Cost of parts for an RS2 Conversion

[Colesy]

Still hunting for an S2 and I was wondering what the going rate was for all the parts to convert a 3B to an RS2 with 300-350 bhp.

As I understand it the parts needed are:

RS2 Turbo
RS2 Inlet Manifold
RS2 Intercooler
Better fuel pump
Better injectors
Piston rods
Bigger exhaust
Fly wheel

Parts I have found/seen:
Inlet Manifold - Ebay £215 - are they any good?
Intercooler - New Wagner one £500ish. Second hand approx £250.


Are there any parts I have missed out?
Any I don't need?
Is a scorpion exhaust a good enough upgrade?
What order should all the parts be fitted? (over months not hours!)

Is it possible to get to 320bhp with just some of these parts?

Thanks in advance.

[Rusty]

Here's my amassed understanding

Still hunting for an S2 and I was wondering what the going rate was for all the parts to convert a 3B to an RS2 with 300-350 bhp.

As I understand it the parts needed are:

RS2 Turbo - £500 to £800
RS2 Inlet Manifold - not required £?
RS2 Intercooler (and XM) - £350 to £400 (Wagner Evo is best but requires ABY XM I think)
Better fuel pump - not strictly necessary could hardwire OE pump, £150
Better injectors - £200 - £400
Piston rods - good idea on 3B & required for max benefit, engine rebuild is about £1500 - £2000 with new parts, HG, WP, OP, gaskets, bearings, rings etc.
Bigger exhaust - £1000 for turbo back 3" custom item
Fly wheel - not required, 3B is better IMO, get it lightened £100
Clutch - £300 - £500
EM - £200- £600
ECU - remap & 3 bar + MAP - £500+

Parts I have found/seen:
Inlet Manifold - Ebay £215 - are they any good?
Intercooler - New Wagner one £500ish. Second hand approx £250.


Are there any parts I have missed out? - exhaust manifold
Any I don't need? - Inlet
Is a scorpion exhaust a good enough upgrade? - not really
What order should all the parts be fitted? (over months not hours!) - do everything except turbo, then bolt turbo on, that's what I'm doing.

Is it possible to get to 320bhp with just some of these parts? - Yes, depends on order of fitting, not really worth doing too many steps

Thanks in advance.

[Sonic]

Being in the middle of an ABY one, and having bought all the parts, id say ~£3-4k in parts for what you've spec'd out.

[HPmuirt]

Are there any parts I have missed out?

- Front brake upgrade (Brembo monoblocks on A8 discs)
- Suspension upgrades (ARB's, bushes, top mounts and koni dampers as a minimum)
- RS2 airbox & Maf - not strictly necessary but helps with breathing (May add 10BHP)
- RS2 Exhaust cam
- RS2 gearbox

What order should all the parts be fitted? (over months not hours!)

1. BRAKES FIRST!!
2. Then suspension
3. The order for the tuning goodies doesn't really matter (unless you want to see the effect of each in turn) but don't fit the injectors until you take the car to MRC for a remap.

Cheers n

Si

[Sonic]

RS2 Exhaust cam

Not strictly required but provides more torque, hard to get hold of though

[Rusty]

At a minimum you want an ABY airbox. I just removed the gauzes from my ABY MAF as they phooked

Took me 4 years to refurb the chassis and now I'm doing it all over again as I want it tighter, harder and lower. (orificer )

[Jamo]

Suddenly DarrenM's old car seems a bargain..........

[Rusty]

Yeah, basically all that RS2 kit FOC, a '96 ABY coupe is worth £5-5.5k all day long now in good condition.

[MattS2]

Having done this conversion last year ;-

Turbo £400 s/h
Ex. manifold £450 new
Airbox £250 new
Injectors £250 new
ECU (Gen. RS2) £450 s/h
Intercooler & xmember £250 s/h (not fitted yet)
3" exhaust £450 new
Sports cat £150 new
Fuel pump £150 new

Plus fitting........£?

All put on my ABY so no need for RS2 inlet manifold.

[lind4hl]

Not strictly required but provides more torque, hard to get hold of though

[Colesy]

Thanks for all the replies.

Piston rods look to be the difficult/expensive bit. If I found someone who knew what they were doing how big a job would it be time and cost wise if I just went for the bare necessities ie just the rods?

If I was to not do the rods and keep the Scorpion exhaust what power levels would it be adviseable to go to? - Which parts will this require?

All put on my ABY so no need for RS2 inlet manifold.

So is an inlet manifold required on a 3B to fit/run an RS2 turbo?

[Colesy]

One other thing.

What would be the benefit of fitting an RS2 intercooler and XM to a 3B or ABY? Would it be a straight swap? Would it provide any benefits? Would the mapping need to be changed?

Cheers all.

[Rusty]

It makes a difference on both but you'll need a remap really. A homefries is fine.

[Sonic]

Rods start from about £350/set - and yes opening up the engine is a big job, especially if your replacing manifolds and turbo's. Your talking days or work not hours.

It depends on whether its 3B or ABY, but ABY is good for up to around 400ft/lb toque (rs2 will do more - hence the problem).

Id recommend getting a lightly modded or standard ABY and getting used to it, then build it up, spreading the cost also.

If you are going for an RS2 turbo a bigger IC and subsequently XM would very highly recommended, but is not required. It can be mapped to take advantage of them, but again is not required and should run fine without.

One thing to bare in mind is that nothing is straight forward when modding - even stuff designed to work!

[Flat on my back]

Thanks for all the replies.

Piston rods look to be the difficult/expensive bit. If I found someone who knew what they were doing how big a job would it be time and cost wise if I just went for the bare necessities ie just the rods?

If I was to not do the rods and keep the Scorpion exhaust what power levels would it be adviseable to go to? - Which parts will this require?



So is an inlet manifold required on a 3B to fit/run an RS2 turbo?

I believe Aelred might be able to help you with the rods...cheap and he knows what he's doing...oh, when i say cheap i mean damn good value for money considering the wealth of experience he has and if you find someone cheaper think hard on your decicsion.

PM him with your thoughts and timescale...he is quite busy...

Blatant Aelred plug...