The diesel Rocco Racekor project.

[xjay1337]

But yes, it's just a bit of fun.

Maty said:

Thanks for that, look forward to it!

I have done a quick video of the Polar add on thing , just need to get 5 minutes to put it off my phone onto Pootube.

SP0TIFY said:

Love Scirocco's (Y)

Cheers. I love them too

[xjay1337]

https://www.youtube.com/watch?v=PAeH4vx2S3Q&li...

Quick overview of the Polar MFD.
Not sure if that's what you wanted...?

[xjay1337]

Helix 6 paddle clutch & pressure plate and new DMF (believe it's a Golf R one because the clutch assembly would not work with a CR170 DMF). Alex very kindly spent a whole load of time researching and measuring on various cars over the last couple of weeks to ensure it was going to work..it as he found out that the normal DMF for these engines when mated to a Helix clutch didn't provide the correct "height" (in effect the clutch would not disengage ... same issue I had with my original Darkside clutch kit back on my old 1.9 TDI). - This one went on and fitted nicely!

In addition to this, a few other general transmission related upgrades, the bleed valve had the restrictor removed from it, which basically is put in place to make the clutch pedal less springy - if you press your clutch down and lift your foot off it at speed you'll probably notice that the pedal is slightly delayed coming up...(it wasn't ever "bad" before...but we could improve it..) so you get a much better clutch feel. Despite the very bitey and grabby nature of any uprated clutch, the benefit is that it's such a "positive" pedal feel, you know exactly what's going on - in addition it makes for rapid gear changes as the clutch engagement is basically instantaneous.

Further more Alex shoe-horned me into getting the complete 42DD shift linkage kit... along with metal side to side linkage from a Mk1 Cupra R I believe..which is metal rather than the CRAPPY, wobbly and pathetic plastic one fitted as stock to the Rocco..which already broke previously and I had to replace it when I could go from 2nd to 4th in one fell motion. He also modified the bolts on my quickshifter to eliminate excess "wobble"...




After another cock up, with me being very poorly lately and not really with it, leaving without the inter cooler at home...meant a 180 mile return journey to pick up my new cooler from home but this doubled as a chance to get to know my new clutch and shifter and i can honestly say i've never been more pleased with how my knob feels in my hand. it feels very slick and positive (not HIV) and again just adds to the driving pleasure. infact i find moving my knob more and more just for pleasure.



So day two...
I started the day with a premier inn buffet breakfast..hehe.

Intercooler time

20150212_110249 by Fat Bear Photography, on Flickr



The whole front end comes off nicely leaving plenty of room to work.

20150212_124513 by Fat Bear Photography, on Flickr

On went the new Darkside intercooler... some interesting facts RE Intercooler...

Stock IC weight.. 3.8kg..
Peron IC ....7kg
Darkside IC... 11kg lol

Also we determined it's basically a THS Intercooler..

Also, the new intercooler being a bit bigger, pushed the whole assembly forward, meaning it wouldn't fit behind this section of the bumper.. basically a tough plasticy piece, can't see any practical purpose...so we chopped it off.

Off came the air conditioning rad too, which we determined that we may as well replace it, because it was very stonechipped and buggered. So was discharged and the condensor replaced with a new one and then re-gassed as appropriate.

20150212_114433 by Fat Bear Photography, on Flickr

20150212_135539 by Fat Bear Photography, on Flickr

Also given new Millers Nanodrive CFS 5w40 oil and gen filter.

Intake temps are well down and now as low as 0.5 degree above ambient (vs 3 degrees above ambient) on a cruise and greatly increase speed in recovery of temperatures, and keeping temps down during acceleration. So well chuffed with that.
The DsD supplied pipework was OK, one side was too long (fine, just cut it down, although needed to be slightly better angled) and one side was very nearly too short..needed to be a bit longer.. luckily Alex was able to get it to work.

[xjay1337]

It is quite big!!

With the DsD cooler I'm now finding that my cruising intake temps are as low as 0.5 degrees BELOW ambient (I monitor on my polar) and recovery rates are greatly improved on the stock cooler..drops from 22-23 to 6 or 7 very quickly. Heatsoak also seems much much less of an issue, I have seen intake temps up to 45 degrees with my old cooler after parking up for a few minutes - the highest I've seen since the cooler went on in similar ambient conditions and pre-shutdown conditions is 22...so a big improvement.

So on Monday morning after setting off at 5am... again..... I arrived at Darkside to see the bumblebee on the ramps..

