The diesel Rocco Racekor project.

[Rtig]

Looks good mate, how does it compare to Jairms Leon?

[xjay1337]

Cheers dude!
i haven't actually driven his Leon, but his is faster in a straight line, I would imagine mine being a bit better in the twisties as I've done all the bushes and adjustable balljoints etc and the bodyshell is a bit stiffer.

Different approaches to the same goal

[ZX10R NIN]

Nice work good thread

[xjay1337]

Sorry, didnt see the reply - Many thanks

Sooo couple of things have gone on which are relatively exciting... I guess?

Got a nice photo :-)

IMG_2903-2 by Fat Bear Photography, on Flickr

In addition to this with the help of a couple of mates we tried to do the rear arm bushes and replace them with Powerflex Polyurethane bushes. However the bolt was completely seized and we could not get it out for love nor money. So I'm going to buy a new bolt so we can cut it out and go again. When we do it again we are going to do a carbon clean.

We did manage to fit the Tyrolsport Deadset kit as well as new bolts all around and that seems to have cured the REALLY annoying clunks and subframe shifting I was getting.

20160113_212007 by Fat Bear Photography, on Flickr

20160113_212049 by Fat Bear Photography, on Flickr

Went to the Autosport International Show on Saturday and bagged myself the following at the DemonTweeks stand.

- Schroth Clubsport ASM 4 Point Harnesses x 2
- FIA Approved Mounting plates x 4
- FIA Approved eyelets x 4

Harnesses were supposed to be £140 + vat each, mounting plates were 5 quid or so and eyelets a couple of quid. With postage and VAT it would have all together been around £350.
Got the lot for £294 delivered, so that's really good deal!



Except in black - I'll be painting the harness bar blue so didn't want to do too much.


And also on the Sunday I managed to get myself a cracking deal!

20160117_140010 by Fat Bear Photography, on Flickr

Complete set of Golf R Replica wheels
4 x 245-40-18 Dunlop Direzza 03g , all pretty much new.
2 x 225-40-18 Vredestein Sessanta, about half worn.
Managed to fit everything in the boot! So that was fun. 200 mile round trip.

20160117_155457 by Fat Bear Photography, on Flickr



Sold the wheels and tyres cheaply to friends, as the wheels do not fit over my brakes and I don't want to have to run spacers (I've sold all 4 of mine).

[xjay1337]

So I did get everything i needed to have done at the weekend.

Car up on stands while the wheels were off being refurbished by Silver Wheels in Bournemouth. I've used Marcus before for 2 sets of wheels prior to this and each time I've been happy and he's a really nice guy and the dog is lovely so always worth the trip.
My friend and I were going to use TWS in Farnbruv as it's closer but they messed us around so thought fk it.

20160213_123305 by Fat Bear Photography, on Flickr

Everything got cleaned underneath. arches, suspension components etc.
No doubt all dirty again by now.

Roadtrip in the TFSI pissrat to collect them

20160213_093017 by Fat Bear Photography, on Flickr

Giving the car a bit of a polish, nothing too heavy as it wasn't that bad before to be honest.

20160213_150932 by Fat Bear Photography, on Flickr

No decent before and afters as a) it wasn't that bad and b) relatively tight working space and time meant no time for 50/50s and before and afters etc.

20160213_162851 by Fat Bear Photography, on Flickr

lovely metallic flake on the wheels. i've ordered new centercaps for them also.

and a dull and dirty picture.

20160214_152220 by Fat Bear Photography, on Flickr

Only a couple of weeks till harnesses go on. can't wait.

[xjay1337]

- harness bar fitted
- new air con condensor (still from the deer)
- 5w40 nanodrive service
- project mu h16 pads and new mtec j hook tts discs
- coolant hose repair (blew out again that's the second time ffs darkside).

arrived lovely and on time and the correct date which is always a good start
was greeted by Chris, alex's new help. have to be honest i was a bit worried when alex told me he got a new guy because i completely trust alex and always have faith in him and when you get a new employee i'm just very cynical but i needent have been
chris is a great guy and a right laugh.

anyway we started by stripping the interior out.

20160304_092125 by Fat Bear Photography, on Flickr

20160304_102252 by Fat Bear Photography, on Flickr

Also as there was alot of stuff during the day that I couldn't really help with (welding/fabbing etc) I brought along loads of paint and my new 310 calipers. need to get discs and pads but i'll do that at a later date as i am really broke now!!! :chicken:

20160304_110321 by Fat Bear Photography, on Flickr

Started with the filler primer after giving them a key up. probably was a mistake as it sunk later i should have topped it with a normal primer but hey ho i can touch it up when we go to fit them.

20160304_111444 by Fat Bear Photography, on Flickr

New project Mu pads...

