Scirocco Central

Right ok so your getting better cooling

Yup, that's it. Better cooling and flow.

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.

Awesome my friend!! Looking forward. Nice project!

Got a trackday booked on the 30th January at Bedford Autodrome SEN circuit, should be a good laugh, going with a couple of friends in his MX5.. lol.

xjay1337 wrote:

Got a trackday booked on the 30th January at Bedford Autodrome SEN circuit, should be a good laugh, going with a couple of friends in his MX5.. lol.

Go Pro

Will be fully charged and stuck to my helmet hehe!

What is the brand of he short shifter that you chosen?
Does it shorten the lateral movement as wel?

Thanks

xjay1337 wrote:Will be fully charged and stuck to my helmet hehe!

Any good vids?

Ummm, unfortunately not.
Snow stopped play and the whole day was cancelled before it even started...thick blanket snow. got credit back so going to book another one for after when the turbo kit is in..silver linings and all of that.

roc82 wrote:What is the brand of he short shifter that you chosen?
Does it shorten the lateral movement as wel?

Thanks

It's just a front to back one.
Ebay cheap one for now.

Big update time!!!


this went on today. (And I immediately stalled it twice and my leg now actually hurts).
 

 
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"...
 

 
 
 
 due to a monumental cock up on my part regarding scheduling dates and what not, I wasn't able to be on hand to assist with the clutch change hence the generic lack of pictures..although as a by product I did get a ride in the Octavia Estate which is around the 400bhp mark...slippy diff and lambo brakes.. yummy. Sounded awesome and it's just insane and hilarious when a pimped out estate Racekor comes blaring past at 120...reminds me of the old Volvo BTCC estates but I'm getting distracted..
 
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.  infact i find moving my knob more and more just for pleasure. 
 
 I started the day with a premier inn buffet breakfast..hehe.

So day two...
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.

Bring on Monday...

Thats some intercooler

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

Cheers for reading.

xjay1337 wrote: 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"...
 

The side linkage was the bit I was on about on Mk5 forum, VWR put the Mk4 GTI one in their kit so essentially the same part

Liking what you are doing on this as it it brings a smile to the face

wigit wrote:
The side linkage was the bit I was on about on Mk5 forum, VWR put the Mk4 GTI one in their kit so essentially the same part

Liking what you are doing on this as it it brings a smile to the face

Ahhh I understand didn't click at the time.
It makes a HUGE difference to the shift feel and it's really nice indeed.

Glad you like it mate, thank you

Let me know next time you are out at Bedford as would like to see this on the move, i'll bring the knob mobile along

Bet this goes like shit off a shovel now

i would say so.... !! It just keeps pulling and pulling at basically the same rate lol...a quick video of the acceleration.
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wigit wrote:Let me know next time you are out at Bedford as would like to see this on the move, i'll bring the knob mobile along

Ha ha ha! Yes, will do... need to save up for H&R rollies and I need Alex to sort me out with a slippy diff... Be good to catch up.

nice of you to indicate at 120 must corner well

DAN180Y wrote:nice of you to indicate at 120 must corner well

Especially on a private road as the video description says.

Mates Runway!
Just indicating to overtake those damn slow planes!