The diesel Rocco Racekor project.
Discussion
I'm waiting on getting my new leased car before starting work with the head.
There's a possibility the block is warped rather than the head/gasket/studs but we'll find out and order a replacement bottom end if we need to.
Went out with a few mates yesterday night to London to get some pics.
IMG_4169-1 by Fat Bear Photography, on Flickr
IMG_4194-5 by Fat Bear Photography, on Flickr
IMG_4214-14 by Fat Bear Photography, on Flickr
Nothing new to report at the moment..
There's a possibility the block is warped rather than the head/gasket/studs but we'll find out and order a replacement bottom end if we need to.
Went out with a few mates yesterday night to London to get some pics.
IMG_4169-1 by Fat Bear Photography, on Flickr
IMG_4194-5 by Fat Bear Photography, on Flickr
IMG_4214-14 by Fat Bear Photography, on Flickr
Nothing new to report at the moment..
Paraicj said:
I had read this thread a while ago and thought it was a fun project but a bit out there. I saw the car on the road yesterday, and actually, it's just cool. Not something I would ever do myself, but it looks great!
I was in the black Panda 100hp with the mountain bike on the roof on the M6 if you saw me...
I did! I think Fiat Panda 100hp are great and seeing one with a bike on the roof made me laugh as the bike looked just as big as the carI was in the black Panda 100hp with the mountain bike on the roof on the M6 if you saw me...
I think you waved, I waved back hopefully you saw
Thanks for checking in!
jsims1 said:
Great thread! Well done for keeping at it and making such a great car, looking forward to seeing the progress with the head work. Sure it's going to be an animal! The stickers aren't to my taste on the pictures with the car on the road but it's a completely different story with the track pictures, looks like a proper 'racekor'
Thanks. I'm looking at re-doing the graphics this year or next.
Hoping to start the cyl head work on the 24th now, as I have my lease car being delivered on the Monday...finally.
I got a Fiesta ST Line
20170327_181415-01 by Fat Bear Photography, on Flickr
I really like it! Very refined for the type of car. And so comfy in comparison to the Scirocco!
I have some good news, the block was fine, the head was warped (which had caused the overheating issues). This was verified by looking at the OEM headgasket where you could see between the cylinders where it had been blowing.
.
But that being said it was in very good condition that aside certainly for a car on 180k miles - no carbon build up on the backs of the valves and no build up in the head or scoring to the cams .
20170409_204300 by Fat Bear Photography, on Flickr
20170409_204248 by Fat Bear Photography, on Flickr
The car is now rebuilt - new turbo will spin for nearly 2 minutes after engine is turned off. Sounds like a mini jet engine under the bonnet
It needs some more work, intake pipe properly fabricating (currently the OEM plastic one is bodged in place) but it starts on the key, idles smoothly and gets up to temperature.
Once the intake is sorted then it can be pushed and mapped properly - currently on my previous software with adjustments to take into account the new larger injectors.
20170327_181415-01 by Fat Bear Photography, on Flickr
I really like it! Very refined for the type of car. And so comfy in comparison to the Scirocco!
I have some good news, the block was fine, the head was warped (which had caused the overheating issues). This was verified by looking at the OEM headgasket where you could see between the cylinders where it had been blowing.
.
But that being said it was in very good condition that aside certainly for a car on 180k miles - no carbon build up on the backs of the valves and no build up in the head or scoring to the cams .
20170409_204300 by Fat Bear Photography, on Flickr
20170409_204248 by Fat Bear Photography, on Flickr
The car is now rebuilt - new turbo will spin for nearly 2 minutes after engine is turned off. Sounds like a mini jet engine under the bonnet
It needs some more work, intake pipe properly fabricating (currently the OEM plastic one is bodged in place) but it starts on the key, idles smoothly and gets up to temperature.
Once the intake is sorted then it can be pushed and mapped properly - currently on my previous software with adjustments to take into account the new larger injectors.
Jackeria said:
I can't believe the negativity early on in this thread, just read it all from start to finish, when I saw you put those stickers on it I was like "YES!!!!" Looks amazing, I saw the nurburgring 24h back in 2011 and it reminded me heavily of a couple of the cars I saw there. Alright it's not exactly the same as those there but it did the job for me which is exactly what it does for you " " I envy the time and effort you've put into this and only wish I could say I do the same with my motors.
It's OK, people can say what they like :-)I'm glad you like it, as you said the 24h spec cars is the look I was going for. I want to re-do the graphics this year but struggling to come up with ideas.
Thanks though :-) it's a lot of time and effort, but most of that is down to some key help from Alex and Bobby , I just bank roll most of it haha.
chuntington101 said:
Glad you found what was causing the over heating issue and are on the way to getting it back sorted. What turbo have you gone with now? Any plans for the intercooling as you said before it was getting a bit on the hot side at the track? Maybe methanol injection, just for the inlet cooling obviously!...
