The diesel Rocco Racekor project.

The diesel Rocco Racekor project.

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xjay1337

Original Poster:

15,966 posts

118 months

Tuesday 4th November 2014
quotequote all
Hi.
I bring to you a new project.
My old car was this.



And I had a thread of the modifications/progress here.

http://www.pistonheads.com/gassing/topic.asp?h=1&a...


After a change of heart and getting bored of the scene and the attitudes of "some" of the people within it, I went back to what I had known previously, building a car to drive, one that performs well, that I can enjoy and will be taking to trackdays, but one that also looks pretty evil and can be enjoyed for what a car is meant to be used for...

Bought from a good mate I work with for a great price.

Quick overview of the spec

2.0 TDI CR170
Full heated leather
Bi-Xenons
DCC Adaptive Chassis

I'll be worrying about how it drives first and then worry about making it look good, with different bumpers, splitters, spoilers and what not.






The first thing I did was enable needle sweep, alarm chirps, and adjust a few other parameters via VCDS.

https://www.youtube.com/watch?v=fvtc8nNjzLE

Had the wheels refurbished in a shadow chrome finish.



In went the Recaro buckets from my Golf.



In went H&R 30mm springs, Powerflex front & rear wishbone bushes, and Super Pro camber adjustable ball joints.








Final alignment... 2 degrees of negative camber given from the ball joints.
I will be getting camber adjustable Ground Control Top mounts as well which remove the rubber mountings and provide a stiffer setup still.


Fitted a GTI gearknob



New Bosch S5 007 Battery.



Adjustable quickshifter which is a fantastic mod for any manual car



On the 15th it's going in for a full service with new fuel filters, uprated polybushed lower engine mounts and most importantly, new brakes - a custom setup courtesy for AKS Tuning compromising of TTRS/DB9 Brembo 4 pot calipers with 340mm J-Hooked discs, custom brackets, braided lines and what not.
I had to work out the caliper clearance and it turns out I need a 12mm spacer. An idea of how it would look minus the J-hooked disc...



How it currently sits.





It's going in on the 21st to have the DPF/Cat and EGR removed and a Stage 2 remap, then after that will be the remaining handling mods - Being H&R anti roll bars front and rear, rear suspensioni arms to be polybushed and R32 rear brakes (310mm)

After that will be the audio build with uprated Hertz ESK163L door speakers, one off subwoofer enclosure with a Rockford Fosgate sub and the usual sound deadening, then I will worry more about the looks aspect and look at R-Line kits and the cup spoilers.
I'll be wanting to put a half cage in as well, remove the rear sits and fitting other chassis-stiffening components along the way.



Edited by xjay1337 on Tuesday 4th November 17:13

Mattknight1984

157 posts

115 months

Tuesday 4th November 2014
quotequote all
114k already - high for its age isn't it! Is that why it was cheap?

Plans sound good, although not sure I'd spend that money on a diesel if you are trying to build a car that's fun to drive - surely the 2.0 turbo petrol would've been a better base?

xjay1337

Original Poster:

15,966 posts

118 months

Tuesday 4th November 2014
quotequote all
Even with the miles I got it for about £1500 under what it should go for, it's been fully serviced by VW and had the cover of a VW Warranty until May this year

I have modified a 1.9 TDI before (with even higher mileage) and I had huge fun with that, and of course, doing a lot of miles (I do around 30k per year) it does save a few pennies.
My GTI was of course 2.0 TFSI and I never really connected with that. Partly because show-car but also because it was missing something.

An Audi S3 was an option (k04/stronger internals) but I got this car for a bargain and do much prefer driving it to my GTI, I'm a fairly relaxed (torque based) driver anyway.

Mattknight1984

157 posts

115 months

Tuesday 4th November 2014
quotequote all
Ah yes, I remember your username from the mk4 forums now (I had a mk4 1.8t then my current mk5 gt tdi that Im sure you offered advice on).

I know what you mean about the torque, I've not long bought a 2012 1 series with the 1.6 twin turbo petrol engine. Great car, but miss the torque of the remapped mk5.

Joe5y

1,501 posts

183 months

Tuesday 4th November 2014
quotequote all
xjay1337 said:
Hi.

