Rotrex powered R32

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Discussion

anonymous-user

53 months

Sunday 23rd October 2016
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Amazing work!

Blue32

Original Poster:

438 posts

168 months

Wednesday 26th October 2016
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AVV EM said:
Amazing work!
Thankssmile

Had some free time today, so I thought I’d try and fix something that’s been bugging me for a while.

Ever since fitting the RNS510 I haven’t been able to get the navigation display on the FIS display, all I could get was latitude and longitude.


To get the display to work properly I needed to re code the RNS510, however I couldn’t access it via the MKIV golf diagnostic interface as it doesn’t support the correct CAN bus version.
The obvious way would be to put the RNS in newer CAN bus based car, however due to the way I installed it I would have to dismantle half the dashboard to get I out.

So I hatched a plan that involved connecting the RNS 510 to the CAN Bus in my MKV golf. First step was to get access to the CAN bus connections to the RNS by digging out the CAN converter I was using to get it to work on the MKIV (black box by gear selector).


I pulled the connector to the CAN converter apart and using CAN bus wiring I recovered from the TT wiring loom (used as source for DSG wiring) I connected to the CAN bus for the RNS


Pulled the radio from the MKV


Connected the CAN bus wires and a ground to the radio connector


Wiring going back to MKV


Fired up VCDS and was able to connect to the RNS


I needed to change the display protocol from BAP to a more basic mode (DIS I think?)


Re coded


Success woohoo

Now have direction and radio station on the FIS display

Displays media info as wellbiggrin


JackP1

1,269 posts

161 months

Wednesday 26th October 2016
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Good Song choice, appreciate how the gearbox went to manual halfway through the photos!

Good effort on this though, all the way through!

piers1

826 posts

193 months

Tuesday 8th November 2016
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That is awesome stuff!

clio007

541 posts

224 months

Tuesday 8th November 2016
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What a fantastic read.
How is the DSG box in the MK4 ? Is it the same as the DSG box in the MK5? This would be my ultimate car. Surely it must be the only MK4 DSG in the UK, nevermind being a charged one?

Blue32

Original Poster:

438 posts

168 months

Tuesday 8th November 2016
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clio007 said:
What a fantastic read.
How is the DSG box in the MK4 ? Is it the same as the DSG box in the MK5? This would be my ultimate car. Surely it must be the only MK4 DSG in the UK, nevermind being a charged one?
Thanks

Yep it’s the same as the DSG box in a mk5, mine has been re-mapped to alter the shift points to suit the supercharger.

As far as I’m aware there is only one other mk4 running a DSG box and that car is running a HGP turbo, so the only two UK mk4 R32’s with DSG are both forced induction!

Jellyfish

52 posts

131 months

Wednesday 23rd November 2016
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What an amazing build, just read from start to finish in one hit. All credit to you and the companies involved.

morganvw1

3 posts

222 months

Thursday 29th December 2016
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Who fitted the charger for you?

alec.e

2,149 posts

123 months

Thursday 29th December 2016
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Wow, epic thread! Very impressed with your 1/4 times, 11 sec make my 13 look slow smile

BuddyLove25

59 posts

149 months

Friday 30th December 2016
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Fantastic build thread... couldn't stop reading from start to finish. You certainly have transformed your car into something very special indeed. Huge congratulations to you and everyone involved.

C7 JFW

1,205 posts

218 months

Friday 30th December 2016
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I was looking around a VW dealership yesterday and my wife asked, do you fancy a Golf R?

Then I read this. Think i'll keep my V6 4Motion.

How does the car drive? Do you have a Haldex controller?

GrantB5

572 posts

87 months

Friday 30th December 2016
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The more threads I look on here the more nice electrical work I see going on.

Would love to get my head around it and give some bits a go in the new year. I'm gonna go and buy a glass of man up.

Nice car op.

If you have been to the Phirm in your time you may of seen my mate Dan's mk1 wrigleys golf there, he's there from time to time.

Blue32

Original Poster:

438 posts

168 months

Friday 30th December 2016
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morganvw1 said:
Who fitted the charger for you?
The charger was supplied and fitted by The Phirm, the bracket was designed and built by United Motorsport.

C7 JFW said:
I was looking around a VW dealership yesterday and my wife asked, do you fancy a Golf R?

