The diesel Rocco Racekor project.

[The Badger]

f1nn said:

Okay, I've got a confession to make....

When I first saw this car, well perhaps not the car...I suppose I mean stickers, bonnet and that thing on the back, I chortled to myself, but I've grown to like it and always enjoy your updates.

Keep it up!

Totally never got folks aversion, phobia etc of cars that nod to motorsport. Whether it be decals, wings or stripes. They don't give a st in The USA. Is it us Brits are just more conservative? Or we're that arsed what others think? - however fleeting our exposure.

[f1nn]

No, I just didn't like it.

[Grant20V]

Looking good mate.

[Zoobeef]

I hate the fact I've had to put a couple more stickers on my racecar for the new season

[xjay1337]

Zoobeef said:

I hate the fact I've had to put a couple more stickers on my racecar for the new season

How will you sleep at night

f1nn said:

Okay, I've got a confession to make....

When I first saw this car, well perhaps not the car...I suppose I mean stickers, bonnet and that thing on the back, I chortled to myself, but I've grown to like it and always enjoy your updates.

Keep it up!

Thanks mate.
It's not to everyones taste but then again it is mine, not everyones

I'm very excited for the next stage in the process!
The parts list is quite long .

Grant20V said:

Looking good mate.

Thanks

[Pacman1978]

How this car/thread can contain negativity is rather odd, it's a car forum after all FFS. I couldn't hold a spanner but respect for all the hard work, tis a very nice project.

(as for people, moaning, they are just s)

:-)

[anonymous-user]

If you don't mind me asking..car excluding how much has been thrown at it financially?

[xjay1337]

Pacman1978 said:

How this car/thread can contain negativity is rather odd, it's a car forum after all FFS. I couldn't hold a spanner but respect for all the hard work, tis a very nice project.

(as for people, moaning, they are just s)

:-)

I will happily take bad and good comments.
Being a diesel pretend racekor you're never going to make many friends on here, but I'm sure many will appreciate the work I just love cars and sharing my progress, even if no-one else cares!

GravelMachineGun said:

If you don't mind me asking..car excluding how much has been thrown at it financially?

Ummm.........



just off top of my head rough figures, don't include regular servicing which I do every 8-15k depending on my driving @ £80 a pop, doesn't include brake pads changes, bulbs, tyres, etc and other little bits I forget about.

Chassis:

H&R Springs - £150
Superpro Ball joints - £150
Powerflex front Wishbone Bushes - £70
Powerflex rear wishbone bushes - £60 (not fitted yet)
Tyrolsport Deadset kit - £190
UltraRacing under bracing (used) - £40
TeamDynamics 1.2 (got the O.Zs for straight swap) - £500
Aston Martin DB9 Calipers, carrier adaptors, Pagid RS4-2 pads, TTS 340mm discs : £1200
Swap to Project Mu H16 pads - £360 (I'm on my second set of these....)
H&R 28/24 Rollbars - £340


Engine/Gearbox:

Darkside Stage 2 tuning (DPF delete / remap) - £900
Darkside GTB2260, Intercooler pipework, Helix 6 paddle clutch - £5000 (labour inclusive)
Polyeurethane Engine mounts - £250
Quickshift Kit, shift linkage, bushes etc - £150
Bobby Singh CP3 Fuel pump / Tune (also inc cambelt and thermostat and some other bits) - £1200
Oil Cooler - £500

New Cylinder Head - £150
New VKLR Hybrid turbo - £850
Porting - TBC around £850
New Injectors / seals - £325
Head rebuild kit - TBC around £80
Other performance parts, fabrication, associated rebuild parts - £250

Interior:

Recaro Pole Positions - £1800
Rear seat removal bits and pieces - £50
Harness, bar, plates welding etc - £1000
Hertz Speakers - £350
Sub - £50
Headunit - £300
Polar FIS Advanced - £180
New cluster & coding - £150

Exterior:

Replica R front bumper / paint - £350
Carbon bonnet - £700
Stickers etc - £350
Big gay wing and carbon hydro dip - £650

As I said there's probably loads I've forgotten.

£19,495

The car was £8000 when I bought it, which was cheap. So that's OK.

I'm going to find the nearest bridge and jump off it now.