"I'll be worrying about how it drives first"


"The first thing I did was enable needle sweep, alarm chirps"


Edited by xjay1337 on Tuesday 4th November 17:13
confused uummmm . . .

xjay1337

Original Poster:

15,966 posts

118 months

Wednesday 5th November 2014
quotequote all
Apologies, some of the pictures seem to not be working? Work on other forums.

Joe5y said:
confused uummmm . . .
Yes, because I can plug in a laptop and do things in 10 minutes at absolutely no cost to myself.
Don't be a potato.


Mattknight1984 said:
Ah yes, I remember your username from the mk4 forums now (I had a mk4 1.8t then my current mk5 gt tdi that Im sure you offered advice on).

I know what you mean about the torque, I've not long bought a 2012 1 series with the 1.6 twin turbo petrol engine. Great car, but miss the torque of the remapped mk5.
Probably biggrin

Yeah, defo - The GTI was a great drive and sounded awesome when flat out, it wasn't that laggy to be honest and did pull well but it's that initial surge that the diesels can provide that I miss... then again I'm compared a modded GTI to a stock diesel engine, if I can get around 210-220bhp from the DPF delete and remap (my old TDI made 221bhp and 365lb ft with a GTB1756vk) then I will be more than happy. With scope to go higher with a larger turbo and updated clutch and what not.. Plus with the full 3 inch TBE and no silencers I'm hoping it will sound the part too.

My old Golf TDI from 3 years ago about 3 runs before I blew up the gearbox lol





Edited by xjay1337 on Wednesday 5th November 12:26

xjay1337

Original Poster:

15,966 posts

118 months

Monday 17th November 2014
quotequote all
So a very busy day on Saturday...

Here's what went on.



AKS Tuning Aston Martin / TTRS BBK - Consisting of 4 Pot Brembo calipers, custom mounting brackets, 340mm (very light for the size) EBC USR disc and Pagid RS4-2 Pads along with HEL braided lines
BMC Panel Filter
Gen oil & fuel filters
Millers Nanodrive 5w40
New genuine drop links
Super Pro Dogbone Insert (from a petrol... will get to this later).
Subframe spacers
12mm H&R Trak+ spacers (front and rear).
Fiscon Advanced PF03

I rocked up very tired, after having 3 hours sleep (working late detailing the nigher before), at around 9:45am to my buddy Alex who owns AKS Tuning over in Bedford, around 2 hours away.
I had been booked in for some time and in preperation for Darkside's increased power levels I felt even at standard power the stock brakes were severely lacking and wouldn't give me the confidence to be able to push on, along with wanting to make sure mechanically everything was spot on.

The calipers up close



Fitted to the car while having a bit of a working lunch...(they're actually delicious).



Pressure bleeding the whole system (front and rear)/



Fitting this bad boy....



Fiscon Polar Advanced (PF03). Works great with my existing Fiscon Basic+ Bluetooth set up (factory Bluetooth removed by previous owner). It was updated first with the latest software prior to installing. The main reason behind getting the Polar was that I wanted a boost gauge. Newsouth did make a 0-35 PSI gauge which would match my standard dash lighting, great, however, Newsouth did not make a air vent pod in right hand drive... they made one for the LHD market, and of course the Mk5 Golf...The only available mount was a steering column mount, which I have had in my GTI and my TDI prior to that - And it was horrible, rubbed on the steering wheel making a squeaky noise. You could resolve this by sanding it down but it still didn't look very factory. On my GTI I bought an air vent pod, but as mentioned, was not available for the Scirocco... so I was left with 2 options. Buy another vent and construct my own vent pod for the Scirocco or come up with an alernative solution. I wanted something that would be in, in time for Darkside, so I spoke to Alex and, the Newsouth Gauge would have come in at around £125 by the time you've bought a self sealing take off. Buying a vent was around £30 and then the time of making one that actually looked factory, still costing around £90 including the gauge, where as I managed to get the Fiscon for £180 new. It was slightly more over all but provided a wealth of additional information, intake air temperature, exhaust gas temperatures, fuel in liters, coolant temperature as a figure, DPF status (which will be irrelevant as it's being removed soon, but nevertheless), I was able to work out when regenerations were happening, see things about fuelling, injector durations, quantities, etc... very clever and geeky.



