them all: which spring did you go with and what's the crack pressure set to?

I went with the Forge wastegate. Same that Trap used. I found that I had to fab a thicker bracket where it connects to the turbo in order to get the clock just right and identical to the K03 (I’m using stock airbox). Otherwise the actuator rod bound and would stick open.

Brand new N75. I snapped the top nipple off of the one on the K03 trying to remove the hose.

Diverter valve from the stock turbo and GFB

Green spring rated for 5-10lbs. Crack pressure set at ~8.75psi.


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[Mars2]

Let's do a game every time you use the word " crack pressure" you have to pay beer's to all the other's 😀😂🤣🤪
Somebody going to have to buy a brewery.

[EvolutionArmory]

Let's do a game every time you use the word " crack pressure" you have to pay beer's to all the other's 🤣🤪
Somebody going to have to buy a brewery.

What they should do is send me a dollar since they’d all be driving around with them set to 5 if I didn’t tell them different.


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[Nano909]

Let's do a game every time you use the word " crack pressure" you have to pay beer's to all the other's 😀😂🤣🤪
Somebody going to have to buy a brewery.

Shouldn't have said that, you basically summoned the turd.

[Nano909]

Creating this thread to continue the discussion and progression brought about from the EBay k04 thread now that is locked... if anyone wants to continue the discussion that is

A place to discuss tunes, logs, hardware, dragy/track times for all of us beyond stock turbo


Expanding the title to be more open to all the other turbo options out there

Dude you should edit the first post and write the parts you ordered and are currently using since it's working flawlessly. Same with Iceman since you guys are using true ebay built turbos.

[Spawne32]

Yeh Trap, you gotta edit that first post and go through your whole setup. Your turbo is basically the pinnacle of ebay turbo building.

[Stubek]

Keep it clean, civil, and adult folks.

[Nano909]

Keep it clean, civil, and adult folks.

My man.

[Traptalk]

Dude you should edit the first post and write the parts you ordered and are currently using since it's working flawlessly. Same with Iceman since you guys are using true ebay built turbos.

I’ll update shorty.

Started this on my first break at work so my time was limited

- - - Updated - - -

Keep it clean, civil, and adult folks.

Thanks for cleaning that up

[Traptalk]

You guys know I’m all for the jokes and clowning around (especially clowning a beige interior) but let’s try to not get insulting on page 1

Want everyone to feel this is accessible if they need help with troubleshooting and logs and not fear intimidation and harsh words

[Nano909]

Thanks for cleaning that up

Would definitely be a nice civil thread without a certain someone coming here with his BS.

Anyway, we got two people with Ebay built turbos that look promising, with a third (Schwiz) on the way.

I wish all this info was out like 4-5 years ago when I got the car. Lol

[Iceman502]

I'll be happy to chime in with my two cents (worth maybe one a half on its best day) once I get the actuator/WG sorted. I've got a new headliner on the way, a set of B12's (thank you Trap and Spawne), and then will have to pull the turbo to make another adjustment.

Looking forward to seeing how schwiz does, as that will be a good test comparison, minus that I'm on the original actuator. I hate to say it, but adding the custom bracket is introducing a whole new variable. Then again, since we've each pulled and replaced the core, the exact angle of how the turbo is clocked will likely vary from setup to setup, meaning the crack pressure value will be skewed to some degree by nature of an angle, unless the actuator rod is coming out perfectly straight from the canister.

[Iceman502]

Brand new N75. I snapped the top nipple off of the one on the K03 trying to remove the hose.

Been there, done that lol gets nice and brittle on a high mileage turbo

[Traptalk]

I'll be happy to chime in with my two cents (worth maybe one a half on its best day) once I get the actuator/WG sorted. I've got a new headliner on the way, a set of B12's (thank you Trap and Spawne), and then will have to pull the turbo to make another adjustment.