(edited to add the polar FIS and new dash cluster)

Edited by xjay1337 on Wednesday 18th January 11:38

[Butter Face]

Good value if you enjoy it!!

[f1nn]

That makes me feel far better about the money I've thrown at an old 3 series!

[Butter Face]

f1nn said:

That makes me feel far better about the money I've thrown at an old 3 series!

It makes me think that I'm definitely not adding my bills up

[anonymous-user]

xjay1337 said:

Ummm.........



just off top of my head rough figures, don't include regular servicing which I do every 8-15k depending on my driving @ £80 a pop, doesn't include brake pads changes, bulbs, tyres, etc and other little bits I forget about.

Chassis:

H&R Springs - £150
Superpro Ball joints - £150
Powerflex front Wishbone Bushes - £70
Powerflex rear wishbone bushes - £60 (not fitted yet)
Tyrolsport Deadset kit - £190
UltraRacing under bracing (used) - £40
TeamDynamics 1.2 (got the O.Zs for straight swap) - £500
Aston Martin DB9 Calipers, carrier adaptors, Pagid RS4-2 pads, TTS 340mm discs : £1200
Swap to Project Mu H16 pads - £360 (I'm on my second set of these....)
H&R 28/24 Rollbars - £340


Engine/Gearbox:

Darkside Stage 2 tuning (DPF delete / remap) - £900
Darkside GTB2260, Intercooler pipework, Helix 6 paddle clutch - £5000 (labour inclusive)
Polyeurethane Engine mounts - £250
Quickshift Kit, shift linkage, bushes etc - £150
Bobby Singh CP3 Fuel pump / Tune (also inc cambelt and thermostat and some other bits) - £1200
Oil Cooler - £500

New Cylinder Head - £150
New VKLR Hybrid turbo - £850
Porting - TBC around £850
New Injectors / seals - £325
Head rebuild kit - TBC around £80
Other performance parts, fabrication, associated rebuild parts - £250

Interior:

Recaro Pole Positions - £1800
Rear seat removal bits and pieces - £50
Harness, bar, plates welding etc - £1000
Hertz Speakers - £350
Sub - £50
Headunit - £300

Exterior:

Replica R front bumper / paint - £350
Carbon bonnet - £700
Stickers etc - £350
Big gay wing and carbon hydro dip - £650

As I said there's probably loads I've forgotten.

£19,165

The car was £8000 when I bought it, which was cheap. So that's OK.

I'm going to find the nearest bridge and jump off it now.

Crikey!

[ZX10R NIN]

You're not in a club of one their Jay so make room on the bridge I don't ever add up my bills they're in a cupboard for the next owner (if for some reason I lose my mind & sell up) but TBH I don't care they do exactly what I want them to do which is put my a on my face.

Anyway no more projects for me this year new house is curbing expenditure but it does have a bigger garage

Keep up the good work Jay it's coming along nicely do you know how much more flow you've got from the head yet?

[Grant20V]

Can't put a price on happiness

[xjay1337]

Turns out you can put a price on happiness Grant, and it's about £28k lol.

I don't regret it though, and unless someone offers me a fair chunk for it in a few years I can't imagine selling it.

GravelMachineGun said:

Crikey!

I kind of wish I hadn't looked now !!

ZX10R NIN said:

Anyway no more projects for me this year new house is curbing expenditure but it does have a bigger garage

Keep up the good work Jay it's coming along nicely do you know how much more flow you've got from the head yet?

Bigger garage is more space for vehicles and "things".... -
Once your house is sorted you are welcome to join me haha

The OEM heads are very restrictive, the inlets are awful.

We won't know exactly until it's fitted and we have tested, as there are variables as you can imagine and we are changing many parts, inlet, cyl head, turbo, intake, etc etc.
Bench tests don't really count for much - on the bench the CR head flows more than BKD 2.0 16vPD head but in practise we know this is not the case.

We anticipate the head will be good for all our future needs. I think I will be happy with 320bhp

But no-one else has pushed a car like this, we are truly into experimental. The new turbo is good for 330 realistically, but as it's roller bearing we should have excellent spool so torque from low rpm.

If we find the new injectors and head are able to support the new turbo running at max capacity then I may change turbos again but I would get a new bottom end and build it up with pistons and rods.