It was a bit fiddly to install, but not difficult at all - the wipers and the wiper motors need to come off and you get access to I think it's the CAN Gateway by removing a small plate under the windscreen



12mm spacers fitted to the front and rear... car looks a little high as it's just been lowered back down and hasn't settled.



The spacers were needed up front due to the adaptor brackets pushing the caliper out slightly, combined with the Scirocco Turbines being really poor for clearance to begin with.. We tried a 10mm and it caught, 12mm clears with barely a sheet of paper between the caliper and the spoke.

The BMC Panel filter was installed, new fuel filter, new oil filter along with high performance Millers Nanodrive stuff, the subframe spacer kit was installed and the Superpro dogbonoe insert fitted...



Alex didn't have any diesel ones in stock, which are softer, as diesels have more vibration, so we put a petrol one in... which is great, reduces transmission movements A LOT, but unlike the insert I had in my PD engine'd Mk5 from years ago (which I didn't notice any extra vibration), on this I get quite a shake at idle and pulling away, or low revs. Now currently the bush is very new and will bed in. I love how it feels, and at the moment the extra NVH isn't annoying, but if it does then I can just swap it out for a softer (diesel) bush.

Anyway, not really put the brakes through any serious strain as it's been wet and I've just been going around doing my usual business - but I've used them a few times and MY GOD they don't half stop you, they literally pull your face off. Pedal travel is great, I was worried that I would end up with a longer pedal but this is spot on, it's quite short and hard (oy oy!) which I like, but not so short that you can't be progressive still around town. The best upgrade I have made to the car yet, period.

Now just onwards waiting for Darkside, which is 4 days away now :-)

xjay1337

Original Poster:

15,966 posts

118 months

Tuesday 25th November 2014
quotequote all
Stayed up till about 3am cleaning the car...needed the therapy lol...

IMG_0542-2 by Fat Bear Photography, on Flickr

Certainly had been putting these Pagid RS4-2 Blue's through their paces..

IMG_0537-1 by Fat Bear Photography, on Flickr

IMG_0539-1 by Fat Bear Photography, on Flickr

Then took my old man to get his new car, a CR170 Octavia VRS - Cool to have my Dad in the same sort of car as mine, already got him primed to pull the trigger on some H&R springs, ball joints and bushes courtesy of Alex

IMG_0557-1 by Fat Bear Photography, on Flickr

Then the next day I set off for Darkside at stupid-o-clock



Arriving on literally no sleep and 3 red bulls... I grab a half-arsed shot of her on the dyno.

IMG_0590-1 by Fat Bear Photography, on Flickr

At Darkside we had the following:

EGR Delete
3 Inch Downpipe / DPF/Cat removal
Hard cut limiter set at 5k


It was down on power compared (normally from my experience VAG engines pull about spot on or just over their rated power) but the end figure is there or there abouts.
I spent a lot of time talking to Darkside and perusing other diesel tuning forums to get a proper idea of what sort of power these engines reach as there's not much in the way of actual dyno'd & verifiable output. Darkside said anything between 195 and 205 is bang on the money.

My Fiscon has also highlighted how quickly the intake temps can rise, even when it's 8 or 9 degrees outside the temps shoot up from about 11-12 degrees to 22 or 23 after a single pull through 3rd and 4th, so an uprated intercooler is on the cards - watch this space...

Regarding the future power, my EGR was apparently very blocked up and they were surprised it hadn't caused me any issues - because of this they recommend that I clear the inlets and remove the swirl flaps which may free up a bit of extra power.
A 2056 and tubular manifold is on the cards but having just spunked £3k on the car in the matter of 2 weeks I need to let my bank account balance settle (and sell my Golf FFS) - I think 240-250bhp and this would be a beast of a car on road and track. For now it's quick enough to put a smile on my face and handles brilliantly.

Driving wise, well the tuning has transformed it - It no longer feels breathless and does pull very well indeed. I would say it's quicker than my GTI was standard. The MPG has also improved quite a bit. Ryan was very complimentary on the handling setup saying it's one of the nicest cars they've driven and how well it handles and rides.

The next plans are pop back over to Alex for my cat-back exhaust section to be made up, giving me a full 3 inch TBE, we will see what he can do RE the swirl flaps as well which is happening on the 19th of December. Gonna tweak my short shift (change some bushes and add some washes to stiffen up the side to side movement) and look into a bit of fabrication for a heat shield or two...