Looking forward to seeing how schwiz does, as that will be a good test comparison, minus that I'm on the original actuator. I hate to say it, but adding the custom bracket is introducing a whole new variable. Then again, since we've each pulled and replaced the core, the exact angle of how the turbo is clocked will likely vary from setup to setup, meaning the crack pressure value will be skewed to some degree by nature of an angle, unless the actuator rod is coming out perfectly straight from the canister.

I’m nervous about his wg bracket modification long term as well.

For me being the first person to do it, I originally bought 2 different forge wastegates

FMACVAG06 and FMACA4L

FMACA4L has the correct bracket but the actuator is not long enough
FMACVAG06 has the incorrect bracket and the correct actuator

So I used the bracket from FMACA4L (which is a bit thicker than the TBO bracket) with the FMACVAG06 actuator, and then I took the left over stuff and returned it to ecs (cuz fuck you ecs)

I had assumed the tbo bracket could work with FMACVAG06 actuator, it does physically fit the bracket, but Schwiz had issues getting the rod to line up with the flapper

So maybe the TBO brackets have a lot of acceptable tolerance

- - - Updated - - -

First post has been updated

[schwiz23]

The modified bracket I used should hold up. Used red loctite on the two (longer) bolts. If it doesn’t then I guess I gotta pull the turbo again. The fact that the wg can’t be adjusted without pulling the turbo is absolutely ridiculous.

I have done an initial pull and my results weren’t as put together as Traps. Checking for boost leaks will be on the agenda tomorrow.


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[Traptalk]

The modified bracket I used should hold up. Used red loctite on the two (longer) bolts. If it doesn’t then I guess I gotta pull the turbo again. The fact that the wg can’t be adjusted without pulling the turbo is absolutely ridiculous.

I have done an initial pull and my results weren’t as put together as Traps. Checking for boost leaks will be on the agenda tomorrow.


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I had leaks I had to get sorted too just most of my trouble shooting happened while on the custom tune so it appears everything just worked first try but not really the case. I just had it more sorted by the time I flashed apr

[Traptalk]

Looks like he’s not meeting boost requests and his maf is peaking at 250 g/s

I suspect a leak. The fact that the boost is at least following the curve of the request lends me to believe the n75 is plumbed correctly and functional

[Traptalk]

My boost curve for reference

Edit : this is absolute pressure with atmosphere *

[schwiz23]

First log, didn’t get a great run, haven’t changed the oil yet. Probably have a boost leak but if anyone wants to take a look and analyze, go for it.

https://datazap.me/u/schwiz/11-30-20...log=0&data=1-5


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[Iceman502]

Looks like he’s not meeting boost requests and his maf is peaking at 250 g/s

I suspect a leak. The fact that the boost is at least following the curve of the request lends me to believe the n75 is plumbed correctly and functional

How is it falling short at lower rpm's, but then meeting request at higher rpms? The engine is sucking more air at higher rpms - typically that's when you taper off, and a leak would become even more pronounced would it not?

If the wastegate actuation isn't smooth, that could be causing it to be stuck open longer than intended, then it closes and hits spec

[Iceman502]

First log, didn’t get a great run, haven’t changed the oil yet. Probably have a boost leak but if anyone wants to take a look and analyze, go for it.

https://datazap.me/u/schwiz/11-30-20...log=0&data=1-5


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Your duty cycle dropped during ramp up before you hit max boost I mean you've got the throttle mashed, I don't see why that would happen

[Traptalk]

How is it falling short at lower rpm's, but then meeting request at higher rpms? The engine is sucking more air at higher rpms - typically that's when you taper off, and a leak would become even more pronounced would it not?

If the wastegate actuation isn't smooth, that could be causing it to be stuck open longer than intended, then it closes and hits spec

Yeah it’s curious isn’t it

When these forge wastegates have too much strain in any direction they can start to leak around the piston/diaphragm but if that were the case I think he’d be over boosting as the spring would be losing its reference

[Traptalk]

I also notice that his wastegate spikes to 100% later in the pull and at the same time absolute load is dipping before it recovers

I’m thinking leak

[Iceman502]

I also notice that his wastegate spikes to 100% later in the pull and at the same time absolute load is dipping before it recovers

I’m thinking leak

A pressure test never hurts, heck it should really be SOP after a new turbo anyways. The turbo boost leak tester and PCV block off plate I have are quite useful

[mnripper]

Anyway, we got two people with Ebay built turbos that look promising, with a third (Schwiz) on the way.