Yes it was a huge relief that the block was OK.I wouldn't have expected iron block to warp but you never know..
The turbo started off as a GTB2060VKLR I believe but it was split and a GTB22 housing was fitted and the unit rebuilt with larger turbines.
Bobby has been busy doing testing and tuning, we are taking it to Surrey Rolling Road at 11am this Saturday (15th) if anyone wants to say Hi
We want to get a baseline figure as to where we are currently and we know how much further to posh. the car is coming along very well and Bobby said it "kinda scared him", bearing in mind he has a 450bhp A4 3.0 TDI then it must be pretty nippy.
The main benefits so far is that we can keep EGT's a lot lower with the new injector and flowed head, and we are making power right up to 5400rpm.
When we have everything settled I'll get a mate to re-make my boost pipework as it's not 100% fitting and when he does that I'll get him to put a port on the intake pipe for WMI
Edited by xjay1337 on Thursday 13th April 11:29
We have finished the rebuild of the engine and we are very happy with the results.
2017-04-16_09-46-10 by Fat Bear Photography, on Flickr
IMG_20170415_212828_762 by Fat Bear Photography, on Flickr
This has been an awful lot of work which without Bobby would not have been possible.
We have many custom fabricated parts for this build.
hybrid VKLR turbo, BSR ported head, bsr custom valve springs, bsr cp3 pump, custom injectors, all engine software and engine build done by Bobby.
We are very very happy with this result. EGTs under 900 at WOT. Still making over 300bhp at over 5k
Some final tweaks are needed to low end to remove some excess smoke but it's pretty clean. I think currently this is the most powerful 2.0 CR VAG engine in the world , but I'm sure some crazy Turkish guy has a mega power build that they are keeping quiet
Edited by xjay1337 on Sunday 16th April 10:45
Sorry for delay in replying.
Clutch has gone so can't really make the most of the performance, changing to an SMF this time around using the same 6 Paddle Helix setup. That's going on 8th June.
And also as before my clutch went I was getting wheel spin in 3rd with the Michelins on the front.
As a temporary measure so it could be mapped we put the AD08R on the front and it seemed a bit more grippy.
With the Michelins running low on tread I bought another set of AD08Rs so now have 245 40 18 AD08R all round.
alec.e said:
Very impressive, well done
Thank you purpleliability said:
Nice work!
Have you looked at locating the battery in the boot?
Along with helping the weight distribution, you will be able to run a straighter intake which can help spool too
Not really something I want to do, spool is a bit slower simply because the turbo is so big lol.Have you looked at locating the battery in the boot?
Along with helping the weight distribution, you will be able to run a straighter intake which can help spool too
Clutch has gone so can't really make the most of the performance, changing to an SMF this time around using the same 6 Paddle Helix setup. That's going on 8th June.
And also as before my clutch went I was getting wheel spin in 3rd with the Michelins on the front.
As a temporary measure so it could be mapped we put the AD08R on the front and it seemed a bit more grippy.
With the Michelins running low on tread I bought another set of AD08Rs so now have 245 40 18 AD08R all round.
Edited by xjay1337 on Tuesday 9th May 15:40
J4CKO said:
I have a Scirocco TDI on the path at the moment, selling it for a mate at work, nice cars, its a top spec white TDi 170 in white.
Half tempted myself, I sat in it and thought it was lovely, just put me off a bit when I started the engine, but I had just stepped from a V8 Merc petrol so to be expected, can hear the engine to feeling like its on your knee might take it for a spin.
Edit, had a go, great fun car and plenty quick enough, nimble, nicely made, lot going for it, downsides are the engine, like all diesels runs out of puff but to be honest it is very effective, can see why people like them, got back in my Merc CLS and it made me realise how quick it is, it just keeps on pulling but then it has 200 plus bhp more, the VW makes better use of what it has though.
Cant totally see why these cars are popular, think I would go for the 2 litre TSI or R as I dont need the economy.
They certainly run out of puff on the stock turbo above 4.5k . That's the issue, smaller turbos spool better for good performance from 1500rpm but run out of puff sooner.Half tempted myself, I sat in it and thought it was lovely, just put me off a bit when I started the engine, but I had just stepped from a V8 Merc petrol so to be expected, can hear the engine to feeling like its on your knee might take it for a spin.
Edit, had a go, great fun car and plenty quick enough, nimble, nicely made, lot going for it, downsides are the engine, like all diesels runs out of puff but to be honest it is very effective, can see why people like them, got back in my Merc CLS and it made me realise how quick it is, it just keeps on pulling but then it has 200 plus bhp more, the VW makes better use of what it has though.