And here's the results.

10376188_380320572136615_3506914564937856865_n by Fat Bear Photography, on Flickr

So went from 161 to 194bhp with a huge jump in torque from 270 to 330lb ft


Am I happy with the figures? No, if I'm honest. Then again I have always been a subscriber to the "under the graph" dyno area, which has improved MASSIVELY everywhere along the rev range - But I take some comfort knowing that Darkside know what they are doing first and foremost, and secondly, have an honest, real world dyno. My old TDI left another tuner with 171bhp and went to Darkside's and pulled 155. I would rather have a solid, safe 195bhp than a dyno-happy and smokey 215-220bhp.

Am I happy with the driving experience, the smoothness, the lack of smoke and the kick up the back when I put my foot down? Yes, absolutely!

It was explained to me that these cars which claim to have up to 220bhp (which are all usually very smokey) can sometimes have sky-high EGT's which are over 1000 degrees C from 3500rpm upwards (they flatline at 1000 which is the maximum sensor reading, so are of course going to climb over that figure!)

My EGT's are limited to 850, and I noticed absolutely no smoke on the drive back. The guys said if they had raised the EGT limit they could have got into the low 200's but the extra stress on components is not worth it for the small (5-7bhp) gain, which at the wheels you wouldn't really notice anyway.

Despite the fairly disappointing end NUMBERS, the driving aspect of the car is great and yes, I would pay the money again knowing the outcome. Albeit feel that I could have gone straight for the GTB kit to begin with... anyway...

IMG_0627-1 by Fat Bear Photography, on Flickr

IMG_0629-2 by Fat Bear Photography, on Flickr

Big thanks to Darkside :-) as finally I no longer feel like my car is dogsh*te slow!!!

JoeCass

1 posts

114 months

Tuesday 25th November 2014
quotequote all
Great Thread, Love these cars, Do you have a link to the thread on another forum? Majority of Pics aren't working for me.

xjay1337

Original Poster:

15,966 posts

118 months

Wednesday 26th November 2014
quotequote all
JoeCass said:
Great Thread, Love these cars, Do you have a link to the thread on another forum? Majority of Pics aren't working for me.
Thanks smile
They're not bad motors! No idea why the pics aren't working, all the coding is correct... perhaps it's the dynamic jpg's it doesn't like on this particular forum.
Anyway all the pics / write up is here too smilehttp://www.mk5golfgti.co.uk/forum/index.php/topic,...

MrBarry123

6,027 posts

121 months

Thursday 27th November 2014
quotequote all
Looks good Jay! Haven't seen it about yet though...

xjay1337

Original Poster:

15,966 posts

118 months

Tuesday 13th January 2015
quotequote all
MrBarry123 said:
Looks good Jay! Haven't seen it about yet though...
Bit late.com.

Thanks Mate (sam I presume) smile


Updates over Christmas and the new year...

Got some new Osram bulbs as the headlights were crap compared to my old Golf, made a good improvement.

Expensive though cos the ballasts are on the back of the bulbs... stupid things.




Finally got the remainder of my exhaust done with my mate Alex over at AKS again..

A Eurojet 3 inch V Band system, designed for a Golf Mk5 GTI, but obviously, being the same as a Golf underneath, it fitted fine. This exhaust was orignally going on my GTI, but as I was selling it, I lined Alex up with another buyer - Who had since bailed. Fortunately for me...

20141219_161642 by Fat Bear Photography, on Flickr

Looks lovely. Very shiney...very big.

Firstly we inspected the Darkside down pipe to see how we'd have to adapt. The Darkside system was 3 inch from the turbo to about half way down the exhaust tunnel, where it was reduced to I think it's 2.5 inchs to the stock system.

We (I say we, Alex did it biggrin) needed to fabricate up an adjoining link pipe. So we started with some 3 inch stainless steel piping.

20141219_163504 by Fat Bear Photography, on Flickr

Measure twice, cut once.
Or in Alex's case, measure once (and do it properly) and cut once.

20141219_163548 by Fat Bear Photography, on Flickr

Out comes the TIG welder! To connect the new link pipe to the existing Eurojet link pipe at one of the 90 degree bends..

