Building A Booster FAQ
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If you’ve ever considered building a kit car and have some basic mechanical skills then you can build a Booster. The ethos of the repower kit was to take as many ”pain points” as possible away from the build process. If you haven’t done this sort of thing before then the enhanced kit contains a full build manual which has full guides for all aspects of the process.
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For the basic build only hand tools, a lift trolley and an engine crane along with a way to lift the car high enough to remove the standard engine are required. Essentially the same tools required to remove the standard engine. From there it depends entirely on what you wish to do yourself with regards exhaust, charge cooling and boost pipework. These components can be made predominantly with off the shelf parts or be entirely bespoke depending on your target power.A double garage is more than sufficient to complete the build in.
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The fundamental kit is designed for those who have experience of building project cars such as the Booster. It contains the components required to physically mount the engine in the chassis but nothing else. This kit is perfect for those planning big power builds, fabrication of their own components and wish to run aftermarket engine management via a bespoke wiring loom etc.
The enhanced kit is designed for those who may not have undertake a project like this before. On top of the engine mounting components it also includes many bespoke components such as a flywheel, fuel pump kit and engine sensors allowing you to rapidly build a Booster without having to design too many parts. It also includes an extensive hard bound build manual which guides a builder through the process and details all aspects of the build process including cooling system, electrical system and fuel system along with a full BOM of standard components and OTS parts required. -
The build time depends entirely on the amount of bespoke components you wish to include in the build. A builder starting with the enhanced kit and having already arranged for exhaust fabrication etc. to suit their chosen turbo charger can have a car up and running in as little as a month of evenings and weekends.
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The Enhanced Fit Kit includes the vast majority of parts required to get the engine running in the chassis, essentially it contains every part required that you can’t buy off the shelf, but it does not provide parts for the cooling system, charge cooling, turbo charger or exhaust.
These items are excluded because they depend entirely on what specification you wish to build. If you are using a standard turbocharger with a lower power requirement you can use an engine bay mounted air/air intercooler and the vast majority of standard parts, alternatively if you are building a 500bhp monster you will likely be custom building or sourcing from the aftermarket items such as the exhaust manifold, downpipe, an air/water charge cooler and various associated components. The nice thing is the aftermarket performance parts market for the 06A 20V engine is enormous and incredibly well supported.
Exhausts are very much personal preference and one persons too noisy is another's too quite, however the requirement for building the exhaust is extremely simple and well within the capability of any exhaust fabricators.
The cooling system plumbing is mostly addressed via the use of an aftermarket silicone hose kit originally designed for the Mk4 Golf GTI with the addition of some generic straight lengths and hose joiners.
Detailed guidance on exactly how to plumb, wire and generally make run is provided in the build manual included with the enhanced kit. This manual also includes a bill of materials for every off the shelf part required.