The diesel Rocco Racekor project.

[xjay1337]

Got all the suspension on on Tuesday, took a bit longer than anticipated so I ended up getting a lift home on Tuesday evening and collected the car on Thursday.

Also got full Superpro rear bush kit, new drop links front and rear, new rear top mounts, and some modifications to my turbo intake pipe and boost pipework.

It's amazing!! So much better. You can certainly tell the suspension is a quality item rather than a budget lowering option. It's actually ever so slightly higher than it was before now too but hey ho.


IMG_20170711_194314_205 by Fat Bear Photography, on Flickr


FB_IMG_1500282516058 by Fat Bear Photography, on Flickr

Tested it out at Donnington Park on Sunday at VAG Tuner VW show.
As a package it was very, very capable. Next chassis mod is a LSD but given the power and torque it does manage really well without one.
Unfortunately I got black flagged twice as I was tripping the noise meters ... 98db driveby, I was around 101 db.

All good in the hood so far

[xjay1337]

Small world! I'm working in Guilford at the moment on a project. Since it was a nice day decided to take the Scirocco over the Fiesta! - traffic really is awful around those parts.

ZX10R NIN said:

Nice work Jay when you get good suspension it's surprising how much of a difference it makes in feel & confidence.

Exactly! It was good before on the road but the B16 are another level. Very stiff, though. But responsive like nothing else on the same level.

AJB88 said:

Did pop by and have a quick look under the bonnet on Sunday.

Nothing much to see is there really. Other than a load of plastic should have said hi matey.

Darren1101 said:

I was following you for a bit near Oxford on Sunday (black Megane R26, also stuck in the F1 traffic).

The car has real presence, and I appreciate the effort put in to it, but I just couldn't get past the level of smoke at various throttle loads. Apart from that, very smart package!

I think I remember you
When you are on it, it does clear itself out. But where we had been in the traffic it seemed worse than it really is and with the heat it was running a tad rich.

But you are right. The smoke is a little bit excessive in certain situations. The issue is with the aggressive head porting swirl air isn't formed correctly so tuning by Lambda doesn't give a true picture.

We will be tweaking the map soon to take some fuel out to reduce the smoke, I just need a chance to hook a go pro up to capture the smoke and plug my laptop in to log it

[xjay1337]

That would be ideal but I'm sure they cost a lot more!

Few pics from the trackday a week ago. The car behaved perfectly. But highlights I do badly need an LSD now.


Cheers Jhk__photography for pics. by Fat Bear Photography, on Flickr


Cheers Jhk__photography for pics. by Fat Bear Photography, on Flickr

[xjay1337]

The PSS10 come with a progressive spring. I need to play around with the damping. To be fair it's not bad if you're going at a reasonable pace but the slower you are the worse the ride is!

I can't find any data myself but found this online RE spring rates

B16 PSS 10 Golf 5:
215 f, 285 r (both progressive)
Front: E4-FD1-Y704A00 = progressive; initial rate 32.8N/mm (approx 190lbs/in), secondary rate 43.4N/mm (approx 250lbs/in)
Rear: E4-FD1-Y754A00 = progressive; initial rate 33.0N/mm (approx 190lbs/in), secondary rate 50.1N/mm (approx 285lbs/in)

But another site claims different from testing -

http://www.golfmkv.com/forums/showthread.php?t=576...

[xjay1337]

Did a day at Curborough yesterday, my first time there, a small group of us, nice atmosphere.

https://www.youtube.com/watch?v=6_UqmPpCpXg

Footage from my second outing. Very technical little circuit. Was getting better towards the end of the day, so that's good

Unfortunately not everything went to plan. Before we had even started (hadn't even parked!!) my clutch master cylinder decided to split leaving me with no clutch. Luckily Euro's had the right part in stock so we did a "DSG conversion" and had it back up and working by 11am.

2017-08-23_07-28-30 by Fat Bear Photography, on Flickr

20170822_124824-01 by Fat Bear Photography, on Flickr

[xjay1337]

Cheers mate. It's just my dash cam as I didn't take the Go-Pro.

It's a Nextbase 402g.

[xjay1337]

AJB88 said:

looks clear, my current cam in Leon is giving up.

I'd defo recommend it. I think it cost around £130, it was an Xmas present last year.

if you are likely to get a lot of footage off I'd recommend stumping up the extra for the WiFi version.

[xjay1337]

DonaldTrump said:

Sure you passed me on the M5 Exeter Northbound earlier today.

Probably did bud. I had the joys of working in Plymouth! What were you in?

Also at some point on the journey my 1st gear synchro decided to die.