Cant totally see why these cars are popular, think I would go for the 2 litre TSI or R as I dont need the economy.
Edited by J4CKO on Tuesday 9th May 19:57
I would have probably started with an R if I could have afforded it but they were still £20k+ when I bought this!
Nice to hear your thoughts compared to your CLS
Quite different beasts.
J4CKO said:
Yeah, not a traditional group test rival is it ?
Was tempted to buy it, really impressed with it, the mag ride dampers are excellent and the whole package is fantastic, CLS is a massivelump of German liability but not sure I could sell it, not get much for it and then have to pay more for the Scirocco, does make me realise though that I do love pointy FWD cars, I think RWD is lost on me and my driving, I like the feeling of FWD, and thats after three RWD cars (944, 350Z and CLS), just not that bothered as long that as a package its good, would be interested to try the petrol variants.
I think when the kids are done at Uni I will go for a TT S or RS.
It's a great car overall, if you don't need back seats often Was tempted to buy it, really impressed with it, the mag ride dampers are excellent and the whole package is fantastic, CLS is a massivelump of German liability but not sure I could sell it, not get much for it and then have to pay more for the Scirocco, does make me realise though that I do love pointy FWD cars, I think RWD is lost on me and my driving, I like the feeling of FWD, and thats after three RWD cars (944, 350Z and CLS), just not that bothered as long that as a package its good, would be interested to try the petrol variants.
I think when the kids are done at Uni I will go for a TT S or RS.
RWD is a bit more pure but most of the time you can't tell the difference, there is something satisfying about the way FWD cars scrabble out of corners.
TTRS is a weapon, if a bit blunt, but as an all round package, brilliant.
funkyrobot said:
Xjay, this may seem like a bit of a rude question. However, I'm intrigued as to how much cash investment it takes to get a car like yours to this level.
I'm not after printouts of your bank account. But what does it take to fund something like this, in a roundabout way?
I posted a page or two ago the total "investment" I've made.I'm not after printouts of your bank account. But what does it take to fund something like this, in a roundabout way?
It was around £28k without taking into account labour , I know the latest round of engine work has cost me nearly £3k. I earn OK money, nothing special, I don't really do anything else with my money other than buy food
funkyrobot said:
Nice. Thanks for posting that.
Seeing as your car seems quite unique, have you had any interest off any car websites or magazines to do an article on it? I thought some places would be quite interested.
I'm not really "scene" enough to get magazine or website feature, and also not sure I would like it. Not really many people know of me or the car and it's nice in a way to not have the recognition and risk that comes with it.Seeing as your car seems quite unique, have you had any interest off any car websites or magazines to do an article on it? I thought some places would be quite interested.
A magazine has been in contact and they wanted to do a full feature on the car but I haven't gotten any dates or much, only that they want to send a pro snapper out.
If it happens then great but if not then no worries.
I'm more looking forward to getting my clutch in and then I can enjoy it properly
GrantD5 said:
xjay1337 said:
I'm not really "scene" enough to get magazine or website feature, and also not sure I would like it. Not really many people know of me or the car and it's nice in a way to not have the recognition and risk that comes with it.
A magazine has been in contact and they wanted to do a full feature on the car but I haven't gotten any dates or much, only that they want to send a pro snapper out.
So which one is it A magazine has been in contact and they wanted to do a full feature on the car but I haven't gotten any dates or much, only that they want to send a pro snapper out.
Just never been something that interests me, there's been talk about it but nothing set in stone yet.
You see some people get lots of social media fame for what, I view, are pretty lackluster projects. Because they seem to have a certain type of personality.
I don't seek fame or approval of my peers so never really gotten into a situation where I would get a feature.
However an opportunity has recently come around so we will see what happens but I'm not holding out hope and I won't be sad if nothing happens.
Still managing with a heavily slipping clutch. No other issues with the car so far, it's been good as gold.
Only 17 days till my new clutch kit goes in and I can actually enjoy my performance.
Went out for the day with some mates and I got a couple of pics from the wood we got lost in.
IMG_4400-1 by Fat Bear Photography, on Flickr
IMG_4404-3 by Fat Bear Photography, on Flickr
20170520_154352_HDR (1)-10 by Fat Bear Photography, on Flickr
Only 17 days till my new clutch kit goes in and I can actually enjoy my performance.
Went out for the day with some mates and I got a couple of pics from the wood we got lost in.
IMG_4400-1 by Fat Bear Photography, on Flickr
IMG_4404-3 by Fat Bear Photography, on Flickr
20170520_154352_HDR (1)-10 by Fat Bear Photography, on Flickr
chuntington101 said:
So what she next on the mods list? Meth injection to help add a little more fuel and cool thinks down? Or maybe some n2o to help with spool? you could do both and spray meth with a wet n2o kit! Haha
Things are pretty cool as they are to be honest, cooler than it was on the old 2260 turbo.For spool I think we will look at changing the turbo internals. Once I have some times at Santa Pod we are going to strip down the turbo and see if we can see anything to improve spool.
