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2006 VW GTI - Jail Bait

There’s one problem with driving a 500whp VW GTI everyday – you’re likely to end up in jail!

Dec 6, 2011
Eurp 1111 01+2006 vw gti+cover Photo 1/9   |   2006 VW GTI - Jail Bait

If you’re thinking this VW GTI looks familiar, you’re right. The BSH Speedshop Mk5 competed in last year’s eurotuner GP.

Arguably one of the sexiest cars in the competition, its results on the dyno and quarter-mile were disappointing because of a fuel system complication. However, the car redeemed itself on the track, coming fourth and beating more powerful cars.

With all the bugs sorted out, the car has been reinstated as a daily driver with more than 500whp at its disposal. So while we were soaking up the sun in Las Vegas at Wuste this year, we caught up with owner of BSH, Phillip Felice, to photograph the GTI and uncover the story behind it.

Rewind to ’06 and Phil was an engineering student. Being a car enthusiast since he could reach the gas pedal, Phil jumped from project to project until he purchased the GTI new. He quickly fell in love but noticed aftermarket support for the 2.0T FSI was slow to develop. That same year, Phil opened the doors to BSH Speedshop and the GTI became the test mule for the company’s expanding FSI product line.

Specializing in everything from machining, prototyping and custom fabrication to manufacturing, the BSH parts catalog grew rapidly. With intakes, methanol injection, catch cans and diverter valves, the Arizona-based tuner was making a name for itself. But the biggest introduction was its ‘Work of Art’ turbo kit for the 2.0T FSI.

Eurp 1111 02+2006 vw gti+full view Photo 2/9   |   2006 VW GTI - Jail Bait

“We wanted the sort of power where you could show up to a drag race, street race, autocross or road course and have a platform that was able to compete with Evos,” Phil explained. “I built the car with a form-follows-function mentality, so all our parts are on it, and it was one of the first Mk5s fitted with a GT30 turbocharger.”

The building block for the kit was the proprietary BSH tubular manifold. It’s designed for maximum flow while still being reliable enough to drive every day.

CNC-machined from 304 stainless steel, TIG-welded and back-purged, it became the ultimate manifold. It also had low-angle merge collectors, designed for better flow and power potential. With the option of ordering á la carte, the manifold worked with any Garrett turbo between a GT28 and GT35. However, a GT3076 is used for the kit: “It’s a mid-level turbo that offers the best balance of street-ability with raw power,” Phil told us.

Accompanying it was a new downpipe, intake adapter, dump tube, charge pipe, oil- and coolant lines plus silicone couplers – all the goodies needed to install the kit at home.

While any 2.0T FSI owner could have bolt-on power with this kit, naturally BSH wanted to push the hardware further to ensure its customers were getting the best product on the market.

Eurp 1111 03+2006 vw gti+gauges Photo 3/9   |   2006 VW GTI - Jail Bait

To handle more abuse, the motor was rebuilt. An upgraded bottom-end included overbored Wossner pistons and Integrated Engineering rods. The 16v cylinder head was ported and polished for good measure.

Eurp 1111 04+2006 vw gti+rear view Photo 4/9   |   2006 VW GTI - Jail Bait

BSH Speedshop also added its catalog of bolt-on parts such as its True Seal intake system, front-mount intercooler, diverter valve, exhaust and motor mounts.

One of the most underrated power-adders, Snow Performance water-methanol injection, was thrown in along with an Autotech fuel pump and Audi RS4 injectors to feed the thirstier 2.0L.

After the six-speed was beefed up with a Southbend stage 5 clutch, and Revo had performed its magic on the ECU with custom software, it was time to hit the dyno.

Hundreds of pulls later, Phil settled on 519whp at 30psi on race fuel and methanol. Not bad!

For daily driving, the power was kicked back to 457whp at 24psi on 91 and methanol. And if the meth tank empties, the computer recalibrates to 418whp at 20psi.

Eurp 1111 05+2006 vw gti+seats Photo 5/9   |   Recaros and roll-bar give the GTI some racecar feel while still being comfortable on the street

“The kit was designed so you could have a comfortable but powerful Mk5 without sacrificing much of anything. You can kick the crap out of anything on the street while still enjoying A/C and a stereo. It was designed to be the ultimate street car,” Phil explained.

And since the proof is in the pudding, his manifold was recently involved in a land speed record for the fastest 2.0T at the Bonneville Salt Flats – 600whp and 227mph!

With the BSH 2.0T tuning program in the bag, Phil spent his spare time finishing the GTI’s chassis and appearance. Working with K-Sport, a set of coilovers were installed with custom spring rates, as well as massive rotors measuring 14" in the front and 13" rear along with eight- and six-piston, calipers respectively.

Not wanting to go too ‘show’, Phil opted for a set of 19" VMR wheels. A local body shop then smoothed and painted the side skirts and rear valance before fitting a Jetta front bumper. The lights and trim were also updated to give the GTI a cleaner look.

Eurp 1111 06+2006 vw gti+wheels Photo 6/9   |   Behind 19" VMR wheels are ginormous 14" K-Sport brakes with eight-piston calipers

Inside, Phil kept the cockpit stock, although the factory seats were replaced with Recaros while a Podi gauge lets Phil know when the boost spikes. To stiffen up the chassis further, an Auto Power roll-bar finished the project.

So despite its setback at etGP, the car is now complete. Yet Phil still has to be careful… “The car has been driven to Las Vegas and Los Angeles several times and has covered thousands of street miles in Arizona with no issues,” he concluded. “I drive it everyday, but I shouldn’t – I’ll go to jail with this thing!”

et Tech Spec

2006 VW GTI
Owner: BSH Speedshop
Location: Phoenix, AZ
Occupation: VW/Audi tuning
Engine: 2.0L four-cylinder 16v with 83.5mm Wossner pistons, Integrated Engineering I-beam rods, lightened and balanced rotating assembly, ported and polished head, BSH Work of Art turbo kit with Garrett GT3076R turbo, front-mount intercooler, diverter valve kit, boost tap, True Seal intake, engine mounts, race PCV system and turbo-back exhaust, RS4 injectors, GReddy Profec B Spec II boost controller, Autotech fuel pump, Revo software, Snow Performance water/meth injection
Drivetrain: six-speed manual with Southbend stage 5 clutch, Wavetrac limited-slip differential, BSH short shift kit
Brakes: 14" front, 13" rear K-Sport rotors with eight-piston front, six-piston rear calipers
Suspension: K-Sport Kontrol Pro coilovers and rear camber kit, 27mm BSH rear sway bar with billet end-links, Auto Power roll-bar
Wheels & Tires: 19x8.5" VMR VM3 wheels with 235/35 R19 Falken FK-452 tires
Exterior: Jetta front bumper, smoothed and painted side skirts and rear valance, Euro R32 tail lights and clear indicators, R-Line foglights, white grille trim, smoked mirror lenses
Interior: Recaro Speed seats, Schroth harnesses, Podi electronic boost gauge, Auto Meter wideband air/fuel gauge

Sources

Sam Du
By
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