20160304_112401 by Fat Bear Photography, on Flickr

New Mtec j hook TTS discs with their black coating.

20160304_114124 by Fat Bear Photography, on Flickr

You may ask why I didn't go for the vagbremtechnic discs, simply they are far too bloody expensive. and i have spoken openly with alex about this too.
everyone knows they are pagid discs which are then machined with the j hook entry.
I haven't checked prices of the pagid discs but I imagine them to be about £100. So for the extra £120 that it costs you are paying for them to put some grooves or hooks in them.
there is no offer of an anti-corrosion coating (black/silver/gold like every other place).

for me appearance is second to function but there's nothing worse than spending a chunk of money on nice wheels and nice brakes but i'm all about a balance and the mtec discs were like £175 posted with the black coating?
i simply cannot justify another £50 or so on discs.
we'll see how these go but i've had mtec before and they were fine.

giving the car a check over i inspected a previous repair from where i had a leaky coolant hose because it was rubbing/catching on the map sensor plug as the darkside pipework has the map sensor housing at a weird angle combined with the larger pipework means it can catch.
luckily i hadn't lost any coolant as the hole was just above the clip but was still a lucky escape.

20160304_125122 by Fat Bear Photography, on Flickr

Alex getting started on my harness bar!

20160304_125158 by Fat Bear Photography, on Flickr

Stacking dimes yo.
Always like Alex's welding, he's very talented at many things..

20160304_134757 by Fat Bear Photography, on Flickr

By this time we had stopped for lunch!
Alex bought me a creme egg

20160304_134932 by Fat Bear Photography, on Flickr

Back to my 310mm rears, i had by now applied the paint and some high temp clearcoat.
Very shiney, considering how st the paint underneath is i'm quite happy with the result.

20160304_140803 by Fat Bear Photography, on Flickr

Harness bar finished, I got to painting it as I didn't want bare metal in the boot, trying to make it look presentable.

20160304_142652 by Fat Bear Photography, on Flickr

Outside after a few coats of zinc primer as we were using t45 just incase of any corrosion
should have then put some filler primer then normal primer instead but was in a bit of a rush

20160304_150136 by Fat Bear Photography, on Flickr

More being stripped out.

20160304_150412 by Fat Bear Photography, on Flickr


Replacing my duff air con condensor.

20160304_151534 by Fat Bear Photography, on Flickr

Finished off the bar, looks presentable enough.

20160304_154128 by Fat Bear Photography, on Flickr

Alex's pretty little face.

20160304_164657 by Fat Bear Photography, on Flickr

Aligning things up to make it as level as possible...
20160304_165241 by Fat Bear Photography, on Flickr

Yet more holes being drilled into my car
20160304_164857 by Fat Bear Photography, on Flickr

I gave the holes a dusting of paint just to seal up any future rust.

Alex got to grinding back the paint inside so he could weld in some FIA approved mounts for the harnesses.

20160304_171355 by Fat Bear Photography, on Flickr

20160304_171558 by Fat Bear Photography, on Flickr

20160304_180937 by Fat Bear Photography, on Flickr
Large 1024 × 576

MIG welded (looks better than some tig!)

20160304_182045 by Fat Bear Photography, on Flickr

Some from the other side.

20160304_182056 by Fat Bear Photography, on Flickr

Given a dusting of paint and the eyelet threaded in!

20160304_183352 by Fat Bear Photography, on Flickr

Sliced the carpets as little as possible and layed the carpet down again so it looks almost oem unless you have a keen eye!

Harness bar bolted in place, harnesses in!

20160304_211257 by Fat Bear Photography, on Flickr

El finito!

20160304_211309 by Fat Bear Photography, on Flickr

In addition thanks to a mate Tom I got an R bumper.

20160301_202810 by Fat Bear Photography, on Flickr

A little thing, got some OZ valve caps!

20160224_193505 by Fat Bear Photography, on Flickr

and I'm starting to get bits to fab up my own intake solution. I have a heatshield from Forge and some 80mm hose. Need to get a suitable filter (I'm still researching which one) and will go from there.

20160229_190052 by Fat Bear Photography, on Flickr

[xjay1337]

A few updates of late.

20160503_112909 by Fat Bear Photography, on Flickr

Got a few parts of the intake system together ready to go on.
Revo filter, some pipework and clamps, Forge heatshield.

My friend Alex made me up a small 80mm pipe and bead rolled it for me so the hoses would clamp better.

20160503_155646 by Fat Bear Photography, on Flickr

Fitted it all.

20160503_161438 by Fat Bear Photography, on Flickr[/img]

Sounds awesome and initial pick up seems better with increased spool.

