Rotrex powered R32
Discussion
BecSte said:
Just read all 10 pages. What an incredible thread & car!!
Thanks
farm2 said:
Well well mate just read though it all great right up looking forward to the dsg !!! I bet you can't wait it's going to fly when that hooks up
Thanks, it will certainly will fly when it’s done, You’ll have to get one so you can keep up
The last few parts I have been waiting for arrived today
I couldn’t resist unpacking some of the bigger bits
Next step is to get it all fitted
.
Update time
In preparation for the gearbox swap I trial fitted the trim pieces on the gear selector to make sure everything was there and fitted.
Still need to work out how to swap the release button on the gear knob from LHD to RHD. In case anyone is wondering what the tape on the button is for, It’s so the button can be pulled out to release it from the stick
I have installed some of the wiring starting with the connector for the gearbox (grey plug).
Also fitted the relays (2x 126 relay).
Couldn’t do much more as I need to remove the clocks and windscreen wipers to access the remainder of the wiring.
Also tidied up the wiring for the water/meth injection as the pump relay and the excess wiring had been tucked behind the relay box in the engine bay. I decided to move the pump relay inside the relay box.
Pulled all the wiring out
I removed a relay base from the TT loom I had cannibalised and remade the connections to use with the water/meth injection
Relay base and fuse contacts fitted to relay box
All finished
You may have noticed some exposed wiring loom near the bottom of the picture. I have left it like this as the power for the gearbox will be connected into the relay box. Once the gearbox is fitted I’ll re-wrap the wiring loom so it's all protected.
The car is booked in at The Phirm for the swap to start on 1st of May
In preparation for the gearbox swap I trial fitted the trim pieces on the gear selector to make sure everything was there and fitted.
Still need to work out how to swap the release button on the gear knob from LHD to RHD. In case anyone is wondering what the tape on the button is for, It’s so the button can be pulled out to release it from the stick
I have installed some of the wiring starting with the connector for the gearbox (grey plug).
Also fitted the relays (2x 126 relay).
Couldn’t do much more as I need to remove the clocks and windscreen wipers to access the remainder of the wiring.
Also tidied up the wiring for the water/meth injection as the pump relay and the excess wiring had been tucked behind the relay box in the engine bay. I decided to move the pump relay inside the relay box.
Pulled all the wiring out
I removed a relay base from the TT loom I had cannibalised and remade the connections to use with the water/meth injection
Relay base and fuse contacts fitted to relay box
All finished
You may have noticed some exposed wiring loom near the bottom of the picture. I have left it like this as the power for the gearbox will be connected into the relay box. Once the gearbox is fitted I’ll re-wrap the wiring loom so it's all protected.
The car is booked in at The Phirm for the swap to start on 1st of May
The gearbox is now in
Gear shifter fitted
Gearbox loom installation, wiring pulled through wiring cover and gearbox connector (white plug)
Gear box power wiring and fuse(yellow fuse) added to relay box
Gearbox loom tucked into wire guide
Wire guide cover refitted
Dashboard disassembly so I can add clock spring, steering wheel paddle wiring and connections up to clocks
Wiring up to clocks, I didn’t fancy un-picking the loom, so ran the new wiring alongside the original loom. The wires are secured with fabric tape
The car is now officially automatic, clutch pedal & master cylinder removed still need to fit the larger brake pedal.
After a false start (I forgot to put a fuse in) it’s working
[
No coding required, display started working straight away, new light on clocks telling me to put foot on brake to take out of park
Lights on shifter
Tiptronic mode
VCDS communicating with gearbox
Centre console back in, there are some minor fitment issues to resolve
Still to fit
Starter motor
Coolant hoses, as gearbox has oil cooler linked to engine coolant
Re map gear box and engine ECU’s
Source replacement drive shaft, as one of the drive shafts I bought (supposedly from a DSG TT) doesn’t fit. If it wasn’t for that it might have been possible to drive the car today
Still need to get a DSG steering wheel
Gear shifter fitted
Gearbox loom installation, wiring pulled through wiring cover and gearbox connector (white plug)
Gear box power wiring and fuse(yellow fuse) added to relay box
Gearbox loom tucked into wire guide
Wire guide cover refitted
Dashboard disassembly so I can add clock spring, steering wheel paddle wiring and connections up to clocks
Wiring up to clocks, I didn’t fancy un-picking the loom, so ran the new wiring alongside the original loom. The wires are secured with fabric tape
The car is now officially automatic, clutch pedal & master cylinder removed still need to fit the larger brake pedal.
