Building 104 EAST, Aston Down Business Park, nr Stroud, Glos, GL68GA
01285 760707 sales@badger5.co.uk
Building 104 EAST, Aston Down Business Park, nr Stroud, Glos, GL68GA
01285 760707 sales@badger5.co.uk
Engine Rebuilds
Looking to unleash the full potential of your 1.8T 20v engine? At Badger5, we specialize in precision-built engines designed for reliability, performance, and longevity. Whether you’re after a standard rebuild or a full performance upgrade, our engine rebuild service has you covered.
A Badger5 engine rebuild is not a generic overhaul—it is a fully engineered rebuild process carried out with precision from teardown to final assembly. Every engine is individually stripped, cleaned, and inspected using a combination of acid and caustic dipping, hot washing, and detailed component-level assessment to ensure the base is structurally sound before any machining begins.
The engine block is then prepared through core plug removal and precision reboring, followed by dynamic balancing of the rotating assembly, including crankshaft, rods, and pistons. Critical components such as crank journals are polished to improve oil control and longevity under load. Once machining is complete, the engine is refinished with a protective coating process, typically featuring a colour-coded block and rocker cover finish, with custom colour options available on request.
Each rebuild is assembled using a carefully selected performance specification designed for strength and reliability. This includes an 82.5mm bore configuration with a 9.5:1 compression ratio (with alternative options available), JE forged pistons, and I-beam forged rifle-drilled connecting rods. Valvetrain durability is addressed with Supertech valves and CatCams Gold valve springs, supported by ARP fasteners throughout the engine, including head, main, and crank hardware.
The rotating assembly is reinforced with ACL Race bearings and KS thrust washers, while timing and service components are refreshed using OEM-quality or uprated parts such as Gates belt kits, OE oil and water pumps, and Elring gaskets. A billet steel crank gear and additional strengthening hardware complete the internal specification.
For customers seeking further refinement, optional upgrades are available, including performance cam profiles, CatCams vernier pulley systems for precise timing control, and a stroker crank option for increased displacement and torque potential.
Every engine is completed with installation and tuning support available, ensuring the final result is not just a rebuilt engine, but a fully calibrated performance package built for real-world use and reliability.
We don’t just build engines – we bring them to life. Your engine can be installed in your car and dyno-tested on request. Full mapping is available to match the engine to your vehicle and other build components, ensuring maximum performance, reliability, and efficiency.
Base Engine: 1.8T 20v Built Engine (1847cc) – £8,367.45
Cam Options:
Exchange Options: Non-Exchange (+£350)
Valve Springs:
Please note: Turbo and manifold are not included in this package.
Donor Engine Surcharge: £292 + VAT if an exchange engine is not supplied.
A core engine strengthening package designed to support higher power and torque levels with improved internal durability and reliability.
The build includes forged rifle-drilled connecting rods fitted with high-strength ARP rod bolts, along with performance ACL big-end bearings for improved load handling. A full top-end and timing refresh is carried out using OEM-quality gasket and bolt sets, along with a new water pump and complete timing belt kit with hydraulic tensioner.
All supporting sealing components are replaced, including turbo, manifold, oil drain, and filtration elements, ensuring a fully refreshed and reliable assembly. This package is intended as the foundation for high-performance engine builds and increased boost applications.
A comprehensive cylinder head rebuild service carried out during engine build or rod upgrade work to ensure full reliability and optimal airflow performance.
The head is fully stripped, chemically cleaned, and decarbonised before undergoing detailed inspection for wear, cracks, and casting integrity. All valvetrain components are assessed, with inlet valves cleaned and prepared for reuse where suitable.
The cylinder head is then precision machined, including new valve guides, 3-angle valve seat cutting, and face resurfacing. After machining, all components are vacuum tested and rechecked for sealing integrity before final cleaning and reassembly.
The rebuild is completed using upgraded valvetrain components including high-performance inlet and exhaust valves, uprated valve springs, and new hydraulic lifters, ensuring improved durability and stability under increased boost and RPM conditions.
A well-balanced performance package designed around the factory K04 turbo platform, aimed at delivering reliable power gains with supporting hardware upgrades throughout the system. This setup improves airflow, cooling, fueling, and engine calibration to safely support increased performance.
The package includes a front-mounted intercooler, uprated exhaust flow components, improved intake system, higher-capacity fuel injectors, and an uprated fuel pump. Engine management is recalibrated via custom ECU mapping to suit the upgraded hardware and optimise drivability and power delivery.
This configuration is intended for use with the K04 turbo platform. For higher power targets in the 350–400bhp range, a Garrett G-Series turbo system is recommended as the next stage upgrade path.
Example 400bhp performance package built around a Garrett G-Series turbo system. This setup combines upgraded forced induction, supporting fuelling and intake systems, standalone ECU control, and bespoke in-house calibration to deliver a complete engineered solution.
Key elements include a G-Series turbo conversion with supporting hardware, upgraded fuel and air delivery systems, ECU integration, and custom mapping carried out by Badger5. The package is fully installed and calibrated as a matched system for reliable high-power operation.