20150216_100340 by Fat Bear Photography, on Flickr

Popped over to the other unit and saw my brand new GTB2260 and tubular manifold... my manifold came off their Arosa after a few dyno runs ... little piece of diesel history if you were such interested in rubbish like that haha and saved me a few bob...which later turned out to be a godsend..as I will explain.

Anyway I left them with the car and we carried on up to Scotland...for a holiday!
Staying in Edinburgh, had loads of fun and I will upload a few pics to share when I've had the chance to pull them off my Camera.

20150216_161613 by Fat Bear Photography, on Flickr

Anyway, the car was due to be collected on Saturday.
It all seemed well and I was getting regular updates. Then I had some bad news...the car wasn't running happily at all...was not boosting right, was very smokey, and would only do 206bhp....the EGT sensor had failed and the battery kept going flat... this was on Wednesday. They also removed the Swirl Flaps on the Inlet for me, something that could have possibly caused issues but it hadn't in this case, although, same as the EGR - they were all gunked up... (I suspect a Terraclean on the car would go down well) as we get closer and closer to Saturday I get an Email at 5:45 on Friday night (by now we were staying in Barnsley) saying basically the car is not running right and they'd need more time... things happen , and I was kept up to date all the time, so I wasn't bothered. But was panicking trying to arrange to borrow cars or worst case, rent a car for the next week.. Darkside had given me FOC a EGT sensor which seemed to do the job...

I popped along at 11:30 on Saturday morning just to check the car over myself. I paid a large chunk of the bill and said that I would leave the car with them..just as we were heading out the door, Ryan came through beaming away saying he thinks he's just fixed it..but wasn't sure - so I waited around. After a few hours I was told the car was ready!! But some bits needed tweaking and we also needed to get a NEW EGT sensor..the one they gave me FOC seemed to work for a while - but then stopped reading over a certain temperature which was limiting power..so we had to get a new EGT sensor.. Very happy and big thanks to DsD for hanging on and really working hard to get it running well.


So the final result is 237bhp and 375lb ft which is a teeny bit low but around the money.. their own CR170 did 242.. and mine has done a fair more few miles to be fair, they are also running a prototype HPFP.

20150221_144510 by Fat Bear Photography, on Flickr

It was interesting to note that after fitting the intercooler, the car made exactly the same power but it held the power at the top end better... from 3800 to 5k, a consistent 5-6bhp more.
The spike on the graph is not ideal but you don't feel it on the road... another aspect of "dyno charts don't tell the whole story".
It drives VERY nicely and smoothly... love it. It feels MUCH more aggressive on the road and it's absolutely quicker than my Stage 2 GTI was...which was never dynoed but they go between 250 and 275. It feels like 280bhp to be fair, and on the road it's much faster than the figures suggest.

Gonna let everything bed in for a few thousand miles then we'll start trackdaying...

Now the plans are...

- Get the new wheels on.. Team Dynamic Pro Race 1.2s - try to find some slicks for 2 of my Scirocco wheels to use at Drag events.
- Superpro rear suspension bushes
- H&R Anti Roll Bars
- 335mm rear brake setup
- Limited Slip Diff
- R Line bodywork and paint


Video of the acceleration.

https://www.youtube.com/watch?v=OmQgQnl1T4M

After having them sat around for a week while I was working on a car I spent yesterday evening applying CQuartz to them. Being white, it's an absolute b*tch to apply because you can't see where you've applied it, and the design is very fiddly so you don't good visibility with the light

I ended up putting 2 coats on the barrels and faces and I left them to cure over night - this evening I will apply Reload as a top up tonight, prior to having them fitted. Just hoping it will enable easy cleaning for a year or so, the brake pads can dust a fair amount!

11046764_427725650729440_5904329334824409369_n by Fat Bear Photography, on Flickr

I need my existing tyres swapped over, probably fortunate as my current front tyres are getting a tad low, so will just rotate them when we put them on.
Am quite happy to finally get them on, hopefully it's tonight and I can clean the car and get some nice pictures

All coated up and ready

11025734_427725690729436_896505323151573400_n by Fat Bear Photography, on Flickr

Cheers for reading.

[mug81]

Really enjoying this thread, thanks. It sounds great!

I'm curious to see how it feels with all that torque, are you London/Kent way at all or anytime soon? Would love a cheeky passenger ride etc.

Cheers

[xjay1337]

I attend weekly meets London way.
First Monday - Cobham Services
Second Tuesday - Krispy Kreme Kingston (A3).
Third Saturday - Tesco Earls Court (first floor Multistory).

all from 8pm onwards**

welcome to a ride anytime then.

