The diesel Rocco Racekor project.

The diesel Rocco Racekor project.

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xjay1337

Original Poster:

15,966 posts

119 months

Tuesday 4th November 2014
quotequote all
Hi.
I bring to you a new project.
My old car was this.



And I had a thread of the modifications/progress here.

http://www.pistonheads.com/gassing/topic.asp?h=1&a...


After a change of heart and getting bored of the scene and the attitudes of "some" of the people within it, I went back to what I had known previously, building a car to drive, one that performs well, that I can enjoy and will be taking to trackdays, but one that also looks pretty evil and can be enjoyed for what a car is meant to be used for...

Bought from a good mate I work with for a great price.

Quick overview of the spec

2.0 TDI CR170
Full heated leather
Bi-Xenons
DCC Adaptive Chassis

I'll be worrying about how it drives first and then worry about making it look good, with different bumpers, splitters, spoilers and what not.






The first thing I did was enable needle sweep, alarm chirps, and adjust a few other parameters via VCDS.

https://www.youtube.com/watch?v=fvtc8nNjzLE

Had the wheels refurbished in a shadow chrome finish.



In went the Recaro buckets from my Golf.



In went H&R 30mm springs, Powerflex front & rear wishbone bushes, and Super Pro camber adjustable ball joints.








Final alignment... 2 degrees of negative camber given from the ball joints.
I will be getting camber adjustable Ground Control Top mounts as well which remove the rubber mountings and provide a stiffer setup still.


Fitted a GTI gearknob



New Bosch S5 007 Battery.



Adjustable quickshifter which is a fantastic mod for any manual car



On the 15th it's going in for a full service with new fuel filters, uprated polybushed lower engine mounts and most importantly, new brakes - a custom setup courtesy for AKS Tuning compromising of TTRS/DB9 Brembo 4 pot calipers with 340mm J-Hooked discs, custom brackets, braided lines and what not.
I had to work out the caliper clearance and it turns out I need a 12mm spacer. An idea of how it would look minus the J-hooked disc...



How it currently sits.





It's going in on the 21st to have the DPF/Cat and EGR removed and a Stage 2 remap, then after that will be the remaining handling mods - Being H&R anti roll bars front and rear, rear suspensioni arms to be polybushed and R32 rear brakes (310mm)

After that will be the audio build with uprated Hertz ESK163L door speakers, one off subwoofer enclosure with a Rockford Fosgate sub and the usual sound deadening, then I will worry more about the looks aspect and look at R-Line kits and the cup spoilers.
I'll be wanting to put a half cage in as well, remove the rear sits and fitting other chassis-stiffening components along the way.



Edited by xjay1337 on Tuesday 4th November 17:13

xjay1337

Original Poster:

15,966 posts

119 months

Tuesday 4th November 2014
quotequote all
Even with the miles I got it for about £1500 under what it should go for, it's been fully serviced by VW and had the cover of a VW Warranty until May this year

I have modified a 1.9 TDI before (with even higher mileage) and I had huge fun with that, and of course, doing a lot of miles (I do around 30k per year) it does save a few pennies.
My GTI was of course 2.0 TFSI and I never really connected with that. Partly because show-car but also because it was missing something.

An Audi S3 was an option (k04/stronger internals) but I got this car for a bargain and do much prefer driving it to my GTI, I'm a fairly relaxed (torque based) driver anyway.

xjay1337

Original Poster:

15,966 posts

119 months

Wednesday 5th November 2014
quotequote all
Apologies, some of the pictures seem to not be working? Work on other forums.

Joe5y said:
confused uummmm . . .
Yes, because I can plug in a laptop and do things in 10 minutes at absolutely no cost to myself.
Don't be a potato.


Mattknight1984 said:
Ah yes, I remember your username from the mk4 forums now (I had a mk4 1.8t then my current mk5 gt tdi that Im sure you offered advice on).