Then I read this. Think i'll keep my V6 4Motion.

How does the car drive? Do you have a Haldex controller?
I have the original Haldex controller, but it has been re-flashed with custom software so it sends more power to the rear quicker. When accelerating out of bends I can feel the rear pushing more, the new software also helps with traction in the wet as with the OEM programming there was some wheel spin from the front when accelerating in the wet, now with the rear pushing none.

GrantB5 said:
The more threads I look on here the more nice electrical work I see going on.

Would love to get my head around it and give some bits a go in the new year. I'm gonna go and buy a glass of man up.

Nice car op.

If you have been to the Phirm in your time you may of seen my mate Dan's mk1 wrigleys golf there, he's there from time to time.
Thanks, good luck with your plans. Yep I have seen Dan's mk1, some really nice work has gone in to that car. Surprised it hasn’t appeared in the decently modified cars thread.

I’m hoping on having another go at VMAX in next year, so to avoid a repeat of last time where the plastic under tray got ripped off at 170mph I wanted to add some extra support.

I had the idea of using bonnet pins


The plan it to attach the pins to the radiator support and fix the locking clips to the under tray. The radiator support had ideal cut outs which were just the right size for the pins.


Pins bolted to radiator support



Position for the clip on under tray


Locking clips fitted, they are held in place with stainless steel bolts and nylock nuts


Finished


Apologies for the poor quality of the 2nd photo, there were too many reflections with the flash.

I also took the opportunity to fit LED number plate lights as seen here http://www.users.on.net/~graeme86/numberLED/number...
I managed to find a pair of used number plate lights on ebay.de for £28 (they are nearly £30 each from VW)


Only managed to get one fitted so far, but managed to get a photo to show the difference between original bulb(right) and the LED light (left)


Blue32

Original Poster:

438 posts

168 months

Sunday 29th January 2017
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Got my place booked on Vmaxcool so wanted to get a couple of things sorted before the event.

First is to replace the lower splash guards which cover the side of the engine and protect the belts from road dirt.
At the last Vmax the splash guards were damaged when the under tray fell off and had to be replaced in a rush so I could use the car. This time I want to make them fit better.

I started by removing the wheel arch liner which revealed the classic MKIV dirt trap at the front of the sill.


Current splash guard which has seen better days


New splash guard (top) vs old, quite a lot needs to be removed to fit around the supercharger


This time I want to reshape the plastic so it fits around the supercharger bracket better, so I made wooden frame to support the guard so I could heat it with a hot air gun to reshape it



After a lot of heating and manipulating I managed to form a curve in the plastic to clear the pulleys and brackets, it was straight before I started.


Newly reshaped splash guard back on the car, I had to do a final tweak the get it to fit better, unfortunately it got a bit too hot hence the wavey edge along the top by the chassis railfrown.


While I was at it, I cleaned and repainted the bracket on the shock which supports the flexible brake hose.


I attacked the bracket with wire brushes and sandpaper to get rid of the rust and old paint which resulted in this.


After a couple of coats of paint the bracket looked a lot better


Bracket back on car, looking better apart from the other rusty bits


Before putting everything back together, I gave all the areas which will be hidden by the plastic wheel arch liners a coat of Dynax to protect it and try and prevent any rust from forming.


All back together, apologies for the poor quality photo, had to use mobile phone as normal camera was flat.

At some point (assuming the rain stops) I want to replace all the rusty screws which hold the plastic arch liner with new screws.

To be continued…..


TheDukeGTi

202 posts

135 months

Monday 30th January 2017
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Incredible thread! Amazing dedication. You must know this thing inside out.

anonymous-user

53 months

Monday 30th January 2017
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Still running a Fabia alongside this?

So many times I have resisted an R32 banghead bad knee means I have to drive auto (and wife only has auto licence!) so no MK4 frown although I could do a DSG swap wink

Nice car biggrin 500bhp means it must go like st off a shovel thumbup props for keeping it all these years...


..and keeping your sanity wink

Blue32

Original Poster:

438 posts

168 months

Monday 30th January 2017
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sleepera6 said:
Still running a Fabia alongside this?

So many times I have resisted an R32 banghead bad knee means I have to drive auto (and wife only has auto licence!) so no MK4 frown although I could do a DSG swap wink

Nice car biggrin 500bhp means it must go like st off a shovel thumbup props for keeping it all these years...


