1g TSI AWD 300-350hp build

[customdsm]

Ok, so I'm planning on doing a 300-350hp build for my car. It's a reasonable goal since I'm only asking like an extra 150hp and 100ft/lb of torque. I'm trying to get an idea of what I need to get together to get going. Don't get all angry about "use the search", because I'm really looking for is suggestions on which parts you guys have had success with, and which path not to go down, etc. Not like a how-to. I've already read the tech articles, etc. I'm looking for people that have already done this and gone through the headaches of shopping as well as getting different brand parts to work together.

Here's what I'm already planning to do.
-Full 3" exhaust, straight pipe from turbo back, no cat. I might go all the way to the bumper or just route out to under the door. Ported O2 housing too.
-Remove emissions.
-Paint, I need it, so I'm going to do that no matter.
-upgrade to 4 bolt rear end. Anyone got one for sale? Or is there a better route to go? Newer driveshafts.
-255 fuel pump, with 550cc injectors. Should I get bigger injectors? I think 550's would be fine.
-Wideband O2. LC-1 or LM-1? or different one altogether?

Stuff I would like advice on:
-BOV, does it matter or keep the stock one? Any advantage of switching to atmospheric type?

-Clutch and flywheel. Ok, I was planning on sticking with my stock one until it blew since I only have 300 miles on it right now. If need one though I probably do a fidanza hybrid flywheel, as full Aluminum. would wear out too quick. Which part number for fidanza as they have like 5 for 1st gen? Brand and type recommendations on clutch? Spec, ACT, etc?

-FMIC going to be bar and plate, yeah I know there is huge treads on this one, especially about ebay cores, which as far as I can tell seem to work fine, and probably what I'll be using. But I'm wondering about size (probably 3 to 3.5") and pipe routing options really. Will I need to get an aftermarket bumber so it can breath properly? I'm not opposed to getting a body kit since I will be painting anyways, but I still want to be able to go over curbs, not a fan of the dropped stuff. By the way any suggestions on that? My plastic stock ones now are kinda warped from age, so might not be a bad idea to do a full body kit.

-Intake, ok there seems to be two routes to go on this one. The GM 3" with the translator, and the 2nd gen intake? Is there a better way besides those or one of the two that works better?

-Exhaust manifold, has a lot to do with turbo too. I was thinking t3/t4 route. With the spiraled type of manifold. Or does that design suck totally and I should just port an evo3 one? Switch to external wastegate while I'm at it? I was thinking about gt30's or gt35, unless you guys think that kinda setup is waste for my goal and there is something cheaper to accomplish the same end. Should I just get turbo/manifold kit, probably cheaper huh? By the way I plan on heat wrapping both the intake and exhaust. I already have a MBC.

-Pulleys, should I even bother? If so what type of setup, there is like 6 different setups. I'm not opposed to removing the A/C.

-Cam gears. Again should I even bother?

-ECU, I have no idea what to do here.

Anything else I should do? Somesort of fuel management system, go piggieback or what? Any non-street legal mods to include? There is no emissions or inspection where I live, so I can do whatever I care to do to my car. Well, besides drive without a hood, because no hood altogether is lighter than CF and way cooler looking, that's a joke incase you missed it. Thanks for reading.

 

[jongreene]

Check out the FP race mani if you want a really nice cast tubular manifold.

The ceramic coating on those should take care of some heat.

As far as FMIC look into the cheap ebay cores, tons of people have had good luck with them...
then buy the piping separate...great upgrade real cheap

 

[customdsm]

Ok, I will post what manifold setup I decide on well actually all the results w/pics when I am done. There is still so many manifolds to choose from. I do like the FP (minus the lack of ewg off the runners though), what about SBR's any luck? I'm not going to move my PS or ALT for a manifold, not yet anyways. Anyways I want to discuss FMIC. I know ebay ones are recommended and work really well, and I will definitely get one of those. I know we have 62 page 2k post forum on it, but I'm just looking for the basic idea/dimensions I should be buying. Make sure I got it right. Bar and plate is better than hybrid yes? I will probably only do 2.5 inlet/outlets not 3". and not thicker than 3" I have seen a 5" thick one, but I think that is overkill and would starve the radiator too much of fresh air. So does overall size of these things, bigger is better? I would think so due to larger cooling area. Pressure drops on these seem minimal, even for the godzilla large ones. I'm not opposed to cutting my bumper cover or even getting a body kit to accommodate one or losing some fog lights, Its the cutting of the actual bumper I worry about. Short route or long route, what's the diff/examples? I can even do my own piping, I don't care, but it seems a lot people love the kits. Straight through inlets are better than 90 degree ones, correct? Did I miss anything? It's near impossible to get accurate flow rates on the ebay cores, so I think I'm gonna' overlook that spec and go by dimensions alone.

 

[customdsm]

So I was shopping for parts and someone on the classifieds under the name of john eaton, had a couple I was looking for (namely a eprom ecu, and fpr). I bought them, you can imagine it was quite a bit, sent a check, 1 month later of emails (which his account is now inactive) and still no parts or hope for my money back. Just wanted to warn you guys. , guess. my project is at a standstill now. As a side note I did pick out a turbo xs fmic, and body kit style. I also ordered a GM 3" MAF, and ended up with a 3.5". Oh well. Maybe I will sell the talon and my collection of oem parts over the years that is taking up space. It has been nothing but setbacks and problems since i got it. I know when to take a hint and stop . Car runs fine, but everytime I try to mod it or something, something goes wrong, not with the car, with everything else.

 

[polen]

id reccommend a 16g