It is so large though that there's only so much we can do
I see yours as well bud
I guess they do want to do a feature after all lol.
Although Darkside have just announced they have got 375bhp out of theirs (Drag car, no details on spec but I suspect s200v and they also have tubular intake), so we are sorting out some new upgrades
Constant upgrade cycle.
I guess they do want to do a feature after all lol.
Although Darkside have just announced they have got 375bhp out of theirs (Drag car, no details on spec but I suspect s200v and they also have tubular intake), so we are sorting out some new upgrades
Constant upgrade cycle.
Few updates .
I went to Santa Pod, managed to get a 13.5 @ 108.
My previous time was 13.6@102 - Unfortunately the strip wasn't playing ball with traction, and it was very hot so my intake temps were crazy high - so there's easily scope to get into the high 12s on a more favourable day.
In other news, I decided to paint my front calipers to match the rears.
Before:
After:
2017-06-13_10-44-26 by Fat Bear Photography, on Flickr
Also went to AKS and got the clutch swapped out - FINALLY - it lasted about 2 days after mapping. Nearly 60k on the previous 6 Paddle and DMF kit so lasted very well indeed.
Replaced with new 6 Paddle unit and SMF. SMF comes with higher clamp force cover plate.
This was the flywheel when it came out.
20170608_140536 by Fat Bear Photography, on Flickr
The clutch plate itself had hardly worn. But the flywheel and cover plate had seen better days.
It does rattle quite a bit on idle without the clutch depressed but it revs quicker and just feels nicer in general.
Also fitted a clutch bypass switch. You always had to have the clutch depressed to start the car before but now it doesn't need that.
This was done as when fitting SMF kits it can damage the thrust bearing which can kill the engine so better to be safe than sorry.
While it was in the air we did the oil and filter as I bought 2 when the engine was rebuilt. Now running Millers CFS NT+ 5w40.
Done around 2000 miles on the new head turbo etc and nothing has broken
I went to Santa Pod, managed to get a 13.5 @ 108.
My previous time was 13.6@102 - Unfortunately the strip wasn't playing ball with traction, and it was very hot so my intake temps were crazy high - so there's easily scope to get into the high 12s on a more favourable day.
In other news, I decided to paint my front calipers to match the rears.
Before:
After:
2017-06-13_10-44-26 by Fat Bear Photography, on Flickr
Also went to AKS and got the clutch swapped out - FINALLY - it lasted about 2 days after mapping. Nearly 60k on the previous 6 Paddle and DMF kit so lasted very well indeed.
Replaced with new 6 Paddle unit and SMF. SMF comes with higher clamp force cover plate.
This was the flywheel when it came out.
20170608_140536 by Fat Bear Photography, on Flickr
The clutch plate itself had hardly worn. But the flywheel and cover plate had seen better days.
It does rattle quite a bit on idle without the clutch depressed but it revs quicker and just feels nicer in general.
Also fitted a clutch bypass switch. You always had to have the clutch depressed to start the car before but now it doesn't need that.
This was done as when fitting SMF kits it can damage the thrust bearing which can kill the engine so better to be safe than sorry.
While it was in the air we did the oil and filter as I bought 2 when the engine was rebuilt. Now running Millers CFS NT+ 5w40.
Done around 2000 miles on the new head turbo etc and nothing has broken
Got some exciting things happening over the next few weeks.
2017-06-23_02-49-25 by Fat Bear Photography, on Flickr
- New Bilstein B16 / PSS10
- New OEM rear top mounts / bump stops (not really needed but hey).
- Powerflex Rear arm bushes (inner and outer)
- Superpro Trailing arm bushes
- New drop links (front + rear)
- N/S outer CV is leaking grease so have a new boot but will replace driveshaft if it's buggered.
- Ground Control Top mounts
- AKS Tuning fast road/track alignment
Not long till they're all fitted, only a couple of weeks, so very excited.
2017-06-23_02-49-25 by Fat Bear Photography, on Flickr
- New Bilstein B16 / PSS10
- New OEM rear top mounts / bump stops (not really needed but hey).
- Powerflex Rear arm bushes (inner and outer)
- Superpro Trailing arm bushes
- New drop links (front + rear)
- N/S outer CV is leaking grease so have a new boot but will replace driveshaft if it's buggered.
- Ground Control Top mounts
- AKS Tuning fast road/track alignment
Not long till they're all fitted, only a couple of weeks, so very excited.
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff