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I ain't no effin padawan
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Discussion Starter · #1 ·
I been after more power from my car for a while now, and after researching all the available kits out there, I kept coming back to the same conclusion. The only one that will fit a RHD car is a kit using the Jabba manifold.

I considered either a GT28rs or the IHI mated to the manifold, and concluded that the GT28rs was too big for the engine, and would push the power band too high in the rev range to be very useful, unless I could get the car to rev reliably to 8000rpm.

This left me with the IHI, and the thought of buying a bolt on kit rather than separate manifold, turbo, downpipe, tip, and oil/water lines had the prospect of being much simpler.

So off I trotted to Jabba to pick up a kit. Took the kit home and did a test assembly on my bench at home and discovered a few minor issues. Some of the banjos supplied in the kit either had the wrong threads on them, or bottomed out in the holes in the turbo.

Luckily I got one of the machinists at work to modify them for me. I told Jabba of the problems which they assure me they have now rectified.

I took the car and the kit up to JBS on the Monday morning, expecting to be without the car for 2-3 days. I spoke to JBS every day over the next week, and was kept up to date on how the fitting was (or should I say wasn?t) going.

It turns out that this is not a simple bolt on kit. The turbo and manifold went on and off the car 5 times to try and fathom a way of fitting the various oil and water lines. Eventually it was discovered that the only way to achieve it (unless you are Houdini) is to split the turbo in the middle, with it mounted on the manifold. It turned out that it was a good job JBS did split the turbo, as it had some nice big lumps of polystyrene packaging in the turbine blades.

Anyway, the kit eventually went on thanks to the determination of Kev and James. I went up to fetch the car the following Monday. I arrived mid afternoon, to see James fabricating the downpipe. Cast iron down pipe adapter welded to stainless steel down pipe. This is not the prettiest of solutions, but there wasn?t really a lot of choice given the parts supplied. JBS are currently having a full stainless steel down pipe made for me to replace the cast turbo outlet, which should be much neater.

For a tip, we had to modify the standard golf item, by sleeving it just before the turbo. I have been waiting for Jabba to finish there silicon TIP for a couple of months now, and it?s always 2 weeks away. If it ever gets finished, I will probably replace the one that JBS improvised for me.

For fueling, I was using a tt/s3 maf housing, and the injectors fitted during my E05 conversion.

Once the kit was on, it was down to Daventry to see Revo Kev. Mitchel had very kindly written a guesstimate program for the kit, and Kev uploaded it for me on the Tuesday morning. We then did an hour or so of road testing, and logging.

The car was smooth, and very tractable. If this was guess number one, then the finished program is going to be special. The cars now running V3 which is still a guess based on my vagcom logs from the car.

At the JBS rr day yesterday it made 331hp and 305lbft. You?ll see from the graph that it is extremely smooth, with no spikes. To say that I am impressed is an understatement, bearing in mind this is a guess for software. I have to conclude that Mitch really knows what he is doing.

I?ve done 4000 miles in the car since the turbo went on, and I?ve not had a single issue. It?s averaged 26mpg, and it?s nicer to drive than it ever was on a k03 or e05. It?s much more progressive, and is a lot less aggressive to drive. It will however upset anything this side of a 911 turbo. (non turbo 911?s are easy)

For anyone else who is considering doing this I?d say go for it. But be warned that the install is a major pain. It is anything but a simple bolt on. JBS are happy to fit the kit (for the right money), and if mine is anything to go by, it will be a very neat, professional install when it?s finished. If you?re sick of waiting for Jabba, then go for it. I would talk to James first though to see which bits to buy, as quite a few bits from the production kit are still in the box, and quite a few more will be replaced soon. If I did it again, I?d just buy the manifold, and source the other bits myself or have JBS source them.

I?ve been told that Revo will be offering maps for this kit, and also GT28rs kits in the near future through JBS.

I have to extend my thanks to JBS for how professionally they approached the whole thing, and to Revo for providing some cracking software. Jabba can take credit for a well engineered manifold, and picking a suitable Turbo for the engine.

Bit of a ramble I know, but I just wanted to share my experience to allow others to avoid some pitfalls.