I know what you mean about the torque, I've not long bought a 2012 1 series with the 1.6 twin turbo petrol engine. Great car, but miss the torque of the remapped mk5.
Probably biggrin

Yeah, defo - The GTI was a great drive and sounded awesome when flat out, it wasn't that laggy to be honest and did pull well but it's that initial surge that the diesels can provide that I miss... then again I'm compared a modded GTI to a stock diesel engine, if I can get around 210-220bhp from the DPF delete and remap (my old TDI made 221bhp and 365lb ft with a GTB1756vk) then I will be more than happy. With scope to go higher with a larger turbo and updated clutch and what not.. Plus with the full 3 inch TBE and no silencers I'm hoping it will sound the part too.

My old Golf TDI from 3 years ago about 3 runs before I blew up the gearbox lol





Edited by xjay1337 on Wednesday 5th November 12:26

xjay1337

Original Poster:

15,966 posts

119 months

Monday 17th November 2014
quotequote all
So a very busy day on Saturday...

Here's what went on.



AKS Tuning Aston Martin / TTRS BBK - Consisting of 4 Pot Brembo calipers, custom mounting brackets, 340mm (very light for the size) EBC USR disc and Pagid RS4-2 Pads along with HEL braided lines
BMC Panel Filter
Gen oil & fuel filters
Millers Nanodrive 5w40
New genuine drop links
Super Pro Dogbone Insert (from a petrol... will get to this later).
Subframe spacers
12mm H&R Trak+ spacers (front and rear).
Fiscon Advanced PF03

I rocked up very tired, after having 3 hours sleep (working late detailing the nigher before), at around 9:45am to my buddy Alex who owns AKS Tuning over in Bedford, around 2 hours away.
I had been booked in for some time and in preperation for Darkside's increased power levels I felt even at standard power the stock brakes were severely lacking and wouldn't give me the confidence to be able to push on, along with wanting to make sure mechanically everything was spot on.

The calipers up close



Fitted to the car while having a bit of a working lunch...(they're actually delicious).



Pressure bleeding the whole system (front and rear)/



Fitting this bad boy....



Fiscon Polar Advanced (PF03). Works great with my existing Fiscon Basic+ Bluetooth set up (factory Bluetooth removed by previous owner). It was updated first with the latest software prior to installing. The main reason behind getting the Polar was that I wanted a boost gauge. Newsouth did make a 0-35 PSI gauge which would match my standard dash lighting, great, however, Newsouth did not make a air vent pod in right hand drive... they made one for the LHD market, and of course the Mk5 Golf...The only available mount was a steering column mount, which I have had in my GTI and my TDI prior to that - And it was horrible, rubbed on the steering wheel making a squeaky noise. You could resolve this by sanding it down but it still didn't look very factory. On my GTI I bought an air vent pod, but as mentioned, was not available for the Scirocco... so I was left with 2 options. Buy another vent and construct my own vent pod for the Scirocco or come up with an alernative solution. I wanted something that would be in, in time for Darkside, so I spoke to Alex and, the Newsouth Gauge would have come in at around £125 by the time you've bought a self sealing take off. Buying a vent was around £30 and then the time of making one that actually looked factory, still costing around £90 including the gauge, where as I managed to get the Fiscon for £180 new. It was slightly more over all but provided a wealth of additional information, intake air temperature, exhaust gas temperatures, fuel in liters, coolant temperature as a figure, DPF status (which will be irrelevant as it's being removed soon, but nevertheless), I was able to work out when regenerations were happening, see things about fuelling, injector durations, quantities, etc... very clever and geeky.



It was a bit fiddly to install, but not difficult at all - the wipers and the wiper motors need to come off and you get access to I think it's the CAN Gateway by removing a small plate under the windscreen



12mm spacers fitted to the front and rear... car looks a little high as it's just been lowered back down and hasn't settled.



The spacers were needed up front due to the adaptor brackets pushing the caliper out slightly, combined with the Scirocco Turbines being really poor for clearance to begin with.. We tried a 10mm and it caught, 12mm clears with barely a sheet of paper between the caliper and the spoke.

The BMC Panel filter was installed, new fuel filter, new oil filter along with high performance Millers Nanodrive stuff, the subframe spacer kit was installed and the Superpro dogbonoe insert fitted...