After a false start (I forgot to put a fuse in) it’s working
[
No coding required, display started working straight away, new light on clocks telling me to put foot on brake to take out of park
Lights on shifter
Tiptronic mode
VCDS communicating with gearbox
Centre console back in, there are some minor fitment issues to resolve
Still to fit
Starter motor
Coolant hoses, as gearbox has oil cooler linked to engine coolant
Re map gear box and engine ECU’s
Source replacement drive shaft, as one of the drive shafts I bought (supposedly from a DSG TT) doesn’t fit. If it wasn’t for that it might have been possible to drive the car today
Still need to get a DSG steering wheel
glasgowrob said:
utterly amazing,
some serious work went into this kudos
Thanks, allot of the credit needs to go to the guys at The Phirm for doing all the hard work on putting it together.some serious work went into this kudos
OliilO said:
Looks awesome, I bet you can't wait to get it finished! Did Tim do some of the work or did you do it all yourself?
Yep can't wait, Jay and Tim fitted the gearbox, I have done all the electrical work.
It’s alive (sort of)
The drive shaft issue is now sorted, the guys at the Phirm made a custom drive shaft which is now fitted. There was always going to be some custom work required when trying to combine MKIV R32, B6 Passat and Audi TT.
I finished up the wiring today by sealing the loom where it enters the rubber boot to go through to the interior.
The gearbox is now plumbed into the coolant system
Larger brake pedal fitted (took me over ½ hour to get the trim onto the pedal
Video of first test drive, didn’t go far as one of the wheel arch liners dropped and was scraping on the road (due to under tray not fitted back yet)
https://www.youtube.com/watch?v=MHasMuODsNc&fe...
There are a couple of minor things to take care of, the first is the lack of speedo, the gear box and engine ECU’s are both showing vehicle speed, but for some reason the clocks aren’t. Second is the brake pedal is sticking a bit.
However just as I was driving it back in the workshop for the weekend all comms with the gearbox were lost causing loss of drive. So kind of spoilt what seamed like a successful day.
Hopefully it ‘s just a loose wire or fuse
The drive shaft issue is now sorted, the guys at the Phirm made a custom drive shaft which is now fitted. There was always going to be some custom work required when trying to combine MKIV R32, B6 Passat and Audi TT.
I finished up the wiring today by sealing the loom where it enters the rubber boot to go through to the interior.
The gearbox is now plumbed into the coolant system
Larger brake pedal fitted (took me over ½ hour to get the trim onto the pedal
Video of first test drive, didn’t go far as one of the wheel arch liners dropped and was scraping on the road (due to under tray not fitted back yet)
https://www.youtube.com/watch?v=MHasMuODsNc&fe...
There are a couple of minor things to take care of, the first is the lack of speedo, the gear box and engine ECU’s are both showing vehicle speed, but for some reason the clocks aren’t. Second is the brake pedal is sticking a bit.
However just as I was driving it back in the workshop for the weekend all comms with the gearbox were lost causing loss of drive. So kind of spoilt what seamed like a successful day.
Hopefully it ‘s just a loose wire or fuse
The car is now running properly with the DSG. All faults are now cleared so everything works as it should.
I took the car out for a test drive and I was really pleased, the gear changes are soo smooth and seamless it just goes. I made a quick video with the gopro to show how it accelerates when in “D” (I haven’t tried launching it yet)
https://www.youtube.com/watch?v=EOrDLIaURVw&fe...
I tried Sport as well, (no video yet) the gearbox map is going to be updated to increase the shift speed in sport.
In manual mode it will hold the gear, and will not change unless I change it.
The only change I have asked for after the test drive was to alter the shift point so when cruising at low speed it will use 6th gear, as with the manual box I could drive at 30mph in 6th whereas the DSG want’s to use 5th.