I wish all this info was out like 4-5 years ago when I got the car. Lol

I have the
https://www.ebay.com/itm/Billet-6-6-...E/323327129914

with the mellet k04 chra in mine
IE 91 K04 tune
mamba WG with 10psi crack

Car runs well
I am still seeing about a 2psi underboost condition after 5000 rpm or so.
Still seeing 280g/s peak
Have not had much time to mess with it lately. Haven't had a good reason to either.
Building a trans for my truck now.
Will likely play with the car more when winter is over.

Thanks to all of you who keep contributing real data for us all to work from.

[Spawne32]

Speaking of checking for boost leaks, me and trap both have this kit and it works wonders. https://turboboostleaktesters.com/au...llet-aluminum/

[Traptalk]

Speaking of checking for boost leaks, me and trap both have this kit and it works wonders. https://turboboostleaktesters.com/au...llet-aluminum/

I’m the reason he offers that block off plate now

Very nice guy

[Nano909]

I have the
https://www.ebay.com/itm/Billet-6-6-...E/323327129914

with the mellet k04 chra in mine
IE 91 K04 tune
mamba WG with 10psi crack

Car runs well
I am still seeing about a 2psi underboost condition after 5000 rpm or so.
Still seeing 280g/s peak
Have not had much time to mess with it lately. Haven't had a good reason to either.
Building a trans for my truck now.
Will likely play with the car more when winter is over.

Thanks to all of you who keep contributing real data for us all to work from.

Oh okay cool. I must have lost you or forgot about yours in the other thread. Glad yours is working fine.

[Traptalk]

I have the
https://www.ebay.com/itm/Billet-6-6-...E/323327129914

with the mellet k04 chra in mine
IE 91 K04 tune
mamba WG with 10psi crack

Car runs well
I am still seeing about a 2psi underboost condition after 5000 rpm or so.
Still seeing 280g/s peak
Have not had much time to mess with it lately. Haven't had a good reason to either.
Building a trans for my truck now.
Will likely play with the car more when winter is over.

Thanks to all of you who keep contributing real data for us all to work from.

Can you share some logs for the data pool?

[SNice]

My boost curve for reference

Edit : this is absolute pressure with atmosphere *

Thanks for getting this thread up and going. The info/data/knowledge you guys are providing has been very helpful and informative. I'm currently working through solving an overboosting issue. I'm getting about 8psi over requested which puts me in the 29-32psi range. This scares me a bit. In looking at the log above - it looks like there is a slight overboost too. My question is when does overboosting/underboosting become too much/too little? How close to the spec value is ideal? I'm assuming it will never be spot on (?).

Really appreciate all the logs - they have helped me start to understand how these curves are supposed to look so I can interpret my own. I hope to get some good logs in the near future so I can post some of my own!

[Traptalk]

Thanks for getting this thread up and going. The info/data/knowledge you guys are providing has been very helpful and informative. I'm currently working through solving an overboosting issue. I'm getting about 8psi over requested which puts me in the 29-32psi range. This scares me a bit. In looking at the log above - it looks like there is a slight overboost too. My question is when does overboosting/underboosting become too much/too little? How close to the spec value is ideal? I'm assuming it will never be spot on (?).

Really appreciate all the logs - they have helped me start to understand how these curves are supposed to look so I can interpret my own. I hope to get some good logs in the near future so I can post some of my own!

It all depends what else is happening at the time of over boost. A few extra psi won’t hurt anything but if fueling isn’t being supplied for it or there is substantial knock then their will be issues


We’re you the guy that posted the log off of obdelevan ?

