The diesel Rocco Racekor project.

[xjay1337]

Thanks Sam

chuntington101 said:

Nice work on tracking the car. Sounds daft but it didn't overhear did it? Are you sure the stock radiator is upto the job?

Also have you flow benched the intake manifold? Just wondering if there would be any benifits to be had there?

It's not overheated on any previous trackdays, plenty of cars even race cars run OEM radiator. My friend was there in his Mk5 gti and that was fine. It's a really weird one.
I suspect it's a combination of head lift pressurising the cooling system and old/perishing seals causing coolant leaks.

We have a different inlet manifold to go on. But 99% of gains are all in the cyl head. We have had a lot of work put into it.

[xjay1337]

Couple of pics from the trackday.

32503975545_f3e023878d_o-4 by Fat Bear Photography, on Flickr

32382744411_59233619b0_o-1 by Fat Bear Photography, on Flickr

[xjay1337]

No major updates.

Friend and I took the whole front end of, as the car was over heating with hard driving, and while I think it's the HG and cyl head studs failing (pressurising coolant circuit) I also had symptoms of a blocked radiator.

We wanted car 100% before we begin tuning so for the small cost decided to fit a new Hella unit.

Also there's a coolant circuit that I have looped due to my oil cooler installation. The hose is not ideal and was only a temporary solution, so I have measured the outlets and gotten an appropriately sized ASH 180 degree silicone hose.

20170208_192931 by Fat Bear Photography, on Flickr

Also ordered some additional silicones up for the upcoming work.
We are beginning strip down on Friday 3rd of March so new cyl head, upgraded valve springs, hybrid vklr turbo and some other cool bits are going on.
Hopefully smash the 300bhp barrier.

It has been very frustrating sourcing parts from europe and getting details for example finding the right upgraded valve spring but thanks to Bobby were have everything we need now.

[xjay1337]

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..

[Paraicj]

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...

[xjay1337]

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 car

I think you waved, I waved back hopefully you saw
Thanks for checking in!

[jsims1]

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'

[xjay1337]

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.

[jsims1]

xjay1337 said:

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.

Sounds good, what are you getting on lease? Be sure to keep us updated! You've done well so far!

[xjay1337]

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.

[Jackeria]

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.

[chuntington101]

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!...

[xjay1337]

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

[xjay1337]

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

[alec.e]

Very impressive, well done

[purpleliability]

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

[xjay1337]

Sorry for delay in replying.

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.

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]

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.

Edited by J4CKO on Tuesday 9th May 19:57

[xjay1337]

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.

Edited by J4CKO on Tuesday 9th May 19:57

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.

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]

xjay1337 said:

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.

Edited by J4CKO on Tuesday 9th May 19:57

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.

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.

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.