Alex didn't have any diesel ones in stock, which are softer, as diesels have more vibration, so we put a petrol one in... which is great, reduces transmission movements A LOT, but unlike the insert I had in my PD engine'd Mk5 from years ago (which I didn't notice any extra vibration), on this I get quite a shake at idle and pulling away, or low revs. Now currently the bush is very new and will bed in. I love how it feels, and at the moment the extra NVH isn't annoying, but if it does then I can just swap it out for a softer (diesel) bush.

Anyway, not really put the brakes through any serious strain as it's been wet and I've just been going around doing my usual business - but I've used them a few times and MY GOD they don't half stop you, they literally pull your face off. Pedal travel is great, I was worried that I would end up with a longer pedal but this is spot on, it's quite short and hard (oy oy!) which I like, but not so short that you can't be progressive still around town. The best upgrade I have made to the car yet, period.

Now just onwards waiting for Darkside, which is 4 days away now :-)

xjay1337

Original Poster:

15,966 posts

119 months

Tuesday 25th November 2014
quotequote all
Stayed up till about 3am cleaning the car...needed the therapy lol...

IMG_0542-2 by Fat Bear Photography, on Flickr

Certainly had been putting these Pagid RS4-2 Blue's through their paces..

IMG_0537-1 by Fat Bear Photography, on Flickr

IMG_0539-1 by Fat Bear Photography, on Flickr

Then took my old man to get his new car, a CR170 Octavia VRS - Cool to have my Dad in the same sort of car as mine, already got him primed to pull the trigger on some H&R springs, ball joints and bushes courtesy of Alex

IMG_0557-1 by Fat Bear Photography, on Flickr

Then the next day I set off for Darkside at stupid-o-clock



Arriving on literally no sleep and 3 red bulls... I grab a half-arsed shot of her on the dyno.

IMG_0590-1 by Fat Bear Photography, on Flickr

At Darkside we had the following:

EGR Delete
3 Inch Downpipe / DPF/Cat removal
Hard cut limiter set at 5k


It was down on power compared (normally from my experience VAG engines pull about spot on or just over their rated power) but the end figure is there or there abouts.
I spent a lot of time talking to Darkside and perusing other diesel tuning forums to get a proper idea of what sort of power these engines reach as there's not much in the way of actual dyno'd & verifiable output. Darkside said anything between 195 and 205 is bang on the money.

My Fiscon has also highlighted how quickly the intake temps can rise, even when it's 8 or 9 degrees outside the temps shoot up from about 11-12 degrees to 22 or 23 after a single pull through 3rd and 4th, so an uprated intercooler is on the cards - watch this space...

Regarding the future power, my EGR was apparently very blocked up and they were surprised it hadn't caused me any issues - because of this they recommend that I clear the inlets and remove the swirl flaps which may free up a bit of extra power.
A 2056 and tubular manifold is on the cards but having just spunked £3k on the car in the matter of 2 weeks I need to let my bank account balance settle (and sell my Golf FFS) - I think 240-250bhp and this would be a beast of a car on road and track. For now it's quick enough to put a smile on my face and handles brilliantly.

Driving wise, well the tuning has transformed it - It no longer feels breathless and does pull very well indeed. I would say it's quicker than my GTI was standard. The MPG has also improved quite a bit. Ryan was very complimentary on the handling setup saying it's one of the nicest cars they've driven and how well it handles and rides.

The next plans are pop back over to Alex for my cat-back exhaust section to be made up, giving me a full 3 inch TBE, we will see what he can do RE the swirl flaps as well which is happening on the 19th of December. Gonna tweak my short shift (change some bushes and add some washes to stiffen up the side to side movement) and look into a bit of fabrication for a heat shield or two...


And here's the results.