In addition, fitted new rear 310mm discs with the larger calipers, and full pressure bleed. Brakes are literally amazing now, squats down proper hard.

20160503_110846 by Fat Bear Photography, on Flickr

After a 2 month plus wait, finally my new Recaro Pole Positions have arrived.

20160531_140502-01 by Fat Bear Photography, on Flickr

My car is away with my tuner now, we are putting an upgraded fuel pump on. I believe it is the first upgraded pump on a 2.0 common rail VAG engine so we are in completely uncharted territory, we are hoping to max the turbo which can do around 300bhp.

In addition after a few months I got my R bumper on.

13226627_1032908796775425_6727841457181736813_n by Fat Bear Photography, on Flickr

Few issues with the sidelight/indicator units as they are LED I think the built in resistor/electronic box has buggered up so I get a constant bulb warning error (either for indicator or side lights depending on what's in use) but they work perfectly from the outside. We will resolve this by using an in-line resistor in the future.

Edited by xjay1337 on Thursday 2nd June 12:15

Edited by xjay1337 on Thursday 2nd June 12:17

[xjay1337]

FB_IMG_1465848031428-01 by Fat Bear Photography, on Flickr

Seats in.

[aka_kerrly]

Very smart!

[aspirated]

Some really good work...



but...


you must have spent about 40k on this?


How does it feel knowing you could have had around 40 MX5's instead?

[MrBarry123]

Looks really good Jay.

[xjay1337]

aka_kerrly said:

Very smart!

Thanks bud appreciate the comment

aspirated said:

Some really good work...



but...


you must have spent about 40k on this?


How does it feel knowing you could have had around 40 MX5's instead?

Haha I don't even keep track of what I've spent otherwise i would retire very quickly to the top of the nearest building and fling myself off it. Including buying it, it has to be around the £25k mark... very scary.

I think the MX5's would be a wonderful choice

Although I am not going to lie, been looking at GT86s with a view to supercharging them.... but also want an E90 M3 saloon or C63 so... but we are not finished with this project yet so not getting rid.

MrBarry123 said:

Looks really good Jay.

Thanks sam, it's ok haha

End of July we are ordering the wing used in the VW Cup, producing some actual downforce. Which I will definitely need on the M4.
Shortly after this we will be getting the car all liveried up.

[xjay1337]

Got some new tyres.
13509134_10157166046720624_2959568176854306964_n by Fat Bear Photography, on Flickr


(Michelin Pilot Sport 4)

That's about it.

weekend of drag strip and trackday activity ahead!

Edited by xjay1337 on Monday 27th June 19:35

[Steve93]

Actually a good amount of work gone into this.

Keep it up

[xjay1337]

Steve93 said:

Actually a good amount of work gone into this.

Keep it up

Thanks
Bit of a labour of love as is the case with these things. Hate it and love it.

[aka_kerrly]

xjay1337 said:

aka_kerrly said:

Very smart!

Thanks bud appreciate the comment



Although I am not going to lie, been looking at GT86s with a view to supercharging them.... but also want an E90 M3 saloon or C63 so... but we are not finished with this project yet so not getting rid.

We clearly have similar tastes!

[lee_fr200]

one of my mates has a gt86 was going the supercharging route but the engine blew up during run in i think so he's using the v8 out the soarer and i think supercharging or turbo,

[xjay1337]

Oh st, are they unreliable at 270-280bhp? I was under the impression that about 300bhp was safe.

[ManOpener]

xjay1337 said:

Oh st, are they unreliable at 270-280bhp? I was under the impression that about 300bhp was safe.

Few people on here running supercharged or turbocharged ones, between 280 and about 320bhp. Don't recall anyone reporting issues but not exactly a fully paid member of the 86 community.

[xjay1337]

Did some track time at Donnington over the weekend.
Other than a few over-zealous idiots (there were 2 red flags within first 10 minutes of my session plus a Mk7 R nearly crashed into the back of me where I can out brake him) after pulling into the pits for 20 minutes to let everyone calm down, I went back out.

Car performed brilliantly other than again EGT and Inlet air limiters causing a slight cutting of boost when it was real hot... over 50 degree charge temps even with the cooler! But with the amount of boost we are running, what can you do.

Only thing that is needed is an oil cooler as I'm hitting 120 degrees in 3 or 4 laps (120 degrees is my max oil temp I am prepared to run to) so I'm going to speak with Alex and we are going to come up with a solution and run 10w50 oil instead of 5w40

Pics were pretty good so I got a couple from Motorsport in Focus and edited them to make them nicer.. no idea why they use 1000 iso in bright sunlight. :grin:

CARS8154-3 by Fat Bear Photography, on Flickr


CARS7935-2 by Fat Bear Photography, on Flickr