Edited by xjay1337 on Wednesday 18th January 13:00

[Pacman1978]

Grant20V said:

Can't put a price on happiness

+1

Seems a fair price for amount of joy it must give. 20k better spent as OP has rather than some bland run of the mill euro box!

[ZX10R NIN]

xjay1337 said:

Bigger garage is more space for vehicles and "things".... -
Once your house is sorted you are welcome to join me haha

Exactly the plan bigger Garage = more toys lol

I already have my eye on the Weistec stage 2 Supercharger kit which will also incorporate the purchase of another CLK63 so the house has to come first along with a new kitchen which will hopefully keep the OH busy enough not to notice another CLK

xjay1337 said:

The OEM heads are very restrictive, the inlets are awful.

We won't know exactly until it's fitted and we have tested, as there are variables as you can imagine and we are changing many parts, inlet, cyl head, turbo, intake, etc etc.
Bench tests don't really count for much - on the bench the CR head flows more than BKD 2.0 16vPD head but in practise we know this is not the case.

We anticipate the head will be good for all our future needs. I think I will be happy with 320bhp

But no-one else has pushed a car like this, we are truly into experimental. The new turbo is good for 330 realistically, but as it's roller bearing we should have excellent spool so torque from low rpm.

If we find the new injectors and head are able to support the new turbo running at max capacity then I may change turbos again but I would get a new bottom end and build it up with pistons and rods.

I hope you get to 320bhp pal

[xjay1337]

Did my first trackday of the year.

https://www.youtube.com/watch?v=W61NeEho4Mg
(Footage from my first session at my first time at Bedford, I got a lot better but didn't take footage, I will explain).

I wanted to test out my oil cooler. It worked. I could go for about 6 or 7 flat out laps which is about 15 minutes, which is about as long as I do in any one sitting anyway.

Unfortunately, the car had other ideas.

20170120_144416 by Fat Bear Photography, on Flickr

The car decided to overheat, luckily caught it before it was too severe, and dump it's coolant onto the track / pits.
Despite this, there was no obvious leak. There was a st ton of water around the reservoir, but it was also all over the engine bay, so no obvious point of egress.
I topped it up, bled it, seemed ok for the next session.
Then my third session, it did it again. So I stopped.

I went to AKS Tuning after, we fitted a braided clutch line.

20170120_163016 by Fat Bear Photography, on Flickr

Didn't really do much, slightly more feel which is good, but the main point is it eliminates the failure parts of the OEM clutch pipe.

We tried to find the water leak, but Alex nor I could see any obvious point of egress. Very annoying.

20170120_162300 by Fat Bear Photography, on Flickr

After further investigation, and an 80 mile drive today, it seems fine.
I suspect a couple of things may have happened.

1) Cylinder head lift (typical on big turbo TDI's).
Oem bolts are 10.9 tensile strength, at high boost and high heat situations you lift the head off the block which allows exhaust gasses into the cooling circuit , pressurising it.

2) A weak/failing O-ring on the coolant temperature sensor.
This seems to have some amounts of coolant on the pipe past it. We think this is the only obvious point of failure as there are no splits or leaks in the system . The o-ring / CTS will be replaced when we re-build the head.
I did go to see Bobby, my tuner, today as he needed to test a known-working Lambda sensor on another car he was tuning, while I was there, we pressure tested the cooling system and there was no leaks. The pressure tester was not 100% but we got to about 17psi and nothing was coming out with engine off or running.

I've parked that issue for now and just avoid extended high speed driving.

I also fitted a new dash cluster. As I had wanted blue needles for a long time and finally got around to getting them done.

Here is my OEM cluster.

20170120_055218 by Fat Bear Photography, on Flickr

and here's the replacement, it's from a Golf Mk6 GTD, but the needles were swapped and the SMD's on the dash cluster themselves were replaced to give the correct OEM blue type needles.

20170122_163922 by Fat Bear Photography, on Flickr

20170122_163944 by Fat Bear Photography, on Flickr

So not all bad news.

That's it for now.

[MrBarry123]

Makes me chuckle every time I familiarise myself with the progress you're making - great work Jay.

[chuntington101]

Nice work on tracking the car. Sounds daft but it didn't overhear did it? Are you sure the stock radiator is upto the job?

Also have you flow benched the intake manifold? Just wondering if there would be any benifits to be had there?