10376188_380320572136615_3506914564937856865_n by Fat Bear Photography, on Flickr

So went from 161 to 194bhp with a huge jump in torque from 270 to 330lb ft


Am I happy with the figures? No, if I'm honest. Then again I have always been a subscriber to the "under the graph" dyno area, which has improved MASSIVELY everywhere along the rev range - But I take some comfort knowing that Darkside know what they are doing first and foremost, and secondly, have an honest, real world dyno. My old TDI left another tuner with 171bhp and went to Darkside's and pulled 155. I would rather have a solid, safe 195bhp than a dyno-happy and smokey 215-220bhp.

Am I happy with the driving experience, the smoothness, the lack of smoke and the kick up the back when I put my foot down? Yes, absolutely!

It was explained to me that these cars which claim to have up to 220bhp (which are all usually very smokey) can sometimes have sky-high EGT's which are over 1000 degrees C from 3500rpm upwards (they flatline at 1000 which is the maximum sensor reading, so are of course going to climb over that figure!)

My EGT's are limited to 850, and I noticed absolutely no smoke on the drive back. The guys said if they had raised the EGT limit they could have got into the low 200's but the extra stress on components is not worth it for the small (5-7bhp) gain, which at the wheels you wouldn't really notice anyway.

Despite the fairly disappointing end NUMBERS, the driving aspect of the car is great and yes, I would pay the money again knowing the outcome. Albeit feel that I could have gone straight for the GTB kit to begin with... anyway...

IMG_0627-1 by Fat Bear Photography, on Flickr

IMG_0629-2 by Fat Bear Photography, on Flickr

Big thanks to Darkside :-) as finally I no longer feel like my car is dogsh*te slow!!!

xjay1337

Original Poster:

15,966 posts

119 months

Wednesday 26th November 2014
quotequote all
JoeCass said:
Great Thread, Love these cars, Do you have a link to the thread on another forum? Majority of Pics aren't working for me.
Thanks smile
They're not bad motors! No idea why the pics aren't working, all the coding is correct... perhaps it's the dynamic jpg's it doesn't like on this particular forum.
Anyway all the pics / write up is here too smilehttp://www.mk5golfgti.co.uk/forum/index.php/topic,...

xjay1337

Original Poster:

15,966 posts

119 months

Tuesday 13th January 2015
quotequote all
MrBarry123 said:
Looks good Jay! Haven't seen it about yet though...
Bit late.com.

Thanks Mate (sam I presume) smile


Updates over Christmas and the new year...

Got some new Osram bulbs as the headlights were crap compared to my old Golf, made a good improvement.

Expensive though cos the ballasts are on the back of the bulbs... stupid things.




Finally got the remainder of my exhaust done with my mate Alex over at AKS again..

A Eurojet 3 inch V Band system, designed for a Golf Mk5 GTI, but obviously, being the same as a Golf underneath, it fitted fine. This exhaust was orignally going on my GTI, but as I was selling it, I lined Alex up with another buyer - Who had since bailed. Fortunately for me...

20141219_161642 by Fat Bear Photography, on Flickr

Looks lovely. Very shiney...very big.

Firstly we inspected the Darkside down pipe to see how we'd have to adapt. The Darkside system was 3 inch from the turbo to about half way down the exhaust tunnel, where it was reduced to I think it's 2.5 inchs to the stock system.

We (I say we, Alex did it biggrin) needed to fabricate up an adjoining link pipe. So we started with some 3 inch stainless steel piping.

20141219_163504 by Fat Bear Photography, on Flickr

Measure twice, cut once.
Or in Alex's case, measure once (and do it properly) and cut once.

20141219_163548 by Fat Bear Photography, on Flickr

Out comes the TIG welder! To connect the new link pipe to the existing Eurojet link pipe at one of the 90 degree bends..

20141219_164615 by Fat Bear Photography, on Flickr

Not bad for a quickie!!!

20141219_165534 by Fat Bear Photography, on Flickr

Now onto the car.....

20141219_165601 by Fat Bear Photography, on Flickr

Having to cut away the reducer off the back of the Darkside DP... not nice frown !!

