When most of us think of a Volkswagen Polo, we imagine an economical city car. Even in its WRC version, offering 220 HP, it’s still a sensible hot hatch. But Belgian company WS-Exhaust Systems has shown that this unassuming car can be transformed into a true beast with over 600 HP!
For several years, the company has documented the entire process on their YouTube channel, allowing us to follow this fascinating evolution step by step.
Project Development Stages
First Stage
The initial phase of the project debuted in January 2016. The Polo at that time was presented with a declared power exceeding 400 HP, although comments from internet users suggest that the actual value might have been around 330-360 HP. Even at these lower estimates, this little Polo already significantly outperformed standard hot hatches in its class, offering acceleration and flexibility far beyond the capabilities of the factory model.
Upgrade to 590 HP
After a year of intensive work, in February 2017, the project underwent a significant transformation. A much more advanced version was presented with a declared power of 590 HP. The car was described as “NR1 fastest street legal Polo WRC,” clearly indicating the ambitions of the WS-Exhaust Systems team. Most of the key modifications that define the final version of the project were implemented at this stage.
Technical Details
This video from March 2017 is a true treasure trove of knowledge for mechanical enthusiasts. It presents a detailed overview of all modified components, from the engine through the exhaust system to the turbocharger and fuel injection system. The level of craftsmanship visible in the hand-made elements, such as the exhaust manifold and intake system, is particularly impressive.
Testing on Standard Fuel
In May 2017, the team published tests of the car running on popular Super 98 fuel, maintaining a power declaration of over 500 HP. The comments under the video where some viewers question the actual performance are interesting. Importantly, in front-wheel drive cars, the declared power doesn’t always directly translate to proportionally better acceleration. With such high torque values, the main limitation is simply traction – even the best tires and electronics have their grip limits. That’s why a car with theoretical 600 HP might achieve acceleration times similar to a 400-450 HP construction, simply due to the physical limitations of front-wheel drive in transferring power to the asphalt.
Launch Control System
In early 2018, the project reached another milestone with a declared power of 618 HP. This video presents the operation of an advanced launch control system integrated with complete engine management by Syvecs ECU, showing impressive launches from a standstill.
100-200 km/h Acceleration
Simultaneously in February 2018, material was published showing acceleration from 100 to 200 km/h, intended as proof of the performance of this claimed 618-horsepower monster. Regardless of the discussion about the actual power, the rate of acceleration at medium and high speeds is extremely impressive, especially considering the compact Polo platform.
Technical Specifications
Engine Modifications
- Base engine: 2.0 TSI (EA113) from Polo 6R WRC (original 220 HP / 350 Nm)
- Original cylinder head retained with reinforced Ferrea valve springs
- Modified crankshaft adapted for increased power
- High-performance Mahle pistons with increased thermal resistance
- Forged IE connecting rods with increased strength
- Calico bearings set with increased durability
- Oil pump conversion to 1.8T pump for improved lubrication under high-rpm conditions
- ARP engine bolt kit with increased strength
Turbocharging and Intake System
- GTX3076R gen1 turbocharger (replacing the factory K04)
- Boulekos Dynamic intake manifold with additional 4 injectors
- Dual injection system (bi-injection) – direct injection to cylinders and additional injection to the intake manifold
- Wagner intercooler with significantly larger capacity and cooling efficiency
- Increased diameter throttle body for improved airflow
Exhaust System
- Hand-made exhaust manifold with thermal insulation
- Complete 3.5″ exhaust system designed and manufactured by WS-Exhaust Systems
- Custom muffler providing an appropriate balance between flow and noise control
- Sports catalytic converter ensuring compliance with regulations
Drivetrain
- SRE Motorsport clutch with single-mass flywheel
- 4th gear input shaft support preventing failures at high torque
- Modified gearbox adapted to increased torque
- Reinforced drive shafts
Suspension
- KW V3 coilover suspension providing precise handling at high performance
Electronics and Engine Management
- Syvecs ECU computer with dedicated mapping from DVX Performance
- Integrated launch control system with traction control
- Advanced monitoring of key engine parameters in real-time
- Ability to switch maps depending on fuel type and driving conditions
- Electronic safeguards protecting the engine from damage
Who’s Behind the Project?
This exceptional Polo was created by two companies: WS-Exhaust Systems responsible for the mechanical part and DVX Performance Belgium handling ECU mapping and electronics. Together they created one of the most powerful Polo 6R WRC Street cars. Particularly noteworthy are the hand-crafted elements, such as the exhaust manifold and intake system with additional injectors, which demonstrate the true craftsmanship of the specialists involved.
Photo source: https://www.facebook.com/media/set/?set=a.1506278716102083
Summary
Regardless of the discussion about exact performance figures, the Polo WRC Street by WS-Exhaust Systems is an impressive example of advanced tuning. This project showcases the potential of the Polo 6R platform and proves that extreme capabilities can be achieved without sacrificing the car’s usability for everyday driving.