Edited by xjay1337 on Thursday 5th March 00:21

[mug81]

xjay1337 said:

I attend weekly meets London way.
First Monday - Cobham Services
Second Tuesday - Krispy Kreme Kingston (A3).
Third Saturday - Tesco Earls Court (first floor Multistory).

welcome to a ride anytime then.

Happy days, and thanks for the reply. Will see how work is looking and drop you a message.

Cheers

[xjay1337]

No problemos.

New wheels!


Ignoring the dirty car...

[MrBarry123]

Hmm... Wonder how it compares to mine...

[xjay1337]

Back from the dead.........

Ummm okay so with a lot of help from my mate Jairm we got around to doing the rear seat/bench delete.

Started by clearing out the boot... someone's obviously had a Christmas tree in the boot . :sick:

20150422_200159 by Fat Bear Photography, on Flickr

Got it all in the front and took it home.

20150422_200221 by Fat Bear Photography, on Flickr

All in my car from drag racing.. think of the weight saving :signLOL: :signLOL:

3 sheets of MDF

20150422_215659 by Fat Bear Photography, on Flickr

Stripped all the interior off.

20150423_101233 by Fat Bear Photography, on Flickr

Left us with this.

20150423_103014 by Fat Bear Photography, on Flickr

Jairm started doing the Hi-Low converters (needed 2) and the rest of the wiring, and I got on with sound deadening.

20150423_132940 by Fat Bear Photography, on Flickr

Drilling out the standard speakers.

20150423_141335 by Fat Bear Photography, on Flickr

Replaced with the Hertz DSKs in the back. Plastic welded the tweeters in place.

More progress with the false floor.

20150424_115401 by Fat Bear Photography, on Flickr

An old sub box that Jairm had lying around. He decided to make use of it for this project, just making some adjustments

20150424_120014 by Fat Bear Photography, on Flickr

While this was going on, I wanted a personal touch so I made out a Fat Bear Photography logo.

20150424_172104 by Fat Bear Photography, on Flickr

Although this isn't going on at the moment, need to buy some more appropriate fabric.

Jairm doing some more trimming.

20150424_173529 by Fat Bear Photography, on Flickr

Things starting to look a little more finished now..

20150424_172240 by Fat Bear Photography, on Flickr

Jairm sorted me out with a 12 inch sub as my 10 inch looked a little bit lost, plus fitted the box... result. As it's brand new, needs bedding in still.

20150424_185801 by Fat Bear Photography, on Flickr

And here's a sort of finished picture.

20150424_190136 by Fat Bear Photography, on Flickr

We ran out of time as we were both working on cars over the weekend... so there's a little bit more to do, around the edges, but it's pretty much there.
Got a few little niggles with the wiring and what not, and need to sort out the amp settings but in time that will come. Very happy with the end result

[xjay1337]

Had a bit of a bad spell with the car as well
The head unit caught fire (my own fault, a screw that dropped in when I was earthing the hi-low convertors earthed out).
Something happened causing the car to lose 8-10 PSI boost (no boost leaks) and coolant pipe blew out because the MAP sensor on the larger pipework was rubbing on coolant hose.

Issue was shagged engine mounts which caused the Actuator to hit the bulkhead which damaged it, was not putting out the right voltage and as such was not producing the correct boost.
Replaced engine mounts with new OEM ones filled with Polyeurethane to keep things stiffer but without sacrificing comfort.

While the car was up at Darkside having the actuator sorted some further tweaks were performed on the map which gave us another 10bhp or so and a better delivery.







However on the day I picked it up I was down Brighton way for a hoon and on my relaxed cruise back a deer ran out infront of me.



Punctured AC condensor
Bent front support (rad packs all attach to this)
Bent front crash panel (can bend it back and should be fine)
F**ked bonnet
Most of the under bonnet plastics broken
front gloss black grill cracked/split (not really visible unless you look up but nevertheless)
Headlight washer was pushed into the bumper
snapped headlight bracket (can be plastic welded)



On the plus side, man-maths dictated that I replaced the bonnet with something a little more sporty.

[DaveyBoyWonder]

Sensible question but in a "racekor", why remove the seats and fill it with a load of thick MDF and speakers?

[xjay1337]

DaveyBoyWonder said:

Sensible question but in a "racekor", why remove the seats and fill it with a load of thick MDF and speakers?