Now for the pictures

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Downpipe close to steering rack

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Turbo inlet

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Downpipe close to steering rack and driveshaft.

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Looks pretty standard up here doesn't it.

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One for the skoda boys

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The gratuitous money shot
 

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That engine cover looks very familiar!

Wilko kindly took me out for a demo drive when it was running V1 software and around 290bhp. It's a very impressive setup, performance is very smooth and traction appears to be better than a remapped 1.8T Golf due to the progressive nature of the power rather than a big hit at low revs. Unfortunately I missed out on a demo of V3 as Wilko was in rush to get off yesterday. Nevermind, I'll wait for V4! [:D]
 

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Looks really good Wilko, bet it flies now! Am continually impressed with the excellent comments and write-ups JBS are getting, seems to be a company that truly take pride in their work. Am looking forward to see what sort of times you get on your next trip to Santa pod.
 

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wilko

I installed the jabba kit locally in malta and who intstalled didnt have any issues, I only found the banjo issues !

How come you didnt use the jabba software ?
 

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Looking good John, I got my downpipe fitted the other day and so far so good ,oh it is very noisy alot noisier than your car at ragley, must be that lack of silencers.

See you soon.
 

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I ain't no effin padawan
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Discussion Starter · #7 ·
Quote: posted by malta18t on 27/09/2004 13:39:35

wilko

I installed the jabba kit locally in malta and who intstalled didnt have any issues, I only found the banjo issues !

How come you didnt use the jabba software ?

Your installers must be double jointed. Or is your car left hand drive?

I didn't use jabba software because I didn't want the 10-12KW of timing retard that you're getting! I believe that the tuner I use has better software tools and skills for tuning. But thats only my oppinion.

I've got a front mount
 

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I ain't no effin padawan
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Discussion Starter · #8 ·
Quote: posted by The Walrus on 27/09/2004 13:43:45

Looking good John, I got my downpipe fitted the other day and so far so good ,oh it is very noisy alot noisier than your car at ragley, must be that lack of silencers.

See you soon.

Cool. So you're a happy (if slightly deaf) bunny.[:D]
 

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What did you say let me put my ear piece in.... TBH it could be down to the fact that the clamps are on there way out but I should know more tonight.

Seriously though I will have to have a chat soon as I am getting an itchy credit card god damn you.....
 

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Nice one john...... Looks the biz. Sounds like your chuft to bits with it matey. The E05 was fast I cant wait to see your times on this one.
 

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Nice curves mate [^]

Mitchell does know his stuff alright, I will just need to convince him to do code so that we can fit the kit to the old AGU with its better flowing head [:D]

Everytime I talk to him about the AGU he goes on about how much more limited the ECU capability is though [:(]
 

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I ain't no effin padawan
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Discussion Starter · #13 ·
So the perfect solution would be an agu head on a drive by wire car? Plans may be afoot
 

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lol, agu head on dbw motor.. now thats a novel idea.. ;)

I would disagree on the timing pull on a finished mapped (dyno'd) Jabba car. Of the few logs I have done on mine, oil breather system overload, induced by late braking and hard cornering on sticky tyres on race tracks, have been the only ign timing pull (to excess mind you) that mines suffered. Keep the oil in the sump and out of the breather system and its happy as larry. Jabba don't ride on ign knock any more than they ride on closed wastegate full boost,... (Judder anyone?)
 

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Nice write up John, I have to say I'm very impressed by your car and would like to go out in it again once you've got it fully remapped.
 

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John's car goes well, very smooth, lots of power. I will emphasise though that this is an experimental code, we would like to offer big turbo software in the future although as you can appreciate these things take time and we have to decide on exact specifications that we would like to provide software for. We are looking to offer big turbo software, but it is going to be in the long rather than short term.
 

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the official brakes to Johns enthusiasm...

Respect to mitch for some real smooth (read safe and sensible) code by email and logs..

Lots to come from it when in the flesh.

Spec a list of parts to suit the code chaps.. Jobs a Goodun.
 

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Yeah nice write up... still makes me scratch my head thou when people moan about the kits from Jabba? my mate at AmD is always sayin "we cant get it to fit?" yet although I hear Jabba have a bit of a back-log they always seam to manage to fit them?
 
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