[xjay1337]

Yes a few pages back. I did a 13.4 @ 108. Need to work on traction.

Few updates!!

I did a day at Cadwell. Had to bleed my brakes in the paddock as I just didn't have time and the first session boiled my fluid.
No fade for the rest of the day.

EN9I8739-3 by Fat Bear Photography, on Flickr


A video from my friend in his 310hp Edition 30 chasing, with similar handling mods.
https://youtu.be/QoRQGNhLvVA?t=189


And onboard for a couple of laps, following a TTE420 powered ED30 - https://www.youtube.com/watch?v=Kf6T81cX9sg


And also at Silverstone on Sunday.
I did try to get some footage but my camera didn't save it!

CT-2130-(ZF-6182-13377-1-002)-1 by Fat Bear Photography, on Flickr

I mentioned my 1st gear synchro has broken so the work around was either to wait 5 or so seconds from pressing the clutch down before engaging 1st, or put it into 2nd and then straight into 1st.

This worked for a while but now 2nd gear has done the same. Which makes the car incredibly difficult to drive around town.

A few weeks ago I bought a gearbox from Ebay to be rebuilt with a limited slip diff (Peloquin) and all the internal strengthening mods. Alex is a very busy guy and finally got around to stripping it down.

These include the 4th gear support and steel shift forks


received_10155918928887244 by Fat Bear Photography, on Flickr

I am not sure when the gearbox will be ready but I'm hoping soon then it's just a case of getting everything swapped over.


In performance land, I have also gone for a new turbo since we are right at the limit of this one (you can hear on some videos we are on the surge line of the turbo)

The new turbo should be on in a month or so, Bobby needs to make a speed sensor mount and sort a few bits before we go. The new unit has been built to go for 400hp.

[xjay1337]

New year, new news.

We received the turbo , but once mounted it clearly sounded very poorly , despite being expensive, brand new and having 0 miles , it was removed and we had to send it off to be rebuilt and rebalanced. That was not fun, nor was it cheap, or an effective use of time.

But now the turbo is coming back now and should be fitted soon.

My gearbox issues have finally been fixed. The new gearbox with LSD and other modifications has been installed and works perfectly. Very happy, completely changes the driving characteristics, and it's nice to have 1st and 2nd gear back.

received_10156039073962244 by Fat Bear Photography, on Flickr

received_10156042100272244 by Fat Bear Photography, on Flickr

received_10156060794312244 by Fat Bear Photography, on Flickr

20180104_114121 by Fat Bear Photography, on Flickr

20180104_153426-01 by Fat Bear Photography, on Flickr

[xjay1337]

Ah thanks mate.


My friend had the 2.0 TSI, they're great cars, a tune really livens them up, they feel quite flat without it!
I'm sure you'll be happy either way

[xjay1337]

Had a bit of a nightmare over the last few months.

So we had a new turbo build from scratch. It has some very fancy internal components and can't be bought off the shelf.
however being brand new, when it was first fitted it had a very loud high pitched whining which was not normal.

we had it rebuilt (again, for a new turbo!) and the balancing was so far out the balancing machine that it cut off.
it was balanced and came back, the noise was gone but it was chugging out a lot of smoke (this is oil / white smoke , not black from fuel). this is with a 1mm oil restrictor as well

https://www.youtube.com/watch?v=WRo4C_pAyIw

So we had to have it rebuilt AGAIN.
this time by an old friend of Bobbys who have to say did a really good job and it is much better now. We also changed the turbine wheel to a slightly different one as well.

Now it was sorted we also plumbed in water cooling, and wired up a sensor to measure turbo shaft speed and got that working with factory inputs.

IMG-20180411-WA0000 by Fat Bear Photography, on Flickr

IMG-20180411-WA0001 by Fat Bear Photography, on Flickr


After a lot of tuning work from Bobby we went to Surrey Rolling Road, unfortunately it so happened to be the hottest day of the year yesterday 18th April.

Nevertheless the end results were 395hp and 660nm torque. Very happy with the end results.


Attached is a graph overlaid with the previous one at 340hp / 625nm

2018-04-19_10-09-12 by Fat Bear Photography, on Flickr

[xjay1337]

Thanks for the kind words everyone.

I am now splitting the car.

Here is a parts list of the juicer parts, if anyone is interested please PM.


parts list. by Fat Bear Photography, on Flickr

Everything is for sale on the car down to the last nut and bolt.

[xjay1337]

Evoluzione said:

Come on now, first question is going to be why?

1) just bought a house, can't keep spending hundreds and hundreds on the car every month
2) i really fancy an m135i

It still runs and drives, so it's not blown up lol.