..and keeping your sanity wink
Thanks

Unfortunately Fabia was written off at the end 2015 (not by me) which was a bit annoying after the work I did to tidy it up. I replaced it with a 105hp MKV TDI, which was meant to be temporary but it has kind of grown on me as it’s quiet and easy to drive

If you need to scratch that VR6 itch there is always the DSG MKV R32 with is a bit more grown upcool

Blue32

Original Poster:

438 posts

168 months

Saturday 18th March 2017
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Slightly delayed update
While the bumper was off I wanted to replace the speed nuts which hold the undertray to the bumper as they were starting to wear out
Old broken speed nut on bumper


After talking with the very helpful parts guy at my local VW dealer I found there were R32 specific speed nuts and bolts:

Standard speed nut (left) R32 speed nut (right)


R32 speed bolt 9Left) standard (right)


New speed nut fitted to bumper


With the new speed nuts and bolts the undertray is now allot more secure so won’t fall off again whilst at vmax.

By the end of next week the front of the car will have a new look. The one thing that has bothered me since getting the supercharger installed was that the intercooler and pipe work were visible. I hid them a bit by painting the intercooler and pipes black, but they were still visible.
In early February I paid a visit to Pro Alloy Motorsport to see about getting a custom intercooler made.
The requirements I had were that the end tanks were hidden behind the bumper either side of the centre grill, and that the boost pipes were hidden behind the side grills to return the front to looking as close to original as possible.

The guys at Pro Alloy were confident that they would be able to meet my requirements so I dropped the car off to them last week.
On Friday they sent me some photos showing the new intercooler before it went off for pressure testing and paint.



New vs old, the new IC will be a lot more efficient and less restrictive so might release a few more hp’sevil

The old intercooler was a generic/ebay intercooler that was fitted back in 2009 when I had the first Rotrex supercharger kit installed.

I’m collecting the car up on Thursday ready for vmax at the weekend so cant waitwoohoo

Blue32

Original Poster:

438 posts

168 months

Thursday 23rd March 2017
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Collected the car today and I’m really pleased with the result, the guys at Pro Alloy have done an amazing job, they have got it exactly how I wanted. They said it was a very tight squeeze to get the intercooler in. To help gain some space the radiators have been moved back slightly.
Just snapped off a couple of quick photos, to show how it looks now.

Just as a reminder, before:


And now


Removing the centre grill gives a better idea


I have new side grills to go in, but where the bumper has been cut for the old pipework the grills are very loose so drop out.

I tried the new grills and it looks how I want, just like a standard R32


So apart from the big brake callipers the car now looks completely stockwhistle

Blue32

Original Poster:

438 posts

168 months

Sunday 26th March 2017
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Had a good day out at VMAX200 yesterday, there were some amazing cars there. The list included 2x Veyrons, a Pagani Huayra, a couple of Mclaren 675LT, various Aston Martin’s etc… basically it was a supercar fans heaven so it was great in that respect.

I managed to complete 7 runs going up against 2x RS6 and a S3, BMW M5, Nissan GTR and a Porsche 996 (I think).

The day didn’t go entirely without problems, the first was in the race against the M5 where I was just ahead until a coil pack failed (fortunately had a spare) so had to limp back to the parking area. On the final run I managed to crack the exhaust manifold somewhere so it sounds a but rough.

As for the top speed, my best was 162 so down on previous of 171, which I think, was down to a lack of space.
Previously there was a short run from the start down to the bottom of the runway, so could carry 40-50 mph onto the runway. Now the start is at the bottom of the runway so only have about a mile to accelerate, which meant it was only getting into 6th gear just before the timing beams.

Some pictures from the day












A couple of videos from the day, the first is from when I was against the M5 when the coil pack failed at about 19 seconds, for some reason the gearbox didn’t change up which probably didn’t help.
https://www.youtube.com/watch?v=yTOg9JV4pZ4

The second video is against the RS6, almost kept up
https://www.youtube.com/watch?v=q0x_H0-bHgc

Even though the car had some problems it surprised a few people and got lots of compliments. On the run from the gate down to the parking area, a guy in a M5 asked what I’d done as he struggled to keep up with me.