20141219_164615 by Fat Bear Photography, on Flickr

Not bad for a quickie!!!

20141219_165534 by Fat Bear Photography, on Flickr

Now onto the car.....

20141219_165601 by Fat Bear Photography, on Flickr

Having to cut away the reducer off the back of the Darkside DP... not nice frown !!

20141219_170931 by Fat Bear Photography, on Flickr

After a slip on sleeve was fitted to connect to the Darkside downpipe, as well as mounting up the rest of the exhaust system less than 2 hours later we had the following:

20141219_172343 by Fat Bear Photography, on Flickr

20141219_173207 by Fat Bear Photography, on Flickr

20141219_173223 by Fat Bear Photography, on Flickr

Very brap brap ting.


one filthy car



Wheels are supposed to be shiny silver somewhere lol



Got a small delivery today from the lads up north...






The intercooler itself, and these two lower Intercooler hoses will be going on in February, along with my new clutch and flywheel. The rest of the pipework will be going on when the turbo kit is fitted in a months time.

Had the car dyno'd again as well today ...

Did broadly the same figures, about 10bhp difference.
201 / 203 bhp
346 / 384 ft lb

at the crank, at the wheels on both runs it did 190bhp and 325 and 358 ft lb respectively.

Flat bhp similar to the darkside dyno, sooo... happy with that for another month lol



Just goes to show different dynos can read differently. I think Darkside's dyno is perhaps a bit more accurate, the first run the car had been sat for a while so had much higher intake temperatures as they were setting up the dyno before turning on the fans.


Made a Mk7 GTI gearknob fit the Mk5 surround, my buddy Jairm did this for me and is the first in the UK as far as I can see.



in february we are up again at DsD for a GTB2260 kit so hoping to max out the stock fuel system and once a HPFP upgrade and injectors are available we can go for the magic 300 which is the figure i am aiming for.

Plan after that would be getting another set of wheels with some trackday rubber and making the most of the show and track season, drag days and the odd track day here and there.
Then we will go for the R body kit and a few other little cosmetic tweaks.

r1chardb

223 posts

242 months

Thursday 15th January 2015
quotequote all
What's a Racekor?

xjay1337

Original Poster:

15,966 posts

118 months

Thursday 15th January 2015
quotequote all
r1chardb said:
What's a Racekor?
Say it out loud 3 times

Maty

1,233 posts

213 months

Friday 16th January 2015
quotequote all
Like the look of this and the work that's gone into it.

Have you got any pictures of this Fiscon kit on the display? I ask because I recently bought an Octavia VRS and added the Fiscon handsfree kit as mine wasn't fitted with the standard VAG Bluetooth module......I like the sound of a boost gauge on the stereo, not fussed about all the other temps etc.


xjay1337

Original Poster:

15,966 posts

118 months

Friday 16th January 2015
quotequote all
Maty said:
Like the look of this and the work that's gone into it.

Have you got any pictures of this Fiscon kit on the display? I ask because I recently bought an Octavia VRS and added the Fiscon handsfree kit as mine wasn't fitted with the standard VAG Bluetooth module......I like the sound of a boost gauge on the stereo, not fussed about all the other temps etc.
If you check back later on I'll make a quick video at lunch time smile

Maty

1,233 posts

213 months

Saturday 17th January 2015
quotequote all
Thanks for that, look forward to it!

What's the noise like with the exhaust on now?


xjay1337

Original Poster:

15,966 posts

118 months

Wednesday 21st January 2015
quotequote all
Sorry, I keep forgetting to do the video. Will do it, promise!

Video of the noise:

https://www.youtube.com/watch?v=3-NdaoB8Ll0

Apologies was just a quick one on the DSLR and I forgot to turn off auto fckus.

SP0TIFY

18 posts

112 months

Wednesday 21st January 2015
quotequote all
Love Scirocco's (Y)

r1chardb

223 posts

242 months

Thursday 22nd January 2015
quotequote all
xjay1337 said:
Say it out loud 3 times
not trying to be an smartarse, but I genuinely don't get it. Are you saying its a silly spelling of race car? If so, I think what you're creating is a "Roadkor" or maybe an "capableofanoccasionalrackdaykor"?