APR building a Super Beetle, transforming a new Beetle into a 6-speed all wheel drive 500 horse monster - 2.0 Engine Build

[Sticky]

APR does amazing work in the VW and Audi world. They are showcasing it with an absolutely awesome build for the newly released VW Beetle which they will be adding all wheel drive to, a 6-speed manual transmission, and an APR Stage IV build to the 2.0 turbo four-cylinder for over 500 horsepower. The goal is to build a high performance Beetle much in the same way VW would using VW parts from the Golf R.

This update concerns the build of the 2.0 EA888 2.0T that comes with the stock beetle in a 200 horse state of tune. This motor will receive a full build bottom end with .5 mm overbore. Forged rods, pistons, ported head, upgraded fuel system, the works.

The complete list of mods includes:

- APR Stage IV GTX Turbocharger System
- APR Boost Tap
- APR High Pressure Fuel Pump
- APR Low Pressure Fueling System
- APR Rail Pressure Release Valve
- APR Intercooler System
- APR Stage IV ECU Upgrade with ESP Delete
- APR Stage IV High Flow Head
- APR Stage IV High Flow Intake Manifold RF Delete
- APR Stage IV Low Pressure Fueling System
- APR Stage IV High Strength Coated Pistons & Wrist Pins
- APR Stage IV High Strength Connecting Rods & Bearings
- APR Stage IV Balanced Rotating Assembly
- APR RSC Turboback Exhaust System
- DXD Racing Stage III Clutch
- Volkswagen Racing Short Shifter

Here are the rods and the crank which is balanced (material removed in certain locations):

Turbo used is a Garrett GTX2867R chosen for its quick low end spool and high end breathing. It will be mated to a custom manifold with new oil and coolant lines along with new boost and vacuum reference lines:

With the new higher power and torque a DXD Stage III Endurance Clutch System will be used to transfer the power:

An APR FMIC rounds out the engine modifications:

The car is expected to be completed in time for SEMA, VWBoost will bring you more updates as they come.

[leo985i]

Wow! That is some serious amount of work. Good job APR!

[Sticky]

Wow! That is some serious amount of work. Good job APR!

This project is insane! And they are making it like it is OEM...

[hworang00]

Wow that's pretty awesome...it'll be awesome to start seeing racing stories of stock M3's and C63's being beat by beetles lol

[Sticky]

Wow that's pretty awesome...it'll be awesome to start seeing racing stories of stock M3's and C63's being beat by beetles lol

I doubt we will see many of these out there, this is just a one-off show piece.

[hworang00]

Still, $#@! would be funny to hear about lol

[Payam@BMS]

Woah. So this is pretty much the first TSI stage 4 build. Get lots of info for this Sticky, it can bring attention to this forum. Make sure you tag TSI engine as this is BIG.

[Sticky]

Woah. So this is pretty much the first TSI stage 4 build. Get lots of info for this Sticky, it can bring attention to this forum. Make sure you tag TSI engine as this is BIG.

It's already posted on other forums as well but I'll do it. It's a badass build.

[chrisisnapping]

Woah. So this is pretty much the first TSI stage 4 build. Get lots of info for this Sticky, it can bring attention to this forum. Make sure you tag TSI engine as this is BIG.

I think the biggest downside is I believe they are using a t25 flange, kind of caps you on turbo possibilities.

[Sticky]

I think the biggest downside is I believe they are using a t25 flange, kind of caps you on turbo possibilities.

But it works with the turbo they chose...

[chrisisnapping]

But it works with the turbo they chose...

you're absolutely right. And going for ~500WHP, they chose a great set up.

I was just stating as a kit to be sold to the public, it would be hard to justify going for the Stage 4 kit if you already had Stage 3+. Same turbo/manifold, stage 3+ just needs the LPFP and HPFP to get to the 500WHP range and max the t25 turbo out.

Of course it wouldn't be surprising if APR did NOT sell the HPFP and LPFP separately (they don't sell the injectors by themselves, just through their Stage 3+ kit). There are other non-apr BT guys out there with a t3 set up, so if they can get their hands on the LPFP and HPFP, there is definitely potential for these cars to see the 600WHP range. Which is, IMO exciting, even if I would never go that route.

[Payam@BMS]

you're absolutely right. And going for ~500WHP, they chose a great set up.

I was just stating as a kit to be sold to the public, it would be hard to justify going for the Stage 4 kit if you already had Stage 3+. Same turbo/manifold, stage 3+ just needs the LPFP and HPFP to get to the 500WHP range and max the t25 turbo out.

Of course it wouldn't be surprising if APR did NOT sell the HPFP and LPFP separately (they don't sell the injectors by themselves, just through their Stage 3+ kit). There are other non-apr BT guys out there with a t3 set up, so if they can get their hands on the LPFP and HPFP, there is definitely potential for these cars to see the 600WHP range. Which is, IMO exciting, even if I would never go that route.

Still there are adapters available for changing the flange. Some downpipe adjustments would probably need to be made because of the 1" movement of the turbo. Not really easy though but that's going up in the 600whp range as you stated lol. The hpfp and lpfp will most likely only be sold with stage 4 kit. I believe all stage 4 kits you have to send your engine to APR for them to build it. I remember one guy in Israel flew like 2 of them out to build it there cause I guess it would have been cheaper or something. I don't even know.

[Sticky]

They have it running:

[chrisisnapping]

i look forward to this running in the 10s. It's fun to see what these little engines can do with a $#@! ton of money thrown at them.

[Payam@BMS]

Meh, $#@! the 10's the stage 3+ trap speeds can yield that, just need traction lol. Stage 4 trap is 130 wow, i'll $#@! myself.