I think you need to get a clearer log still. I remember it was hard to tell if that was actual or absolute pressure. If those are absolute values than that’s 32psi with atmosphere so closer to 18psi of actual pressure


You should post a raw data log (unedited) and make sure that boost request and boost actual are in the same unit of measure and make sure you get a reading of the ambient pressure

Also help to see the wgdc, absolute load, throttle position, accelerator position, maf, timing advance, timing corrections, fuel rail pressure actual + request, rpm, short term fuel trim, and lambda to start

[Iceman502]

Thanks for getting this thread up and going. The info/data/knowledge you guys are providing has been very helpful and informative. I'm currently working through solving an overboosting issue. I'm getting about 8psi over requested which puts me in the 29-32psi range. This scares me a bit. In looking at the log above - it looks like there is a slight overboost too. My question is when does overboosting/underboosting become too much/too little? How close to the spec value is ideal? I'm assuming it will never be spot on (?).

Really appreciate all the logs - they have helped me start to understand how these curves are supposed to look so I can interpret my own. I hope to get some good logs in the near future so I can post some of my own!

Trap has a good point, if you're seeing 32 psi in your log, that more than likely is the absolute pressure value, so minus 14.7 for gauge pressure. A while back, my N75 failed in the open position so that it was diverting all air back to the intake, and with my WG being closed through most of the RPM band until backpressure forced it open, I maxed out the MAP, showing a flat line because the sensor can't even read that high (See pic). The only good thing that came out of that was showing the throttle body would close to protect against overboost, and that my intake system had no leaks. Sadly I was over spinning the turbo, but that hasn't seemed to lead to any issues. Yet....

[mnripper]

Can you share some logs for the data pool?

https://datazap.me/u/moddoo/log-1606...&data=1-4-5-18

Quick log from yesterday in 3rd gear.

I'll try and get a cleaner 3-4 pull one of these days.

[Perry01]

Thanks Traptalk for a fresh new discussion on turbocharger upgrades and troubleshooting. This has the potential to be very helpful and informative if forum members produce good data and others chime in with helpful input instead of banter and bickering.

First log, didn’t get a great run, haven’t changed the oil yet. Probably have a boost leak but if anyone wants to take a look and analyze, go for it.

https://datazap.me/u/schwiz/11-30-20...log=0&data=1-5

First of all, don’t be afraid to take it beyond 6000 RPM. There’s a lot of good data to be read up top. Editing your data logs by deleting all rows prior to, and after going WOT is helpful when analyzing logs. It removes the insignificant data and doesn’t cloud the picture. Here are a couple of your edited logs:

I agree with what the others said about a boost leak. I would check all the clamps and hoses. What are used for data logging? Your IE flash tool? If so it has ignition advance scaled incorrectly, If you have VCDS, it will show a correct value.



You’re N75 chart looks like it has a decent checkmark but your ECU is shutting the wastegate 100% up top to try to give you more boost.

[schwiz23]

Thanks Traptalk for a fresh new discussion on turbocharger upgrades and troubleshooting.

First of all, don’t be afraid to take it beyond 6000 RPM. There’s a lot of good data to be read up top.

I agree with what the others said about a boost leak. I would check all the clamps and hoses. What are used for data logging? Your IE flash tool?

Thanks Perry.

I didn’t have a good run. Took this log entering a freeway from a ramp and ran into traffic instead of heading out to the country like I normally do. This whole process is pretty frustrating but has been a learning experience. After I got my tune last night I immediately knew something wasn’t right and just went into defeated mode.

Hoping there is a boost leak. I don’t want to remove a turbo for the 3rd time if I don’t have to. I’m getting pretty good at it at this point but if I can avoid it, I’d like to.

I am using the IE flash tool for logging. Good spot.

I ordered the same boost leak tester that Trap and Spawn have but while I wait for that, I plan on taking soap and water bottle to all the connection points to see if I can spot something easy.

Thanks for chiming in on my initial log. Appreciated.


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[Jake@JHM]

Is there any interest in a bolt-on TD05H-R Turbo kit specific to the B8 A4?

Here is our B7 kit for example: https://jhmotorsports.com/jhm-td05h-...7-a4-2-0t.html