The next step is to sort the launch control which will be fully adjustable (launch rpm), and recalibrate the clutches, if all goes to plan I get it back next Saturday.
I took the car out for a test drive and I was really pleased, the gear changes are soo smooth and seamless it just goes. I made a quick video with the gopro to show how it accelerates when in “D” (I haven’t tried launching it yet)
https://www.youtube.com/watch?v=EOrDLIaURVw&fe...
I tried Sport as well, (no video yet) the gearbox map is going to be updated to increase the shift speed in sport.
In manual mode it will hold the gear, and will not change unless I change it.
The only change I have asked for after the test drive was to alter the shift point so when cruising at low speed it will use 6th gear, as with the manual box I could drive at 30mph in 6th whereas the DSG want’s to use 5th.
The next step is to sort the launch control which will be fully adjustable (launch rpm), and recalibrate the clutches, if all goes to plan I get it back next Saturday
. Car is now all done and driving really well. It had its first major test at GTI international at the weekend.
Managed 4 runs up ¼ mile before it rained with the best being a 12.096 @ 113mph
I was hoping to get into the 11s, but overall I was happy with how it ran.
Video of my last run on the ¼ mile where it did a 12.2, my reaction time was a bit slow (my excuse is the 4am start to get there
)
https://www.youtube.com/watch?v=3GjQIxw0ufQ
And from inside
https://www.youtube.com/watch?v=Z2OuLOWr6BQ
Managed 4 runs up ¼ mile before it rained with the best being a 12.096 @ 113mph
I was hoping to get into the 11s, but overall I was happy with how it ran.
Video of my last run on the ¼ mile where it did a 12.2, my reaction time was a bit slow (my excuse is the 4am start to get there
)https://www.youtube.com/watch?v=3GjQIxw0ufQ
And from inside
https://www.youtube.com/watch?v=Z2OuLOWr6BQ
aka_kerrly said:
12sec is mighty good going for a full interior and road tyres.
Looking back at the video, the gearbox short shifted on the change from 2-3. It should change at 7000rpm, but fore some reason it changed at 6200, so there is potential to get it into the 11’s. There is also the option to run 109ron race fuel
Just got back from a 1,500 mile road trip in France. Found some lovely twisty mountain roads, which were great fun, there were also some nice straight clear roads.
It was very tempting to go for a vmax, but the French
have a habit of hiding under camouflage (not very sporting) the picture was taken on the A20 heading towards Cere in central France.The DSG was great in the stop start Paris traffic, it made the journey so much easier which helped when the outside temp was 41c and the AC was struggling.
The only downsides were on the return from Dover the front number plate fell off somewhere on the M20 (does look so much better without it).
And the bumper is a now bug graveyard.
So it’s off to VW today for a new number plate & plinth then out with the bug remover to get it cleaned up
New brake pads fitted yesterday. I fitted the toureg callipers at 70k, the car is now on 112k so the pads have lasted about 40k.
On disassembly I was surprised to see the state of the pads. On the driver side the inner pad still had the slots from manufacture, the outer pad was a lot thinner and had lost a chunk of the pad material.
Inner pad
Outer pad, with missing chunk
New Brembo pad
New vs old
Pads fitted with new retainers and bolts
Passenger side, again the outer pad had a lot more wear than the inner.
I had also planned to replace the rear disks and pads but couldn’t get the disk of the hub (yes I did remember to remove the screw). After applying lots of heat and beating on the disk with a wooden mallet for ½ hour I gave up.
On disassembly I was surprised to see the state of the pads. On the driver side the inner pad still had the slots from manufacture, the outer pad was a lot thinner and had lost a chunk of the pad material.
Inner pad
Outer pad, with missing chunk
New Brembo pad
New vs old
Pads fitted with new retainers and bolts
Passenger side, again the outer pad had a lot more wear than the inner.
I had also planned to replace the rear disks and pads but couldn’t get the disk of the hub (yes I did remember to remove the screw). After applying lots of heat and beating on the disk with a wooden mallet for ½ hour I gave up.
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