20141219_170931 by Fat Bear Photography, on Flickr

After a slip on sleeve was fitted to connect to the Darkside downpipe, as well as mounting up the rest of the exhaust system less than 2 hours later we had the following:

20141219_172343 by Fat Bear Photography, on Flickr

20141219_173207 by Fat Bear Photography, on Flickr

20141219_173223 by Fat Bear Photography, on Flickr

Very brap brap ting.


one filthy car



Wheels are supposed to be shiny silver somewhere lol



Got a small delivery today from the lads up north...






The intercooler itself, and these two lower Intercooler hoses will be going on in February, along with my new clutch and flywheel. The rest of the pipework will be going on when the turbo kit is fitted in a months time.

Had the car dyno'd again as well today ...

Did broadly the same figures, about 10bhp difference.
201 / 203 bhp
346 / 384 ft lb

at the crank, at the wheels on both runs it did 190bhp and 325 and 358 ft lb respectively.

Flat bhp similar to the darkside dyno, sooo... happy with that for another month lol



Just goes to show different dynos can read differently. I think Darkside's dyno is perhaps a bit more accurate, the first run the car had been sat for a while so had much higher intake temperatures as they were setting up the dyno before turning on the fans.


Made a Mk7 GTI gearknob fit the Mk5 surround, my buddy Jairm did this for me and is the first in the UK as far as I can see.



in february we are up again at DsD for a GTB2260 kit so hoping to max out the stock fuel system and once a HPFP upgrade and injectors are available we can go for the magic 300 which is the figure i am aiming for.

Plan after that would be getting another set of wheels with some trackday rubber and making the most of the show and track season, drag days and the odd track day here and there.
Then we will go for the R body kit and a few other little cosmetic tweaks.

xjay1337

Original Poster:

15,966 posts

119 months

Thursday 15th January 2015
quotequote all
r1chardb said:
What's a Racekor?
Say it out loud 3 times

xjay1337

Original Poster:

15,966 posts

119 months

Friday 16th January 2015
quotequote all
Maty said:
Like the look of this and the work that's gone into it.

Have you got any pictures of this Fiscon kit on the display? I ask because I recently bought an Octavia VRS and added the Fiscon handsfree kit as mine wasn't fitted with the standard VAG Bluetooth module......I like the sound of a boost gauge on the stereo, not fussed about all the other temps etc.
If you check back later on I'll make a quick video at lunch time smile

xjay1337

Original Poster:

15,966 posts

119 months

Wednesday 21st January 2015
quotequote all
Sorry, I keep forgetting to do the video. Will do it, promise!

Video of the noise:

https://www.youtube.com/watch?v=3-NdaoB8Ll0

Apologies was just a quick one on the DSLR and I forgot to turn off auto fckus.

xjay1337

Original Poster:

15,966 posts

119 months

Thursday 22nd January 2015
quotequote all


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 smile

xjay1337

Original Poster:

15,966 posts

119 months

Thursday 5th February 2015
quotequote all
https://www.youtube.com/watch?v=PAeH4vx2S3Q&li...

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

xjay1337

Original Poster:

15,966 posts

119 months

Wednesday 4th March 2015
quotequote all


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. smile 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

Original Poster:

15,966 posts

119 months

Wednesday 4th March 2015
quotequote all
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 smile

11025734_427725690729436_896505323151573400_n by Fat Bear Photography, on Flickr

Cheers for reading.

xjay1337

Original Poster:

15,966 posts

119 months

Wednesday 4th March 2015
quotequote all
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

xjay1337

Original Poster:

15,966 posts

119 months

Thursday 5th March 2015
quotequote all
No problemos.

New wheels!


Ignoring the dirty car...





xjay1337

Original Poster:

15,966 posts

119 months

Tuesday 21st July 2015
quotequote all
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 smile

xjay1337

Original Poster:

15,966 posts

119 months

Tuesday 21st July 2015
quotequote all
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.










xjay1337

Original Poster:

15,966 posts

119 months

Tuesday 21st July 2015
quotequote all
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 smile

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

I just like music smile

xjay1337

Original Poster:

15,966 posts

119 months

Wednesday 26th August 2015
quotequote all
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