The MDF and Subbox isn't that heavier, certainly lighter than the rear seats which weighed SO much.
The Recaro buckets are also about half the weight of the standard seats

It's never going to be a fully stripped out car as I do 40k a year, my commute is 100 miles a day

I just like music

[xjay1337]

Improved on my PB at Santa Pod from 14.22 to 14.08.

however...


20150823_125345 by Fat Bear Photography, on Flickr

Pretty sure that something's wrong there haha.
Royce towed me a little bit up the road with a borrowed tow-rope


20150823_125554 by Fat Bear Photography, on Flickr

Something seems to have been missing from the end of the shaft.....

20150823_154128 by Fat Bear Photography, on Flickr

Completely ruined that lol, spline sheered off and took the hub nut out with it.

20150823_154601 by Fat Bear Photography, on Flickr


My mate Alex at AKS very very kindly came up from his Workshop with a spare driveshaft and hub nut. What a lad.

20150823_155355 by Fat Bear Photography, on Flickr

Swapped it over, nice and easy, drove home. Result.

Edited by xjay1337 on Wednesday 26th August 15:13

Edited by xjay1337 on Wednesday 26th August 15:55

[skene]

Knew I recognised this car (and your old TDi) from somewhere! The customers cars section of Darkside


Out of interest do you have a thread (anywhere) for your old TDi? Ive got a 1.9 BKC and coming from a 230hp-9kRPM-fire spitting EP3 it's not very exciting

[xjay1337]

Bet that's a bit of a downgrade lol

http://www.mk5golfgti.co.uk/forum/index.php/topic,...

Most of the pictures don't work anymore but it's there in writing.

[xjay1337]

Little bit of painting.






Considering I rattle-canned it outside and didn't flat/polish it, really happy.





Didn't really like the black on black. looked weird.



Much better IMO.



Jack at Royal Steering Wheels did me an Alcantara retrim.

Got this on Wednesday.

12088425_516968715138466_2896232797219045099_n by Fat Bear Photography, on Flickr

12038456_516968728471798_8951643108511226607_n by Fat Bear Photography, on Flickr

I also did a trackday!

The RS4-2s would cause pad build up meaning MASSIVE steering vibration (shaking the whole car) and it felt like the subframe was going to fall off.
Shame really as they stopped the car well and there was absolutely no fade and I was pushing it hard, the rainy conditions were handled well by the car.

I also knew how bad the subframe was with the shifting but it was again a problem on the tracky day making some pretty horrible noises.

To this end I have purchased a Tyrolsport Deadset Kit from Alex @ AKS Tuning . It comes with some ARP bolts to replace some ste OEM ones, I'm going to get a complete set of replacement bolts for the subframe anyway to mount when fitting the subframe kit.

Also have some Powerflex rear arm bushes to go in as well as mine have had it and that will be pretty much the whole car Polybushed then.

Going to fit both as they will require an alignment after and no point doing it twice. Will aim to do this in a few weeks.

Looking at getting fresh discs and some new pagids, either some Project MU H18s or Pagid RS29 Yellows.
Time will tell.


A couple of obligatory-well-overpriced-trackday-watermarked-photos

trackday1 by Fat Bear Photography, on Flickr

trackday2 by Fat Bear Photography, on Flickr

[dragonheart]

I know you have had your fair share of criticism on here and I really don't want to add to it, but honestly that bonnet is hideous. Possibly function over form but I think it cheapens the look of the whole car.

[xjay1337]

No worries mate :-) Each to their own.
I love it personally. in pics it's not particularly appealing but it's just one of those things that looks better IRL.
Not everyones cup of tea. Eventually when I get the GT24 kit it will be painted blue and smattered with stickers.

[xjay1337]

New wheels! Swapped them with a friend for my Team Dynamics as these are 9inch wide all round and poked out too much on his S3.
They're fine on my car though.
When I come to change tyres I'll fit 245/40 or 255/40 Michelin PSS as the wide running Vreds 235/40 are just a bit too thin giving a little stretch instead of a nicer square sidewall.

They also need a refurb (coming after Xmas) but are structurally sound and I really like the look of them
I think they're also a tad lighter than the old Pro Race 1.2s.

2015-12-15_10-46-55 by Fat Bear Photography, on Flickr




in addition I hit 150k a few weeks back. The car is racking up the miles!



It goes in at the start of March for a cross bar to be welded in (be the first part of the half-cage) to mount harnesses to, as we all know harnesses with high angled harnesses are not good !